Service Manual

Buses
Section 0 (03)
Specifications B7L

TP 16179/2
 Foreword

The specification data in this Service Manual is based on

information available by December 1998. Volvo Bus Cor-
poration reserves the right to make specification changes after
the date of publication.

Contents

page
General ....................................................................... 1
Service and maintenance ............................................ 4
Engine ......................................................................... 6
Electrical system and instrumentation ........................ 13
Power transmission, rear axle ..................................... 14
Brakes ......................................................................... 18
Front suspension and steering .................................... 21
Frame, suspension and wheels ................................... 22

Order number: TP 16179/2

 General
Scope
This Specifications Manual relates to Volvo B7L bus
models with the following principal characteristics:
Wheelbases Engine types2 Transmission types Rear axle types Wheel suspension types
29451 Volvo D7C215 ZF 4HP 500/590 (Automatic) Portal Full air with bellows
6000 Volvo D7C250 ZF 5HP 500/590 (Automatic)
Volvo D7C290 Voith D863.3 (Automatic)
Volvo D7C310 Voith D864.3 (Automatic)
1
Chassis transport wheelbase, to be extended by coachbuilder.
2
Certified in accordance with Euro 2 regulations.

Weights(kg), 6000 mm chassis

Max. front axle load* 6 300a/6 900b
Max. rear axle load* 11 600a/12 500b
Max. GVW (Gross Vehicle Weight) 17 900a/18 900b

Weights can vary by ±1.5%

* The quoted axle load limits apply to the maximum speeds shown below, i.e. they have technical restrictions relating to tyres and wheels.
a) 100 km/h and tyre load index marking 148/145 J.
b) 70 km/h and tyre load index marking 151/148 E (dual marked).

Vehicle identification (VIN no.)

This is punched into the right-hand side of the chassis
longitudinal member, and can be seen inside the right
front wheel housing, directly behind the wheel. It is quite
visible with the wheel in place, when the steering is
turned to full left lock.

Example: *YV3 R7 C7 1 8*
*X A 000028*
*YV3R7C718*
*XA000028* where YV3 denotes the manufacturer
(YV3 = Volvo Bus Corporation,
Sweden)
R7 chassis version (R7 = B7L)
C7 engine version (C6 = D7C 215)
(C7 = D7C 250; C8 = D7C 290;
C9 = D7C 310)
1 brake system
(1 = compressed-air brakes)
8 check digit
X model year (X = 1999, Y = 2000, etc.)
A assembly plant (A = Borås, Sweden)
(E = Volvo do Brazil)
000028 chassis number

1
Product data plate The data plate is divided into a legislation part, outlined
separately on the plate, and three rectangular data fields
for chassis type, drive configuration and wheelbase (this
field is only completed for trucks, not buses).
On buses, the product data plate is attached to a location
next to the driver’s seat, and it contains the following
information.

If special national approval is required, the approval number is punched in here

If national regulations relating to GVW or axle load prescribe values
that are lower than the technical maximum values, the general agent or
importer must supplement the manufacturer’s data by inserting appro-
priate values in the left-hand column of the plate.
by the relevant general agent or importer.
The VIN number, i.e. the same number as is stamped on the frame member, is
punched in here.
This field shows the max. technical GVW, in kg. This is the weight for which the
bus was designed.
Max. technical front axle load, in kg.
Max. technical rear axle load, in kg.
When relevant, the maximum technical axle load for the third axle is given here,
in kg.

Component identification
Engine identification labels
Various labels, located as shown in the diagram, provide
engine identification and important information as fol-
lows. In addition, a label with the engine control unit
specification is located on the rear valve housing.

1. Engine model (D = Diesel, 7 = 7 litres,

C = Third engine generation)
2. Engine version
3. Nominal power rating
4. Engine speed to obtain nominal rated
power
5. Engine swept volume
6. Low idle speed
7. Volvo part number for label
8. Smoke rating under free acceleration
9a. Relevant EU Emissions Directive and
certificate number
9b. Relevant EU Speed limiting Directive
and certificate number
10. Country code (E = Europe, 11 =
Country,
where 11 = UK, 5 = Sweden)
11. Regulation 49B, emissions certificate
number
12. Regulation 24, smoke and power
certificate number
13. Engine manufacture factory code
14. Engine model
15. Engine assembly factory code
16. Engine serial number, punched into
cylinder block

2
ZF automatic transmissions:
Data plate attached to the top face of the housing.

Voith automatic transmissions:

Data plate attached to the top face of the housing.

Rear axle type designation, part number,

serial number (FABR NR) and ratio
This information is punched into fields on a plate at-
tached to the right hand side of the rear of the housing.

3
 Service and maintenance

Engine
Oil grade ....................................................................... – Volvo Drain Specification VDS-2
– or VDS
– or API CE, CF, CF-4, CG-4
– or ACEA E1-96, E2-96, E3-96
For oil change intervals, refer to Service Bulletin group 17
Oil change volume including oil filter .......................... 18 litres

Viscosity as shown in the diagram below

The diagram assumes constant temperatures.

-30 -20 -10 0 10 20 30 40 C

-22 -4 14 32 50 68 86 104 F 1. Refers to synthetic or VDS/VDS-2 oil.

SAE 10W/30
2. VDS-2 oil.
SAE 15W/40
SAE 10W/40 2)
SAE 5W/30 1)
SAE 5W/40 2)
SAE 30
SAE 40

ZF HP 4 HP and 5 HP 500 automatic transmissions

Oil grade ....................................................................... – ATF Dexron II D to Volvo STD 12735,5
spec. 97335
– or Volvo Synthetic oil to Volvo STD 1273,31
spec. 97331
Dry transmission filling volume ................................... approx. 20 litres
Oil change amount ........................................................ approx. 17 litres

Voith D863.3 and D.864.3 automatic transmissions

Oil grade ....................................................................... ATF Dexron II D, IIE, III
Dry transmission filling volume ................................... 25 to 28 litres
Oil change amount ........................................................ 23 to 26 litres
Additional amount if oil cooler is empty ...................... approx. 2 litres
Oil capacity between MAX and MIN dipstick marks .... approx. 2.5 litres
The dipstick must always be used to check for correct oil levels after filling or topping-up.

4
Final drive
Oil grade ....................................................................... API-GL-5 (MIL-L-2105D)
Viscosity ....................................................................... SAE 80W/90, 85W/140 or 90
Oil change volume ........................................................ Approx. 20 litres

Power steering
Oil grade ....................................................................... ATF Dexron II D

Steering angle gear

Oil grade ....................................................................... ATF Dexron II D

Wheel hubs
Front wheels, lubricant ................................................. Engine oil SAE 30 (Final drive oil not permitted)
Oil volume, per hub ...................................................... Approx. 0.3 litres
Rear wheel bearings, lubricant ..................................... Lithium/lead wheel bearing grease with EP additive
and consistency as per NLGI-2

5
 Engine

Type designation .......................................... D7C 215 D7C 250 D7C 290 D7C 310

Net power kW/hp at 36.7 r/s, 2200 rpm ....... 158/215 184/250 213/290 228/310

Max.torque Nm ............................................. 900 1 050 1 200 1 350

at rpm ............................................................ 1 400 1 400 1 200 1 200

Power outputs in accordance with ISO 2534 and SAE J 1995.

These engines comply with the smoke requirements of the ECE/EEC Euro 2,
Swedish and US Federal Register regulations.

All engines
No. of cylinders ............................................................ 6

Bore .............................................................................. 107 mm

Stroke ............................................................................ 135 mm

Displacement ................................................................ 7.3 dm3 (7.3 litres)

Compression ratio ......................................................... 19.5:1

Firing order ................................................................... 1-5-3-6-2-4

Direction of rotation (viewed from the front,

engine installed in bus) ............................................. Clockwise

Low idle speed .............................................................. 575 to 625 rpm (9.6 to 10.4 r/s)

High idle speed ............................................................. 2 425 to 2 475 rpm (40.4 to 41.2 r/s)

Maximum full load engine speed ................................. 2 200 rpm (36.7 r/s)

Overall length ............................................................... 1140 mm

Overall width ................................................................ 763 mm

Overall height ............................................................... 1005 mm

Dry weight, engine with flywheel and clutch housing

but without starter motor, approx. ............................ 750 kg

6
Engine block Gudgeon pins
Standard gudgeon pin hole diameter .... 47,02 mm
Gudgeon pin fit to connecting rod
Cylinder head bush .................................................. 0.026 mm
Type ................................................ 1 per 3 cylinders
Length ............................................. 421 mm
Width .............................................. 223 mm
Height ............................................. 109 mm
Valve mechanism
Cylinder head bolts
No./cylinder head ........................... 20 Valves
Thread dimension ........................... M11 Head diameters:
Length ............................................. 150 mm inlet ............................................. 43 mm
exhaust ........................................ 39 mm
Cylinder block Stem diameters:
Length ............................................. 859 mm inlet ............................................. 7.96 to 7.97 mm
Height, upper block surface exhaust ........................................ 7.95 to 7.96 mm
to crankshaft centre (A), min. ..... 403 mm Valve face angles:
Height, lower block face – inlet ............................................. 29.5°
crankshaft centre (B), min. ......... 90 mm exhaust ........................................ 44.5°
Contact face widths:
inlet ............................................. 2.3 mm
exhaust ........................................ 2.1 mm
Valve seat angles:
inlet ............................................. 30°
exhaust ........................................ 45°
Distance below cylinder head ......... 0 to 0.4 mm
Min. Min.

Cylinder liners
Type ................................................ Wet, detachable
Total height ..................................... 256.5 mm
Liner extent above top of block ...... 0.12 to 0.18 mm
Max. height difference between
cylinder liners 1, 2, 3 and 4, 5, 6 .. 0.02 mm Valve clearances, cold engine:
Internal diameter ............................. 107.0 mm inlet ............................................. 0.40 mm
exhaust ........................................ 0.55 mm
Pistons The valves on D7C engines can be adjusted using the
Total height ..................................... 134.45 mm two groups method:
Height above top of block .............. 0.40 mm When piston no. 1 is at t.d.c. after compression, adjust
No. of ring grooves ......................... 3 valve clearances 1, 2, 3, 6, 7 and 10.
Front markings ................................ Arrow forward When piston no. 6 is at t.d.c. after compression, adjust
valve clearances 4, 5, 8, 9, 11 and 12.
Piston rings
Compression rings
No. .................................................. 2
Groove clearances
upper compression ring .............. 0.3 to 0.32 mm
lower compression ring .............. 0.070 to 0.102 mm
Ring end gap ................................... 0.6 to 0.62 mm

Oil scraper ring

Number ........................................... 1
Groove clearance ............................ 0.040 to 0.082 mm
Ring end gap ................................... 0.30 to 0.55 mm

7
Valve seats
Outer diameter (dimension A), standard:
inlet ............................................. 46.08 mm
exhaust ........................................ 42.07 mm
Oversize:
inlet ............................................. 46.28 mm
exhaust ........................................ 42.27 mm
Height (dimension B):
inlet ............................................. 8.15 mm
exhaust ........................................ 8.65 mm
Valve seat position
Diameter (dimension C), standard (mm):
inlet ............................................. 46.000 to 46.025
exhaust ........................................ 42.000 to 42.025
Diameter (dimension C), oversize (mm):
inlet ............................................. 46.200 to 46.225
exhaust ........................................ 42.200 to 42.225
Depth (dimension D)
inlet ............................................. 9.95 to 10.05 mm
exhaust ........................................ 9.80 to 9.90 mm
Bottom radius of seat recess (dimension R):
inlet, max .................................... 0.5 mm
exhaust, max ............................... 0.5 mm
Valve guides
Inner diameters:
inlet ............................................. 8.000 to 8.015mm
exhaust ........................................ 8.000 to 8.015 mm
Heights above cylinder head spring plane:
+0
inlet ............................................. 19.5 –0.25 mm
exhaust ........................................ 19.5 +0 –0.25 mm
Stem to guide clearances:
inlet ............................................. 0.025 to 0.050 mm
exhaust ........................................ 0.038 to 0.064 mm
Camshaft
Drive ........................................ Gear
No. of bearings ........................ 7
Minimum camshaft bearing journal diameters (mm):
front (1st) ................................. 68.985 to 69.015 mm
2nd ........................................... 68.420 to 68.450 mm
3rd ............................................ 67.835 to 67.865 mm
4th ............................................ 67.235 to 67.265 mm
5th ............................................ 66.610 to 66.640 mm
6th ............................................ 66.010 to 66.040 mm
7th ............................................ 56.285 to 56.315 mm
Valve lift,
inlet and exhaust valves ....... 13 mm
Check camshaft setting with a cold engine and valve
clearance set to 0: With flywheel at 10º after t.d.c., the
inlet valve for cylinder no. 1 should be open by 1.4 to
1.9 mm.
Camshaft bearings
Camshaft bearing diameters (mm):
front ............................................ 69.050 to 69.075
2nd .............................................. 68.485 to 68.510
3rd ............................................... 67.900 to 67.925
4th ............................................... 67.300 to 67.325
5th ............................................... 66.675 to 66.700
6th ............................................... 66.075 to 66.100
7th ............................................... 56.350 to 56.375
Timing gears
Numbers of gear teeth
crankshaft gear (1) ............................. 30
idler gear (2) ...................................... 51
fuel injection pump drive gear (3) ..... 60
coolant pump drive gear (4) .............. 23
compressor drive gear (5) .................. 33
servo pump drive gear (6) ................. 19
camshaft drive gear (7) ...................... 60
idler gear for oil pump (8) ................. 48
oil pump drive gear (9) ...................... 27
5 4
6
3

Valve springs, inlet and exhaust valves 2

Outer valve springs:
free length ....................................... 64.1 mm 1
with 270 to 310 N load ................... 48.6 mm
Inner valve springs:
7
free length ....................................... 60.1 mm
with 110 to 130 N load ................... 44.6 mm 8 9

8
Crank movement Main bearing shells
Thickness (D)
standard .................................... 2.931 mm
oversize 0.25 mm ..................... 3.058 mm
0.50 mm ..................... 3.185 mm
0.75 mm ..................... 3.312 mm
1.00 mm ..................... 3.439 mm
1.25 mm ..................... 3.566 mm

Crankshaft
Endfloat .......................................... 0.068 to 0.228 mm
Main bearing running clearance ..... 0.065 to 0.119 mm

The crankshaft is nitrocarburized. Note that a nitrocar-

burized crankshaft may only be ground as far as the
second undersize. If more grinding is required than this,
the crankshaft must be nitrocarburized again.
Main bearing journals
Diameter (Ø) (mm):
Standard ................................... 90.528 to 90.550 mm
Undersizes: 0.25 mm .............. 90.274 to 90.296 mm
0.50 mm .............. 90.020 to 90.042 mm
0.75 mm .............. 89.766 to 89.778 mm
1.00 mm .............. 89.512 to 89.534 mm
1.25 mm .............. 89.258 to 89.280 mm
Maximum journal out-of-round. ..... 0.08 mm
Maximum journal taper .................. 0.05 mm
Crankpins
Diameters (Ø) (mm):
Standard ..................................... 73.831 to 73.850 mm
Undersizes: 0.25 mm ................ 73.577 to 73.596 mm
0.50 mm ................ 73.323 to 73.342 mm
0.75 mm ................ 73.069 to 73.088 mm
1.00 mm ................ 72.815 to 72.834 mm
1.25 mm ................ 72.561 to 72.580 mm
Width (A): ...................................... 43.900 to 44.000
Fillet radius (R) .............................. 3.75 to 4.00 mm
Maximum crankpin out-of-round. .. 0.08 mm
Maximum crankpin taper ............... 0.05 mm

Widths (A) (mm): Big-end bearing shells

standard ........................................... 45.975 to 46.025 Thickness (C),
oversize 0.2 mm Standard .......................................... 1.912 to 1.922 mm
(0.1 mm thrust bearing) .................. 46.175 to 46.225 Oversizes: 0.25 mm ..................... 2.039 to 2.049 mm
oversize 0.4 mm 0.50 mm ..................... 2.166 to 2.176 mm
(0.2 mm thrust bearing) .................. 46.375 to 46.425 0.75 mm ..................... 2.293 to 2.303 mm
oversize 0.6 mm 1.00 mm ..................... 2.420 to 2.430 mm
(0.3 mm thrust bearing) .................. 46.575 to 46.625 1.25 mm ..................... 2.547 to 2.557 mm

Fillet radius (R) .............................. 3.75 to 4.00 mm

Connecting rods
Length between centres (E) .......... 247.5 mm
Thrust bearings Little-end bush internal dia. (G) ... 47.020 to 47.026 mm
Widths (B) Max. endfloat,
standard .................................... 2.312 to 2.362 mm crankshaft to connecting rod .... 0.350 mm
oversize 0.1 mm ..................... 2.412 to 2.462 mm Max. running clearance,
0.2 mm ..................... 2.512 to 2.562 mm connecting rod bearings ............ 0.087 mm
0.3 mm ..................... 2.612 to 2.662 mm Marked 1 to 6, “FRONT” to front of engine.

9
Lubrication system
Oil pressures:
normal running ........................... 300 to 500 kPa
idling, minimum pressure ........... 150 kPa
Lubricating oil pump
Type ................................................
No. of teeth:
drive gear ....................................
idler gear .....................................
Diameters:
idler gear bearing sleeve .............
idler gear bush ............................
End floats:
pump gear ...................................
idler gear .....................................
Pump gear flank clearance ..............
Clearance, pump gear to housing ...
Full-flow and bypass oil filters
Tightening torque
(with oiled sealing ring) ............. Hand-tight
Lubrication system valves
A. Overflow valve
Free spring length ........................... 68.8 mm
Length with max. load .................... 30.0 mm
B. Bypass valve
Markings ......................................... White
C. Reducing valve
Markings ......................................... Blue
Reducing valve for piston cooling
+10
Opening pressure ............................ 100 /–0 kPa
10
Fuel system (all engine variants)
Fuel injection pumps and regulators
Pump type ....................................... H1
Regulator ........................................ Electronic, with
built-in α control
Gear-driven Pump rotation,
viewed from coupling end .......... Clockwise
27 Fuel injection sequence .................. 1-5-3-6-2-4
48 Basic pump settings ........................ Not adjustable
Feed pressure, normal ..................... 130 to 180 kPa
63.99 mm minimum .................................... 80 kPa
64.05 mm
0.07 to 0.15 mm
0.10 to 0.18 mm Overflow valves
0.15 to 0.30 mm Opening pressure ............................ 130 to 280 kPa
1.0 to 1.5 mm
Injectors
Injector retaining collars, cyl.1 ....... KBEL 98 P 173
cylinders 2 to 6 ........................... KBEL 98 P 102
Control pins .................................... REF DLLA-145-PU
318 6582
Numbering
Cylinder 1 ....................................... 0 432 191 505
Cylinders 2 to 6 .............................. 0 432 191 506
Pressures
Opening pressure
(all injector types) ....................... 25.0 +8/–0 MPa
Setting pressure
(all injector types) ....................... 26.0 +8/–0 MPa
Injector spray holes
Number of holes x diameter ........... 7 x 0.203 mm
Fuel filter
Quantity .......................................... 1
Fuel tanks
Transport only ................................ 50 litres
Above right front wheel arch .......... 220 litres
Above left front wheel arch ............ 220 litres
Inlet and exhaust system Wear tolerances
Turbocharger Cylinder liners
Full load boost pressures at 2000 rpm The cylinder liners (together with their pistons and
D7C 250 engines piston rings) must be replaced if their internal diameter
(2 000 rpm, full load) ............... 160 to 175 kPa has increased by 0.35 to 0.40 mm, or if the oil consump-
Wastegate opens 1 mm at ............ 185±2 kPa tion is abnormally high.
End float (mm) ............................ min. 0.04, max. 0.09
Radial play (mm) ......................... min. 0.33, max. 0.50
Crankshaft
NOTE: The specified values must not be exceeded, as this can Max. permitted out-of-round on
damage the engine. main bearing journals and
crankpins .................................... 0.08 mm
Wastegate Max. permitted taper on main
Opening pressure for testing ............. 185±2 kPa bearing journals and crankpins ... 0.05 mm
Setting value for control travel Maximum crankshaft endfloat ........ 0.40 mm
(at 185 kPa) .................................. 0.5 to 1.04 mm Max. permitted ovality on centre
Reference value for control travel main bearing journal ................... 0.15 mm
(at 185 kPa) .................................. 0.33 to 1.27 mm

Air intake pressure drop indicator Connecting rods

Red indication at fall in pressure drop .. 5 kPa
Exhaust gas pressure regulator
Pressure at start and warm-up ........... 7.5±0.5 bar
Pressure during exhaust braking ....... 7.5±0.5 bar
Exhaust gas back pressure
Maximum back pressure ................... 12 kPa
Cooling system
Type .................................................. Overpressure
Pressure valve opens at ..................... 75 kPa
Coolant
Type ................................................ C
Consists of ...................................... Antifreeze with
corrosion-inhibit-
ing additives
Colour ............................................. Blue-green
Coolant pump
Type ................................................ Gear-driven
centrifugal pump
Straightness, max. permitted
deviation per 100 mm
measured length .......................... 0.01 mm
Twist, max. deviation per 100 mm
measured length .......................... 0.10 mm
Valves
Max. permitted valve stem wear .... 0.02 mm
Max. permitted clearances
between stem and guide:
inlet ............................................. 0.20 mm
exhaust ........................................ 0.30 mm
Minimum contact face width
on valve head disc:
inlet ............................................. 2.0 mm
exhaust ........................................ 1.0 mm
The valve seats may be reground until the distance from
the inlet (A) or exhaust (B) valve face is not more than
0.04 mm. If the distance exceeds this amount, the valve
seat or seats must be changed.

Thermostat
Type ................................................ Piston thermostat
Opening temperature ...................... 82±2°C*
Fully open at ................................... 92°C
* 75ºC for buses in hot climates, and those with ZF automatic
transmission

Engine control system

Sensor gaps
Camshaft sensor, injection pump ... 0.20 to 0.65 mm
Flywheel sensor .............................. 1 to 2 mm

11
Camshaft Idler gearwheel bearing
Max. permitted out-of-round securing screw ............................ 90±9 Nm
(with new bearings) .................... 0.05 mm Rocker shaft bearing bracket
Max. permitted bearing wear .......... 0.05 mm securing screws........................... 50±7 Nm
Oil sump securing screws ............... 24±3 Nm
Minimum tappet heights:
Oil sump drain plug ........................ 80±9 Nm
inlet ............................................. 8.33 mm Flywheel securing screws ............... 190±10 Nm
exhaust ........................................ 8.33 mm Flywheel casing securing screws .... 140±14 Nm
Crankshaft belt pulley
Flywheel, in place securing screws........................... 90±9 Nm
Max. permitted axial throw Crankshaft centre bolt ..................... 260±25 Nm
(manual gearboxes), at 150 mm Piston cooling nozzle nut ................ 33±4 Nm
measurement radius .................... 0.15 mm Oil pump idler gearwheel
securing screws........................... 33±4 Nm
Flywheel housing, in place Oil delivery pipe nut
with compression ring, new ........ turn nut 180°
Max. permitted axial throw Oil delivery pipe nut
of flywheel housing contact with compression ring, re-used .. turn nut 60°
surface to clutch housing ............ 0.15 mm Fuel injection pump bracket,
Max. permitted radial throw screws securing bracket to pump 24±4 Nm
of internal Fuel injection pump bracket,
flywheel housing screws securing bracket
edge to clutch housing ................ 0.25 mm to engine block ........................... 48±8 Nm
Fuel injector securing yoke nuts ..... 50±5 Nm
Exhaust manifold securing nuts
step 1 ........................................... 10±2 Nm
Tightening torques step 2 ........................................... 60±5 Nm
Turbocharger compressor wheel
lock nut
Cylinder head (tightened in 4 stages, in the order shown (NOTE: left-hand thread) ........... 17 Nm
in the diagram below) Turbocharger bearing housing
first stage .................................... 30 Nm securing screws to turbine
second stage ................................ 90 Nm housing ....................................... 14 Nm
third stage ................................... 90 Nm Exhaust gas pressure regulator
fourth and final stage .................. 60° further piston nut .................................... 10.5±0.5 Nm

Tightening torque table for nuts marked 8:8

Note: Any bolts or screws that are not listed above, but
carry the standard 8:8 marking should be tightened in
accordance with the following table:

Thread Diameter Tightening torque

Nm Turn nut
Main bearing cap nuts M5 5 mm 6±1 Nm
(step 1) ........................................ 150±10 M6 6 mm 10±1.5 Nm
(step 2) ........................................ 90°±5° M7 7 mm 17±3 Nm
Big-end bearing cap nuts M8 8 mm 24±4 Nm
(step 1) ........................................ 35±3 M10 10 mm 48±8 Nm
(step 2) ........................................ 90°±5° M12 12 mm 85±15 Nm
Camshaft thrust bearing M14 14 mm 140±25 Nm
securing screws ........................... 65±5 Nm
Timing gear casing and noise
damping plate securing screws ... according to torque Tightning pattern exhaust manifold
table for nuts
marked 8:8
Camshaft drive gearwheel
securing screws ........................... 90±9 Nm
Fuel injection pump drive gearwheel
+30
nut ............................................... 300 –0 Nm

12
 Electrical system and instrumentation
System voltage .............................................................. 24V

Batteries
Number of batteries, voltage, individual capacity ........ 2 x 12V, 170 Ah
Ground (earth) connection ............................................ Negative terminal
Specific gravity of electrolyte:
in fully charged battery ............................................. 1.28
when battery needs to be recharged .......................... 1.24
Recommended charging voltage .................................. Approx. 28V
Charging time from full discharge ............................... Approx. 16 hours

Alternator 2 x 80A
Manufacturer and designation ...................................... Bosch N1-28V 10/80A
Rotation ........................................................................ Reversible
Drive ............................................................................. Belt
Weight, per alternator ................................................... 6.8 kg
Maximum output power, per alternator ........................ 2 240 W
Pair connection ............................................................. Parallel
Cut-in speed .................................................................. 1 350 rpm
Maximum load speed ................................................... 6 000 rpm
Maximum permitted speed ........................................... 11 000 rpm
Resistance over slip rings ............................................. 7.5±0.75 ohms
Stator resistance between phases .................................. 0.115 to 0.1265 ohms
Minimum diameter of slip rings ................................... 26.8 mm
Protrusion distance for new carbon brushes ................. 14 mm
Minimum protrusion of worn carbon brushes .............. 5 mm
Maximum radial run-out of slip-rings .......................... 0.03 mm
Maximum radial run-out of rotor ................................. 0.05 mm
Belt pulley nut tightening torque .................................. 50 Nm
Charging regulator ........................................................ Integrated, transistorised
Maximum ambient temperature ................................... 80°C

Alternator 115A and 180A

Manufacturer and designation ...................................... Lucas AC 203 R
Rotation ........................................................................ Reversible
Drive ............................................................................. Belt

115 A 180 A
Maximum output power, per alternator 3 200 W 5 000 W
Maximum load current 115 A 180 A
Cut-in speed 620 rpm 990 rpm
Maximum permitted speed 8 000 rpm 8 000 rpm
Resistance over slip rings 10 to12.2 ohms 9.3 to 9.7 ohms
Minimum diameter of slip rings 22 mm 22 mm
Protrusion distance for new carbon brushes 14 mm
Minimum brush length 81 mm 81 mm
Belt pulley nut tightening torque 90 to 100 Nm 90 to 100 Nm
1
Min. 6 mm from brush end to brush holder.

13
Alternator 140A
Manufacturer and designation ...................................... Bosch T1-28V 10/80A
Rotation ........................................................................ Reversible
Drive ............................................................................. Belt
Weight .......................................................................... 12 kg
Maximum output power ............................................... 3 920 W
Maximum load current ................................................. 140 A
Cut-in speed .................................................................. 1 100 rpm
Maximum load speed ................................................... 7 000 rpm
Maximum permitted speed ........................................... 11 000 rpm
Charging regulator ........................................................ Integrated, transistorised
Maximum ambient temperature ................................... 80°C

Starter motor
Manufacturer/Designation ............................................ Bosch JF (R) 24V, 4.0 kW
Mode of operation ........................................................ Sliding pinion
Polarity ......................................................................... Negative ground
Power rating .................................................................. 4.0 kW
Number of brushes ....................................................... 4
Lubricant ....................................................................... Volvo Grease (Equivalent to Bosch FT2V3)
Gear ratio, starter motor-engine ................................... 15.6:1 (9 teeth on the starter pinion)
Starter motor electrical testing values
Free running starter motor:
Speed ............................................................................ 116.7 r/s (7 000 rpm)
Current .......................................................................... 50 A
Voltage ......................................................................... 23.5V
Stalled starter motor
Voltage ......................................................................... 13.5V
Current .......................................................................... 900 to 1050 A
Starter solenoid
Minimum actuating voltage .......................................... 18V

Tachograph calibration values

Refer to the current Tachograph and Speedometer Service Bulletin 3(38) for details of the calibration methods and
values applicable to the instruments installed in B7L buses.

Power transmission, rear axle

Automatic transmission, ZF 4/5 HP 500/590
Type .............................................................................. Fully automatic 4 speed transmission
with torque converter and built-in retarder
Gear selector ................................................................. Push-button type
Mechanical gear ratios:
1st ............................................................................. 3.43:1
2nd ............................................................................ 2.01:1
3rd ............................................................................. 1.42:1
4th ............................................................................. 1.00:1
Reverse ..................................................................... 4.84:1
Torque converter hydraulic ratio .................................. 2.16:1

14
Sizes and distances
Torque converter, dimension of gearbox housing to
torque converter (attachment surface) ...................... 81.25±0.5 mm (without starter ring)
Gap between inductive sensor and gear teeth tips ........ 0.6 to 0.8 mm

Oil pressure
Values checked at normal transmission operating
temperature, 60 to 80°C: MPa bar Engine speed, rpm
1. Main pressure, N position ......................................... 1.8±0.2 18±2 approx. 700 to 2 000
D position with lock-up engaged .............................. 1.0±0.2 10±2 over 2 000
2. Modulator pressure ................................................... 0.60 to 0.65* 6.0 to 6.5*
* reduces to adjusted pressure for the respective gear at the instant of change (less than 1 sec. approx.); approx. 0.5 bar in N or D
while idling.

Tightening torques Nm
Drain plug, oil sump (1) ............................................... 50 to 60
Oil filter cover and oil sump securing screws (2) ......... 25
Oil cooler plugs (3) ....................................................... 21 to 25
Output shaft and turbine speed inductive sensors (4) ... max. 50
Output shaft speed inductive sensor cover nuts (5) ...... 10±1.5
Turbine speed inductive sensor plug inside sump (6) .. 80 to 100
Engine to transmission securing screws:
large (M12) ............................................................... 70 to 90
slotted screws on starter ring (M8) ........................... 20 to 26
Flywheel cover mounting nuts ..................................... 67±6
Torque converter centre plug (7) .................................. 190 to 210

Tightening torque reference illustrations for ZF 4/5 HP 500/590

15
Automatic transmissions, Voith D863.3 and D.864.3
Type .............................................................................. Fully automatic transmission with torque
converter on first stage, also acting as a retarder.
Built-in Neutral on Bus Stop function.
Gear selector ................................................................. Push-button type, with 3, 4, 5 or 6 buttons
(1-2-3-D-N-R)
Retarder engagement .................................................... 3 steps via hand control and footbrake pedal valve
Gear ratios:
1st (hydraulic) ........................................................... 4.96:1
2nd ............................................................................ 1.36:1
3rd ............................................................................. 1.00:1
4th (D.864.3 only) .................................................... 0.73:1
Reverse ..................................................................... 4.80:1
Torque converter pressures ........................................... Refer to Service Manual TP 16135/1
High oil temperature sensor closes at ........................... approx.140°C

Tightening torques (see next page for reference illustrations)

3/8" bolts securing spring clutch to flywheel (A) ......... 38 Nm
Nuts securing flywheel housing (B) ............................. 61±6 Nm
Four bolts on propeller shaft flange bolts ..................... 175±30 Nm
Three bolts securing flange to output shaft (C) ............ 72 Nm
Drain plugs
– sump (D) ............................................................... 50 Nm
– torque converter (E) ............................................. 50 Nm
– oil filter (F) ........................................................... 25 Nm
M8 nuts for oil filter housing cover and sump (G) ...... 25 Nm
Two external plugs for testing oil pressures (H) .......... 25 Nm
n2 and n3 speed sensors (J) .......................................... 30 Nm
Valve bodies cover securing bolts (K) ......................... 25 Nm
Bolt, control valve block (L) ........................................ 20 Nm
Heat exchanger securing bolts, M12 (N) ...................... 85 Nm
Cap nuts securing heat exchanger oil hoses (P) ........... 100 Nm
Sensor cabling protection bolts (M) ............................. 15 Nm

Propeller shaft
Flange, max. permitted axial play ................................ None

Tightening torque, flange bolts

ZF and Voith automatic transmissions ..................... 175±30 Nm

Universal joints, recommended lubricant ..................... Shell Retinax LX or equivalent

Final drive
Type .............................................................................. Portal, 80° offset input, double reduction gearing
Reduction ratios ............................................................ 4.07:1, 4.54:1, 5.13:1, 5.74:1

Tightening torques
Pinion nut ...................................................................... 1000 Nm
Casing nuts and bolts .................................................... 200 Nm

16
Tightening torque reference illustrations for
Automatic transmissions, Voith D863.3 and D.864.3
G K B

H F
G
A N G
P

D
J (n3)

J (n2) L M

17
 Brakes
Front wheel brakes
Type .............................................................................. Disc brakes with ventilated discs, floating calipers
and automatic adjustment
Operation ...................................................................... Compressed air via brake cylinders and levers
Lubricant for brake mechanism and caliper sliding su
rfaces ......................................................................... Shell Darina or equivalent

Brake pads
Brake pad friction material ........................................... ABEX 921
New brake pad friction material thickness ................... 19 mm
Minimum permitted pad friction material thickness .... 5 mm

Brake discs
New brake disc thickness ............................................. 45.0 to 45.2 mm
Minimum thickness due to wear and/or regrinding ...... 39 mm
Maximum disc run-out ................................................. 0.40 mm
Maximum permitted run-out after regrinding .............. 0.10 mm

Disc brake adjustment

Play between pads and disc .......................................... 0.4 to 0.7 mm
Maximum permitted lever stroke with 72 mm long lever
at 7 bar operating pressure ............................................ 45 mm

Tightening torques
Carrier bracket M20 screw ........................................... 550 Nm
Caliper housing cover plate securing screws ................ 220±10 Nm
Short screws securing carrier bracket to caliper housing 50 Nm, then 96 to 101° further
Long screws securing carrier bracket to caliper housing 50 Nm, then 132 to 137° further
Screws securing brake disc flange to wheel hub .......... 275 Nm, tightened diagonally
Bolt securing steering arm to caliper housing .............. 750 Nm
Brake cylinder securing screws .................................... 105±15 Nm
Brake cylinder fork ....................................................... 45±5 Nm
Operating lever clamp screw ........................................ 85±15 Nm
Pressure equalizing plate securing screw ..................... 42 to 52 Nm

Rear wheel brakes

Type .............................................................................. Simplex type S-cam
Operation ...................................................................... Compressed air via brake cylinders
Diameter ....................................................................... 393.7 mm
Operating pressure ........................................................ 7.1 to 8.3 kgf/cm2

Brake drums
Maximum permitted wear (including turning) ............. 3 mm on the diameter
Maximum permitted out-of-round ............................... 0.25 mm
after machining ......................................................... 0.1 mm on the diameter

Brake linings
Width ............................................................................ 203 mm (front), 254 mm (rear)
Size (10") ...................................................................... 250 x 19 x 381 mm
Oversize, thickness ....................................................... 20.5 mm
Clearance, lining to drum ............................................. 0.30 to 0.35 mm
Effective brake friction area ......................................... 3810 cm2

18
Compressor
Designation ................................................................... Knorr-Bremse LP 4968
Type .............................................................................. Piston, water cooled head
Number of cylinders ..................................................... 2
Air capacity at 1200 kPa (12 bar)
and engine speed 2000 r/min .................................... 570 dm3/min (litres/min)
Max.pressure ................................................................ 13 bar
Max. operational speed, compressor ............................ 3 000 rpm
Cylinder bore, standard ................................................ 88 mm
Stroke ............................................................................ 50 mm
Displacement ................................................................ 600 cm3

Check measurements, wear etc.

Cylinder bore, maximum wear ..................................... 0.16 mm
Piston rings, max.permitted play in groove .................. 0.05 mm
Piston ring gap, minimum, in cylinder ......................... 0.50 mm
Crankshaft bearing, max. permitted wear ..................... 0.13 mm
Big-end bearing, max. permitted wear ......................... 0.20 mm
Crankshaft axial play, max. permitted wear ................. 0.60 mm

Tightening torques
Drive gear wheel ........................................................... 200 to 250 Nm
Cylinder-block bolts ..................................................... 22 to 24 Nm
Cylinder head bolts, stage 1 .......................................... 3 Nm
Cylinder head bolts, stage 2 .......................................... 30 to 33 Nm
Valve plate, long screws ............................................... 12 to 15 Nm
Valve plate, short screws .............................................. 11.4 to 12.6 Nm
Connecting rod bolts, without bearing shells ............... 13 to 16 Nm
Connecting rod bolts, with bearing shells .................... 33 to 38 Nm
Bottom cover ................................................................ 5.5 to 6.5 Nm
Rear cover ..................................................................... 22 to 24 Nm

Air drier
Type .............................................................................. Haldex single-tower type with replaceable element
Pressure regulator ......................................................... Built-in
Maximum cut-out pressure ........................................... 8.7 bar
Minimum cut-in pressure ............................................. 7.3 bar

Safety valve
Opening pressure .......................................................... 0.93±0.035 MPa

Tightening torques for cap nuts at brake pipe connections

Steel pipes Nm kpm
6 mm pipe ................................................................. 20 2
8 mm pipe ................................................................. 25 2.5
1/4" pipe ................................................................... 20 2
3/8" pipe ................................................................... 25 2.5
5/8" pipe ................................................................... 40 4

Plastic pipes
1/4" pipe ................................................................... 15 1.5
3/8" pipe ................................................................... 20 2
1/2" pipe ................................................................... 30 3
5/8" pipe ................................................................... 40 4

19
Compressed air tanks
Two-axle bus
Primary (wet) tank ........................................................ 30 dm3 (litres)
Regeneration tank ......................................................... 6 dm3 (litres)
Front brake circuit tank ................................................ 30 dm3 (litres) capacity, aluminium
Rear brake circuit tank .................................................. 30 dm3 (litres) capacity, aluminium
Parking brake circuit tank, B7LA ................................. 30 dm3 (litres)
Centre axle brake circuit tank, B7LA ........................... 35 dm3 (litres)
Rear axle brake circuit tank in front chassis, B7L ........ 15 dm3 (litres)

Articulated bus
Primary (wet) tank ........................................................ 30 dm3 (litres)
Regeneration tank ......................................................... 6 dm3 (litres)
Front brake circuit tank ................................................ 30 dm3 (litres)
Rear brake circuit tank .................................................. 30 dm3 (litres)

Drain valves
Type .............................................................................. Manual

Four-circuit protection valve

Designation ................................................................... Knorr-Bremse AE 4427
Closing pressure, footbrake circuit ............................... min. 580 kPa
parking brake and other air equipment ..................... min. 470 kPa
Opening pressure, footbrake circuit ............................. 670–700 kPa
parking brake and other air equipment ..................... 540-570 kPa

Footbrake valve (2-circuit)

Max. permitted difference in brake pressure between
the two circuits in the entire pressure range ............. 20 kPa

Low-pressure indicator
Activation pressure, parking brake ............................... 510–570 kPa
footbrake circuit ........................................................ 460–520 kPa

Brake light switch

Closing pressure ........................................................... 10–50 kPa

Relay valve
Type .............................................................................. With connector for silencer

Hand control, parking brake

Type .............................................................................. Knorr HB 1143

Blocking valve
Valve closes when pressure falls below ....................... 340–400 kPa
Control button remains pressed in if the pressure
in the tank exceeds the closing pressure.

20
Brake cylinders
Front wheels
Size ............................................................................... 30# (= diaphragm area in sq.in.)
Max. permitted stroke ................................................... 51 mm
Rear wheels
Type .............................................................................. MGM 30

Test nipple
Connection thread ......................................................... M16 x 1.5 mm

Lubricant
Brake cam, automatic slack adjuster
(when dismantling) ................................................... Grease Li/EP NLGI no. 2, available in 80 g or 400 g

Front suspension and steering

Wheel angles
Caster angle .................................................................. 2.0°±0.5°
Camber ......................................................................... 0.75°±0.25°
Inward inclination of king-pin (KPI) ............................ 5.75°±0.25°
Toe-in ........................................................................... Parallel ±1.5 mm
Curve angles (max. wheel lock), front axle
inner wheel with 275/70R22.5 tyres ......................... max. 50°
outer wheel ............................................................... 43°
Clearance to tyre ........................................................... 10 mm minimum

Front axle
Type .............................................................................. Independent suspension
King-pin diameter (in bushing) .................................... 50 mm
Shims for king-pin bearing, thickness .......................... 0.25 mm, 0.35 mm, 0.40 mm
Axial clearance for king-pin bearings .......................... 0.05–0.10 mm

Power steering
Manufacturer and designation ...................................... ZF 8098
Type .............................................................................. Recirculating ball and nut with integral servo unit
Max. operating pressure ............................................... 130 bar
Max. output torque ....................................................... 6 726 Nm
Steering wheel diameter ............................................... 500 mm
No. of steering wheel turns lock to lock ....................... approx. 4.5

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Servo pump
Type .............................................................................. LUK vane pump
Max. pump pressure ..................................................... 11 MPa
Min. capacity ................................................................ 15.5 litres/min
Max. capacity ............................................................... 20.4 litres/min
Reduction ratio, engine – pump .................................... 1:1.58

Tightening torques
Steering
Steering wheel nut ........................................................ 75 Nm
Pitman arm nut ............................................................. 550 Nm
Steering gear to bracket securing screw ....................... 560* Nm
Steering gear bracket to chassis frame securing screw. 220 Nm
Castle nut, link rods and bearing
for intermediate steering arm ........................................ 200 Nm and then further to nearest split pin hole
Steering shaft to steering shaft joint clamp screw ........ 60 Nm
Angle gear attachment screw ........................................ 85 Nm
Attaching screw, bearing/anchor bracket,
intermediate steering arms ........................................... 140 Nm
Link rod clamping screws ............................................ 47.5 Nm
Steering arm attachment screws ................................... 750* Nm
Axle spindle castle nut .................................................. 500 and then further to nearest split pin hole
Axle spindle cover securing screw ............................... 40 Nm
Servo pump drive lock nut ........................................... 100 Nm
Steering gear cover securing screw .............................. 189 Nm
Load relief valve lock nut ............................................. 30 Nm

Wheel suspension
Upper support arm M16 bolt ........................................ 220 Nm
Upper support arm M20 bolt ........................................ 430 Nm
Spindle bushing in upper support arm, M10 screw ...... 48 Nm
Inner spindle securing screw, upper support arm ......... 48 Nm
Lower support arm M20 bolt ........................................ 430 Nm
Lower support arm distance rod M20 screw ................ 430 Nm
Spindle bushing in lower support arm, M12 screw ...... 85 Nm
Lower support arm member securing screw, M16 ....... 275 Nm
* Secured by locking wire after tightening to correct torque.

Frame, suspension, wheels

Frame
Front module ................................................................ Combination of open channel sections and boxed
sections, with built-up wheel arch structures
Rear module .................................................................. Mainly square-section tubular steel components
with shear panels
Overall length, 6000 mm wheelbase
Normal Steering position (NS) ................................. 11 690 mm
Forward Steering position (FS) ................................ 11 790 mm
Overall width
front wheels .............................................................. 2 476 mm
rear wheels ................................................................ 2 456 mm

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Electronically controlled suspension system (ECS)
No. of air bellows in non-articulated bus ..................... 2 at front, 4 at rear
No. of air bellows in articulated bus ............................. 2 at front, 4 at centre, 4 at rear
Working pressure at full load
front .......................................................................... 930 kPa at 6900 kg axle load
centre (B7L Artic) .................................................... 650 kPa at 10 000 kg axle load
rear ............................................................................ 800 kPa at 12 000 kg axle load
Maximum air pressure for suspension system .............. 1 180 kPa
Minimum operating pressure ........................................ 1 020 kPa
Air suspension low pressure warning at ....................... 750 kPa

Air bellows height

Front axle ...................................................................... 230±3 mm1
Centre (B7L Artic) ....................................................... 236±3 mm1
Rear axle ....................................................................... 236±3 mm1
1
Distance measured between bellows piston lower edge and lower edge of upper attachment plate.

Shock absorbers
Type .............................................................................. Double-acting hydraulic telescopic
Number of shock absorbers in non-articulated bus ...... 4 at front, 2 at rear
Number of shock absorbers in articulated bus ............. 4 at front, 4 at centre, 2 at rear

Height sensors
Number of height sensors in non-articulated bus ......... 2 at front, 2 at rear
Number of height sensors in articulated bus ................ 2 at front, 2 at centre, 2 at rear
Signal scaling ................................................................ 0.0313 V/°
Output signal, normal height ........................................ 2.50 V
Output signal, min. height ............................................ 1.70 V
Output signal, max. height ............................................ 3.44 V
Diameter of tool used to set normal level ..................... 4 mm

Rear suspension circuit pressure limiting valve

Operating pressure ........................................................ 1.3 MPa
Limit pressure ............................................................... 750 kPa

ECS control unit

Operating voltage ......................................................... 18–32 V
Reference voltage to height sensor ............................... 5.00 V
Power consumption, stand-by ...................................... 4 W max.
Power consumption, in operation ................................. 12 W

Manual height control

Height increase ............................................................. ±80 mm
System pressure at max. load ....................................... 1050 kPa

23
Tightening torques
Lock nuts, front wheel hubs ......................................... 450* Nm
Hub caps, front wheel nuts ........................................... 250 Nm
M12 attaching screw, reaction rod brackets
and reaction rods ....................................................... 85 Nm
Shock absorber attachment, front axle
upper ......................................................................... 200 Nm
lower ......................................................................... 115 Nm
Shock absorber attachment, rear axle
upper and lower ........................................................ 200 Nm
* Slacken 60° after tightening.

Wheel rim dimensions

Steel disc 10-bolt wheels
Steel rims .................................................................. 7.50-22.5"

Tyres
Tyres ............................................................................. 275/70-22.5"

Recommended inflation pressure (cold tyres) as per graph.

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 Volvo Bus Corporation
Göteborg, Sweden

TP 16179/2 English 1500.12.99 Printed in Sweden by Novum Grafiska AB, Göteborg