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Volvo DH10A 245 Service Manual

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Service Manual
Buses
Section 2 (20–27)
Engine DH10A,
245, 285, 345, 350, 360
TP 16031/1

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Summary of Contents for Volvo DH10A 245

  • Page 1 Service Manual Buses Section 2 (20–27) Engine DH10A, 245, 285, 345, 350, 360 TP 16031/1...

  • Page 2: Table Of Contents

    Contents Group 20: General Group 23: Fuel system Variant description DH10A ......Detailed list of contents ........88 Performance ............Injection pump ..........91 Specifications ........... Injection timer ..........92 Wear tolerances ..........15 Injectors ............94 Tightening torques ..........16 Special tools .............
  • Page 3 Engine DH10A Variants been changed but still build on the re-entry model, that Common characteristics: The DH10A-series is largely is, a more favourable air rotation and thereby a more based on the earlier THD104 engine. Characteristics: complete combustion. The injection system is electron- Horizontal design, turbocompressor feed, 9.6 liter dis- ically controlled (EDC).

  • Page 4: Performance

    Torque Vridmoment Drehmoment Couple Par motor 1200 1600 360 EC96 1000 285 EC96 1400 350 TW95 245 EC96 345 J96 1200 1000 1200 1400 1600 1800 2000 2200 2400rpm 1000 1200 1400 1600 1800 2000 2200 2400rpm DH10A 245, 285 DH10A 345, 350, 360...

  • Page 5: Specifications

    Specifications General ENGINE DH10A Type designation ......Net output* kW/hp ......180/245 210/285 254/345 255/350 265/360 at speed r/s / r/min ...... 33/2000 33/2000 33/2000 33/2000 34.2/2050 Max. torque Nm/kpm at 20 r/s (1200 r/min) ....1050/107 1200/122 1440/146 1500/153 1500/153 * Net as per ISO 1585.
  • Page 6 Engine block Piston rings Compression rings Number ........Cylinder head Piston-ring clearance in groove, Type ........1 per cylinder upper compression ring ..0.13 mm Height, new ......114.85–115.15 mm lower compression ring ..0.09 mm after machining min. 114.65 mm Piston-ring gap in ring opening 1st ring ......
  • Page 7 Valve clearance, cold engine Depth (meas. D) Inlet ........0.40 mm Inlet ........8.8–8.9 mm Exhaust ........ 0.70 mm Exhaust ........ 11.8–11.9 mm Recess bottom radius (meas. R) Inlet ........0.5–0.8 mm Exhaust ........ 0.5–0.8 mm Meas. between valve disc and cylinder head face should be min.
  • Page 8 Camshaft Timing gears Drive ......... Gear Number of teeth: No. of bearings ......crankshaft gear (1) ....intermediate gear (2) ....Bearing journal diameters, min. injection pump drive gear (4) .. Front bearing journal ... 68.94 mm servo pump drive gear (8) ..2nd ........
  • Page 9 Crank Mechanism Oversizes 0.2 mm (axial bearing 0.1 mm) .. 46.175–46.225 mm Crankshaft 0.4 mm Length ........1154 mm (axial bearing 0.2 mm) .. 46.375–46.425 mm Crankshaft, end float, max..0.4 mm 0.6 mm Main bearings, radial (axial bearing 0.3 mm) .. 46.575–46.625 mm clearance, max.
  • Page 10 Big-end bearing journals connecting-rod bushing internal diameter (G) ... 52.022–52.028 mm Diameter (Ø) for machining standard ....... 86.003–86.025 mm Axial clearance, crankshaft – undersize 0.25 mm ..... 85.753–85.775 mm connecting rod, max.... 0.35 mm 0.50 mm ..... 85.503–85.525 mm Connecting-rod bearings, radial 0.75 mm .....
  • Page 11 Lube oil pump Type .......... Gear-driven Direct oil filters Number of teeth ......Number ........ Axial play, gear wheel ....0.02–0.08 mm Volvo P/N ......466634-3 Backlash ........0.15–0.35 mm Tightening torque Diameter, (oiled sealing ring) ....25 Nm bushing for pump shaft ..
  • Page 12 Injection pump direction of rotation ......Clockwise Injection sequence ............1-5-3-6-2-4 Injection pump basic setting on engine: DH10A 345 ..............5.5±0.5° B.T.D.C. DH10A 245, 285, 360 ..........7.0±0.5° B.T.D.C. DH10A 350 ..............9.0±0.5° B.T.D.C. Performance check Bus stationary • Engine switched off •...
  • Page 13 Feed pump Designation ..............FP/KG 24 P 307 Feed pressure (depending on speed and load) ....100–400 kPa (1–4 bar) Injectors DH10A 245, 285 Nozzle stand ..............KBEL 117 P 73 Nozzle (Volvo P/N) ............DLLA 150 P555 (425694) Number marking (complete injector) ......
  • Page 14 Anti-freeze Type ........... C Consists of ......... Glycol with rustproofing Colour ........Blue-green Volvo art no. 1 kg ...... 1128700-9 5 kg ...... 1129701-7 235 kg ....1129702-5 Radial clearance at compressor wheel .......... 0.33–0.50 mm For engine DH10A 345, 350, 360 Designation ........
  • Page 15 Opening temperature ....58–62°C Pump, type/designation .... Vickers PVE 19 R Fully open at ......approx. 77°C Fan motor, type/designation ..Volvo Flygmotor F11-19 Fan speed at engine speed 1000 r/min Coolant pump and coolant temperature under 90°C ....... approx. 700 r/min above 94°C ......

  • Page 16: Wear Tolerances

    Exhaust ........ 0.25 mm Valve disc edge should be min. Pump type/designation ..... AFGP 31.5 L Inlet ........1.9 mm Volvo P/N ......... 3118711 Exhaust ........ 1.4 mm Fan motor/designation ....Sauer Sundstrand 551/1/00888/ETC The valve stem insert may be ground down so Volvo P/N .........

  • Page 17: Tightening Torques

    Tightening torques Groups 20–21 Group 22 Bracket, oil pump ..... 40±4 4.0±0.4 Cylinder heads (see note 1) Intermediate gear, oil pump ..17±2 1.7±0.2 Main bearings ......340±25 34.0±2.5 Sump ......... 18±2 1.8±0.2 Big-end bearings ....... (see note 2) Sump cover ....... 24±2 2.4±0.2 +1.0...

  • Page 18: Special Tools

    Special Tools 1084 1801 1819 1866 2000 2013 2089 2267 2268 2269 2337 2479 2529 2654 pressing in bearings, injection pump (999)- Description, 2267 Drift, drive 1084 Drift, pressing out valve guide 2268 Drift, pressing out/in bearing coolant pump 1801 Standard handle fitting bearings coolant pump 2269...
  • Page 19 2658 2659 2665 2666 2671 2677 2679 2807 4706 2800 6049 6065 6066 6068 6088 (999)- Description, 2807 Centering tool, coolant pump 2658 Puller, crankshaft drive gear 4706 Stop tool, flywheel pressing in crankshaft drive gear draining coolant, pressure-testing 2659 Press tool, 6049 Hose,...
  • Page 20 6222 6239 6394 6395 6398 6413 6419 6441 6579 6591 6600 6603 6625 6626 6640 6643 (999)- Description, 6579 Lever 6222 Hydraulic pump, air-driven for hydraulic 6591 Connection nipple, checking charge pressure cylinder 6600 Hydraulic cylinder 10 tonnes 6239 Lift chain 6603 Adapter, used with 6600...
  • Page 21 6645 6647 6656 6662 6664 6666 6669 6670 6671 6672 6685 6781 6796 6815 6816 (999)- Description, 6670 Filter tool 80 mm, fuel filter 6645 Puller yoke, cylinder liners 6671 Oil filter tool copper sleeves oil filter 6647 Reaming tool, 6672 Filter tool 108 mm, 6656...
  • Page 22 6831 6848 6849 6850 6858 6859 6899 6931 8009 8010 8011 8012 8014 8039 8068* 8074 (999)- Description, 8010 Extractor, crankshaft rear seal 6831 Pressure-drop gauge, low-pressure indicator 8011 Extractor, seal injection pump drive 6848 Measuring tool, setting injection angle 8012 Press tool, fitting seal injection pump 6849 Drift,...
  • Page 23 8075 8079 8113 8134 8140 8180 8190 8419 8449 8487 9314 9511 9551 9696 9708 (999)- Description, 8419 Pin spanner, for cleansing plugs 8075 Cover washer, pressure-testing oil cooler, pressing in valve guides 8449 Drift, used with 2800 8487 Tool, for oil filter for camshaft 8079...
  • Page 24 9711 998 5423 998 5468 998 6187 998 7600 998 7057 998 8539 998 8460 951 0060 981 2546 (999)- Description, (981)- Description, cleaning copper sleeve seats 9711 Torque multiplier, 2546 Cleansing tool, (951)- Description, (998)- 0060 Multimeter 5423 Piston ring rod 5468 Valve spring tester 6187...
  • Page 25 5654 8993 8994 999 9954 (998)- Description, (999)- 9954 Component jack, for radiator assembly 5654 Engine carrier trolley 8993 Lift table 8994 Engine fixture...

  • Page 26: Removing And Installing Engine

    Removing and installing engine Weight, engine with gearbox approx. 1300 kg Draining coolant Warning! Special tool: Handling heavy components as those men- (999) 6049 Drain hose tioned above, requires experience in stacking and lifting. Work involving this must never be done by inexperienced personnel.
  • Page 27 Check the coolant level after having run the freezing. engine warm. Volvo coolant is recommended even when the coolant NOTE! For the B10M (late prod. or older that has been does not require anti-freeze. It provides very good pro- altered afterwards) where the vent line from the radi- tection against corossion.
  • Page 28 Removing and installing engine Special tools: (998) 8993 Lift table 8994 Engine fixture Drain the oil and coolant. Switch off the power Release the steering servo pump. with the battery main switch. Release the fan prop shaft. Detach/disconnect necessary cables, hoses and pipes.
  • Page 29 Observe due care with regard to the fuel pipes! The location of the delivery pipes between the in- jection pump and the injectors require the engine to be angled slightly so that the pipes do not catch on the frame member. Note in connection with lifting out engine…...
  • Page 30 Removing and installing rear engine To observe when removing/installing the engine Special tool: Fuel system (998) 5654 Engine carrier trolley Open the fuel pipe joint at the gearbox. Drain the coolant and engine oil (see pages 25 and 26). Bolting The engine is suitably lifted out together with the gear- Engine mounts 80 Nm (8 kpm)
  • Page 31 Adjust in the supports on the lift unit as shown in the pictures below.

  • Page 32: Servicing The Engine

    Servicing the engine The VOLVO warranty for exchange engines (factory new or overhauled) applies on the following condi- tions: Fuel filters, oil filters Air cleaner Both the engine’s fuel filters and both the oil filters Thoroughly clean the air cleaner housing and con- must be changed at the same time.

  • Page 33: Topping-Up Oil

    The oil level must never go below the Min. mark! Oil quality According to VOLVO DRAIN SPECIFICATION (VDS, VDS2) or API CD, CE OR CCMC -D4, D5. Viscosity, see graph below. The temperatures refer to stable air temperatures.

  • Page 34: Replacing Oil Filters

    Replacing oil filters Special tools: (999) 6672 Filter removal tool (Alternative tool: (999) 8487 Filter removal tool) Remove the plate underneath the engine Replace both oil filters when changing the engine 6672 The filters cannot be cleaned – renewal the only service measure permitted.
  • Page 35 Dat. - - - - - - - - Read-off the compression gauge at normal starter motor speed (3.7 r/s). Pressure should be: DH10A 245, 285 ....... 3.6 MPa (36 kp/cm DH10A 345, 350, 360 ....3.2 MPa (32 kp/cm Best. Nr. 5 1341 250 00...

  • Page 36: Charge Pressure

    Charge pressure Mechanical testing (pressure gauge) Special tools: (999) 6065 Pressure gauge 6666 Nipple At too low charge pressure: Check: 6065 – for compressor wheel damage – that the compressor wheel rotates easily – that the axial/radial clearance feels normal –...
  • Page 37 Charge pressure Electrical testing (multimeter) Special tools: (999) 6899 Test box 6931 Adapter 8180 Adapter The charge pressure is checked in two stages; on the (951) 0060 Multimeter engine switched off and on it when driving. The volt- age measured corresponds to a kPa measuring value. Connect-up as in figure.

  • Page 38: Fuel Feed Pressure

    With low charge pressure, check: – for any damage to the turbocompressor ( V ) – fuel filters, fuel feed pressure – charge pressure sensor 4.0 v – control rod travel, injection pump (see Testing in- jection pump). 3.75 Example At 0°C ambient temperature, the turbo pressure voltage should be 3.7 V.

  • Page 39: Oil Pressure

    Oil pressure 6398 Special tools: (999) 6398 Pressure gauge 6666 Nipple At normal engine operating speed and temperature, the oil pressure should be 300–50 kPa (3.0–5.0 kp/cm If the oil pressure is below 60 kPa (0.6 kp/cm ) with a 6666 warm engine and at low idle, this does not mean any- thing is amiss as long as the pressure does not go below...
  • Page 40 Measure valve lift as follows: When the valves “change” direction (open/close) Measure valve lift on cylinder no. on cylinder no. 1 ............ 6 5 ............ 2 3 ............ 4 6 ............ 1 2 ............ 5 4 ............ 3 Check the valve time for no. 1 cylinder (see table below).

  • Page 41: Cylinder Head

    Group 21 Engine Contents Cylinder head – Description ..................– Removing, cleaning ................– Pressure-testing ................... – Valve guides ..................– Valves, valve seats ................– Valve springs ..................– Rocker arm mechanism ............... – Face-grinding cylinder head ..............– Copper sleeve for injectors ..............–...

  • Page 42: Cylinder Head - Description

    Cylinder head The cylinders have separate cylinder heads, which are interchangeable and bolted to the cylinder block by four 3/4" bolts per cylinder head. Having separate cylinder heads is not only technically advantageous with regard to sealing between cylinder head and cylinder block, it also makes servicing easier. Sealing against the cylinder block consists of a special groove in the cylinder head face, a steel gasket and a stepped edge on the cylinder liner collar.

  • Page 43: Removing, Cleaning

    The valve mechanism for each cylinder head consists – an inlet valve and an outlet valve – valve guides – double valve springs with washers and valve locks – rocker arms with adjusting screws – rocker arm shaft with bearing brackets –...

  • Page 44: Pressure-Testing

    Cleaning Disassemble the cylinder head. Clean all the parts and the cylinder block contact surface. Rust and carbon deposits, etc., must be removed from the bolt holes and threads in the cylinder block and cyl- inder head. Paint and dirt must be removed from cylinder head sur- faces in contact with bolt heads otherwise there is risk of leakage and damage to seals and gaskets.

  • Page 45: Valve Guides

    Valve guides Special tools: (999) 1084 Drift 6668 Drift 6669 Drift 9696 Magnetic stand (998) 9876 Dial indicator Valves Max. permitted clearance between valve stem and valve guide: – inlet valve ..........0.15 mm – exhaust valve ........... 0.25 mm Replacing Press out the old valve guides with drift 1084.

  • Page 46: Valves, Valve Seats

    Valves, valve seats Grinding valves Both inlet and exhaust valves should have a contact Before grinding, check the valve guides for wear. surface that is 1/2° smaller than the valve seat contact Replace worn guides and ream. surface. The smaller contact surface gives better seal- ing with a newly ground valve.
  • Page 47 In connection with removal: grind the valve disc on an Weld old valve so that it can be pressed down into the valve seat. Then weld according to the illustration. Tap out the valve seat. Use carbon dioxide snow to cool the seat down to –70°C and –80°C when refitting.

  • Page 48: Valve Springs

    Valve springs Outer valve spring Length unloaded ......... 61 mm With load of 300–390 N (30–39 kp) .. 49.6 mm Inner valve spring Length unloaded ......... 53 mm With load of 80–170 N (8–17 kp) ..42.6 mm Rocker arm mechanism Special tools: (999) 2677 Drift 2267 Drift...

  • Page 49: Face-Grinding Cylinder Head

    2677 2677 2267 Note the oil holes! Face-grinding cylinder head If leakage is discovered or if there is a trace of a blown head gasket, there is no reason to check for unevenness. The head must be machined or renewed anyway. A rough check can be made with the help of a straight- steel edge.

  • Page 50: Copper Sleeve For Injectors

    Copper sleeve for injectors Special tools: (999) 6419 Extractor 8134 Threading tool 6647 Reaming tool 8140 Extractor 8134 6419 Steel ring Sealing ring Make threads in the copper sleeve tap. NOTE: If threading is done with the cylinder head in the engine, the thread die must be greased to prevent thread fil- Pull out the steel ring.

  • Page 51: Installing Cylinder Head

    Installing the cylinder head Special tools: (998) 9876 Dial indicator (999) 2479 Stand 2666 Press tool (two) 6239 Lift chain 2666 2479 Clean the cylinder block face, if this has not been done already. The cylinder block contact surface against the gasket must be shiny before installing the head.

  • Page 52: Cylinder Liners, Pistons, Connecting Rods - Description

    Cylinder liner, piston, connecting rod Piston ring set Upper O-ring Installed dry Gudgeon pin and lock rings Lower O-rings Lubricant packed with gasket set Marked FRONT Cylinder liner Piston Connect- Tightened in ing rod stages (see specifications) Precisely at the end of the compression stroke the air The engines have wet, replaceable cylinder liners.

  • Page 53: Pistons, Piston Rings

    Piston/piston rings Special tool: (998) 5423 Piston ring pliers NOTE! To prevent damage to the piston cooling nozzles, they must first be removed before removing piston and connecting rod. Remove the piston and connecting rod. Measure the piston ring clearance. 0.13 mm Remove the piston rings.

  • Page 54: Gudgeon Pins, Connecting Rods

    Gudgeon pin, connecting rod 1801 Special tools: (999) 1801 Standard handle 2013 Drift 2529 Drift 2013 Disassembling Remove the gudgeon pin lock rings. Press out the gudgeon pin from the piston using drift 2013 and standard handle 1801. Press the bushing out of the connecting rod using drift 2529.

  • Page 55: Cylinder Liners

    The tools used for removing the old bushing can 1801 also be used for pressing in the new one. Make sure the bushing is fitted correctly. Ream the bushing to correct fit. An oiled gudgeon pin should glide under its own weight through 2529 °...

  • Page 56: Installing Cylinder Liners And Pistons

    Removing 6394 Special tools: (999) 2089 Puller plate 2479 Holder 6394 Spacer (two) 6645 6395 Spacer (two) 6395 6645 Extractor If the liner is to be refitted, mark the cylinder liner seating against the cylinder block with a coloured pen. 2089 Pull the cylinder liner up out of the cylinder block.
  • Page 57 Thoroughly clean the cylinder liner collar. Fit a new O-ring on the cylinder liner. Note: The O-ring must be dry. Apply an even, max. 0.8 mm, thick bead of seal- ant round the liner shelf. Within 20 minutes from the time this is done, the cylinder liner must be fitted in the cylinder block.
  • Page 58 8. Fit the piston cooling nozzle. Important… Follow also the instructions on page 90! 9. Fit installation ring 6664 on the piston. Fit the pis- ton, along with the connecting rod, in the cylinder. 6664 10. Fit the connecting-rod cap along with bearing as per line-up marks.

  • Page 59: Cylinder Block/Crank Mechanism

    Cylinder block/crank mechanism...

  • Page 60: Description

    Description Upper cylinder liner seat The cylinder block is one-piece cast of special alloy. Stresses on the cylinder head bolts from combustion pressure are transmited via reinforced ribbing in the cylinder block walls directly to the main bearings. The DH10A engine has a drilling and nozzles for pis- ton cooling.
  • Page 61 Crankshaft The crankshaft is either nitro-carburized or induction- hardened (both alternatives exist). It has a new rear 14- bolt flange against the flywheel (previously 10 bolts). The crankshaft is single-piece forged in special steel. The bearing surfaces are nitro-carburized to increase strength and reduce risk of cracks.

  • Page 62: Cylinder Liner Seats, Machining

    Cylinder liner seats Checking Coolant will leak if the cylinder liner seats and /or the underside of the cylinder liner collars are cor- roded. The cylinder liner must have a tight fit to prevent gas leakage. Machining Special tools: (999) 2479 Holder for dial indicator 2666 Press tool (holder) for cylinder liner 9511 Expander tool 9551 Milling tool...
  • Page 63 Use of special milling tool 9551 Before grinding the cylinder liner seat, measure the cylinder liner height in order to calculate the compen- sation space for removed material. 2666 2479 Use the dial indicator and note the measurement. Assume, for example, that the seat has sunk a bit and is 0.12 mm.

  • Page 64: Cylinder Block, Face-Milling

    9551 Milling cylinder liner seat Feed sleeve Milling head 8. Calculate the milling depth. Example how to calculate shim thickness and machining depth 9. Use a T-handle and flexible joint to move milling A. Read-off the cylinder liner height (from the dial in- tool 9551 round.

  • Page 65: Front Sealing Ring, Crankshaft

    Front sealing ring Special tools: (999) 2000 Standard handle 2337 Lever 2679 Puller 8014 Hollow drift Remove the thrust ring. If necessary, use puller 2679. ± 2679 Tightening torque for thrust ring bolts: 60 6 Nm (6.9±0.6 kpm). 8014 2000 2337 Fitting Removing...

  • Page 66: Timing Gears

    Timing gears 1. Crankshaft gear 2. Intermediate timing gear 3. Injection pump drive gear 4. Power steering oil pump drive gear 5. Camshaft gear 6. Space normally occupied by air compressor drive gear 7. Intermediate oil pump gear 8. Oil pump gear Remove: –...
  • Page 67 Pull off the crankshaft drive gear with puller 2658. Injection pump drive gear. If necesssary use stand- ard puller 2679 with hex socket screw 952076-8. 952076-8 2679 2658 Camshaft drive gear. Remove the oil pump intermediate gear. Replacing timing gears When replacing the compressor and/or the power steer- ing pump on a factory overhauled engine, it is impor- tant to check the data plate to make sure which type of...
  • Page 68 Timing gears Checking Check all clearances when fitting the timing gears. Axial clearance for all intermediate gears: max. 0.15 Check the key-way in the crankshaft for damage and that it sits correctly in the crankshaft groove. Radial clearance for all intermediate gears: max. 0.082 mm.
  • Page 69 Pressing on crankshaft hub Timing gears (polygon hub) Installing Smear the crankshaft end with molybdenumndi- 1. Make sure the crankshaft crosskey is fitted in sulphide grease before pressing on the crankshaft position.Use tool 2659 and fit the crankshaft gear. hub. 6626 2671 8004...

  • Page 70: Drive Mechanism, Injection Pump

    Sealant for timing gear cover Injection pump drive mechanism Sealing agent Volvo P/N 1161231-4 is used instead of Replacing seal, output shaft a gasket. The sealing areas must be thoroughly cleaned before Special tools: applying the sealant. Allow the sealing surfaces to dry.
  • Page 71 Pull out the old seal by screwing down the extrac- tor. At the same time hold tight the extractor with the drift. NOTE! Because the drive mechanism does not have a wedge at the front flange, it is most important that the clamp bolt is tightened to the correct torque: Tightening torque Clamp bolt (A)
  • Page 72 Fit a new sealing ring. Fit the bolts and washers as shown in the figure. Fit the shaft and the rear discs. To torque tighten the bolts properly, a tool like the one shown here should be made by the workshop. Fit the front discs.
  • Page 73 Injection timer, Remove the drive belts, pulley, vibration damper and timing gear cover. removing/installing DH10A, 345, 360 Remove the injection timer drive gear bolts and lift off the gear (with stiff removal, we recommend Special tools: use of a standard puller 999 2679 together with in- (999) 8068 Crank tool hex plug socket to pull off the gear).

  • Page 74: Replacing Camshaft

    Installing Crank the flywheel until no. 1 cylinder is at top dead centre, compression stroke. Note the following… The sealing surface between the timer and the timing gear casing must be clean. Fit a new sealing ring on the timer. The six bolts on the injection timer gear should be ±...
  • Page 75 Remove the valve tappets. Remove the thrust washer. Always check the tappets. Fit extractor 8079. Crank the camshaft one turn so that the valve tap- pets are moved aside. Remove the camshaft. Checking Check cams and bearing races for wear. Cams can wear at an angle.

  • Page 76: Crankshaft

    Crankshaft Checking Prior to any machining, check the crankshaft for cracks. Seizure can cause overheat cracks, which can only be detected by using special equipment. The recommended test involves using a magnetic powder, type MAGNAGLO, which is fluorescent and is scrutinized under ultraviolet light. For pow- der type, concentration, current and magnetizing, follow the instructions of the manufacturer.

  • Page 77: Aligning, Machining

    Straightening the crankshaft To assess straightness, the crankshaft must be support- ed under main bearings 1 and 7 and main bearing 4 checked for out-of-round. Below 0.2 mm No straightening. Between 0.2 Careful straightening, not more and 0.7 mm than necessary. Above 0.7 mm Replace crankshaft.

  • Page 78: Replacing Ring Gear

    Replacing ring gear Punch holes in the ring gear tooth gaps with a chisel. Crack the ring gear at the punched hole. Brush clean the contact surface. Polish the ring gear to a shine at several points round the ring. Evenly blue-anneal heat the pol- ished sections.

  • Page 79: Replacing Support Bearings, Replacing Crankshaft Rear Seal

    Replacing support bearings Special tools: (999) 1801 Standard handle 1819 1819 Extractor 2665 Press tool Remove the support bearing using extractor 1819. Tap in the new support bearing into position in the flyhweel. 2665 1801 Replacing crankshaft rear seal (Clutch removed) Special tools: (999) 2000 Handle 6088 Drift...

  • Page 80: Oil Pump

    Group 22 Lubricating System Contents – Description ..................Oil pump – Removing, installing ................– Servicing ....................Oil cooler – Oil cooler ..................... – Oil pressure, piston cooling ..............
  • Page 81 Lubricating system 2. Relief valve, oil filter 4. Reducer valve lube system From reducer valve From oil tank 1. Piston cooling valve 15773-13 3. By-pass valve oil tank The system has four control valves: 1. Piston cooling valve 2. Relief valve for oil filters 3.
  • Page 82 The piston cooling valve opens when engine The reducer valve opens at excessive lube oil speed has just reached above low idle and oil pres- pressure to return the excess oil back to the sump. sure has increased. The oil is then led by a drilling to the piston cooling duct in the engine block.
  • Page 83 The oil pump is of the gear type and has three pump units. The front unit functions as an oil delivery pump and the other two as scavenging pumps. They all pump the oil back to the oil tank via the oil cooler. The oil pumps are gear-driven from the crankshaft via an inter- mediate drive gear.
  • Page 84 The piston-cooling valve is normally closed at low en- gine speed, this to prevent the oil pressure from drop- ping at low idle. As engine speed increases, the piston- cooling valve opens to direct the oil to six calibrated nozzles, one under each piston. Piston-cooling nozzles If piston cooling is cut-off, reduced or wrongly aimed, the piston will seize after a relatively short period under...
  • Page 85 Installing Special tools: (999) 2807 Centering tool 6656 Centering tool 1. Connect up the pipes. Fit the sump. Tightening torque 2. Insert centering tool 2807 in the crankcase hole for Main bearings ....340±25 34.0±2.5 the drive gear. Insert centering tool 6656 in the Sump .........
  • Page 86 Servicing oil pump Special tools: (999) 2654 Puller 6849 Drift 6850 Reamer Use puller 2654 to remove the oil pump drive gear from the shaft. Dismantle the oil pump. 2654 Check the pump body for scoring and wear also for leakage signs between the bracket and the pump body.
  • Page 87 Reaming bushings 6850 Checking pump gears axial clearance 1. Check the axial clearance for the pump gears. In both cases, place a feeler gauge 1.0–1.5 mm be- tween the pump gear and the bracket. Correct clearance: 0.02–0.08 mm. 2. There are two ways in which to fit the oil pump drive gear: –...
  • Page 88 Assemble the pump. Draw the pump body halves together with the two bolts. Check to make sure the gears rotate easily. NOTE! Fit the main bearing bolts before final assem- bly. ± Tightening torque, oil pump intermediate gear: 22 Nm (2.2±0.3 kpm) Oil cooler Pressure testing Special tools:...

  • Page 89: Injection Pump

    Group 23 Fuel System Contents – Description ..................– Injection timer ..................Injectors – Replacing, testing ................– Cleaning copper sleeves ..............Injection pump – Removing, installing ................– Basic timing injection pump (EDC) ............ – Idling speed ..................– Venting fuel system ................100 –...

  • Page 90: Description

    Fuel System Electromagnetic governor Feed pump Stop device Injection pump setting values, chiefly fuel flow and pre-injection angle, differs for the various engine types. The reason for this is that these values are adapted to the properties that the engine has with regard to emis- sions and power output.
  • Page 91 Pump camshaft The feed pump supplies the injection pump with fuel under pressure. Fuel flows through the fuel filters be- fore reaching the injection pump. Push rod The pump camshaft pressing down the piston causes the pump chamber in the feed pump to fill with fluid. When the cam has passed its highest point and the pis- ton spring presses back the piston, the pump discharges the fuel.
  • Page 92 Injection pump D10A THD104 Differences The delivery valves have been replaced by damper valves in order to maintain a higher pressure at the in- jectors, without having to raise the injection pump pressure. The delivery valve holders (delivery pipe connections) are now longer and have only one damper valve.

  • Page 93: Injection Timer

    The governor adjuster device (1) is placed in the gov- ernor housing end and consists of an electromagnet that works directly against the injection pump control rod. The control rod position sensor (2A and 2B) gives the control unit the opportunity of deciding if current to the adjuster device should be increased or decreased.
  • Page 94 Function The injection timer alters the -angle to suit operating The value of a and b can be seen from the following conditions, see diagram below. When there is no cur- table: rent in the solenoid valve, the engine -angle is the same as the basic setting value (a).

  • Page 95: Injectors

    Injectors Special tool: (999) 6643 Puller Replacing Make sure the injector is thoroughly clean before removing or fitting it. Make sure no paint flakes stick to the sealing surfaces of the pipe ends. Remove the injector. If necessary use puller 6643. Installing 6643 Clean the copper sleeve according to instructions...

  • Page 96: Cleaning Copper Sleeves

    Read-off the opening pressure. Volvo specifies an adjusting pressure in addition to the opening pressure. The adjusting pressure refers to new injectors with new thrust springs. It is high- er than the opening pressure and provides a certain margin to allow for thrust spring fatigue.

  • Page 97: Removing/Installing

    Injection pump Removing/installing Special tool: (999) 8068 Crank tool Remove the inspection panel from underneath the Remove the delivery oil pipe from the engine flywheel casing and fit crank tool 8068. block. Crank the flywheel until no. 1 cyl. piston has just Disconnect the fuel pipes and cables.

  • Page 98: Basic Timing Injection Pump (Edc)

    To make sure the cable connection is tight enough, pull the cable unit axially, see fig, to ensure there is no gap, which is the case with an improperly tightened coup- ling. Tighten to take in this gap, if any, and then a fur- ther hex side (approx.
  • Page 99 Remove the plug from the pump governor hous- ing. Fit on position sensor for timing tool 998 7057 in the governor housing plug hole and earth the tool. Crank the flywheel in the engine direction of rota- tion. When both the tool diodes light, read-off the degree on the flywheel.

  • Page 100: Idling Speed

    Low idling speed EDC Setting, permanent If the engine is warm (above 45°C), the bus stationary and the clutch pedal released (parking brake on and gearbox in neutral on buses with automatic transmis- sion), idling speed can be set with the help of the break- ers on the direction indicator stalk.

  • Page 101: Venting Fuel System

    Venting fuel system In the same way slacken each delivery pipe and use the feed pump hand primer to get fuel free from air bubbles and then tighten up the pipes Open the vent screw on the fuel filter housing. while the fuel is still flowing out.

  • Page 102: Injection Timer

    Injection timer, checking DH10A, 345, 360 Special tools: (999) 8060 Crank tool 8190 Measuring instrument Crank the flyhweel to where the 0° mark is oppo- site the indication pin. Connect up the measuring instrument’s two sen- sors: one on the injection pump governor housing and the other on the right-hand side of the flywheel casing;...

  • Page 103: Testing Injection Pump

    Testing injection pump, DH10A Before testing the injection pump, fill the injection pump with engine oil SAE 20W20 up to the level of the lube oil return outlet. Concerning adjustment details, refer to the diesel test standard sheet, Serv- ice Bulletin, Group 23. Special tools: (998) 6551 Bracket 7057 Setting tol...

  • Page 104: Adjuster Device

    C. Adjuster device The first to check on the injection pump is the control rod travel. Position sensor for control rod travel (pump speed 0/min) Test No. 3.10 norm Control rod travel: 12.95–13.05 mm (Setting value) 12.90–13.10 mm (check value) 1.70 norm Control rod travel:...

  • Page 105: Synchronizing

    A. Synchronizing Open the tap on the test bench injector for no. 1 cylinder. Fit the bracket and dial indicator on the rear side of the pump to measure the lift from the basic circle on no. 1 Increase the voltage to the adjuster device (control pump piston.
  • Page 106 Checking pulse gear cam Fit special tool 998 7057 on the injection pump and earth the tool. 7057 Both the diodes should light when no. 1 pump piston is in stroke position. If both diodes light, carefully crank the pump and at the same time read-off the protractor on the test bench.

  • Page 107: Speed Sensor

    D. Speed sensor This check is carried out only if there are problems with speed control or when the sensor/toothed gear has been removed. . SPEED SENSOR (Control rod in stop position) Pump speed: r/min Positive amplitude 0.8–2.0 V (Setting value) Positive amplitude 0.6–3.0 V (Control value)

  • Page 108: Checking Oil Pump

    Run the tests as specified in the diesel test standards and check that the flow difference between the pump elements is as little as possible. The difference must not exceed “Difference max. cm ”. Adjust fuel flow and the differences by turning the pump element flange bushings within the area for ob- long holes.

  • Page 109: Anti-Tamper Sealing

    Checking oil pump, cont… Fill the governor housing with engine oil up to the hole (see arrow). Connect a vacuum guage to the hole in the governor housing. Remove the plug at the front of the pump (where the control rod travel is measured). Start the test bench and run the pump according to the diesel test standards.

  • Page 110: Replacing Damper Valve Holder, Injection Pump

    Replacing damper valve holder, Important! If the washer has fallen down, in all probability the in- injection pump jection pump is damaged and must be repaired. If the pump is damaged, the delivery pipes and the injectors Special tool: will also have to be replaced. 425973 Removal/installation tool Remember that cleanliness is of utmost importance when working on the injection system.

  • Page 111: Air Cleaner

    Group 25 Inlet and Exhaust Systems Contents – Description ..................111 – Air cleaner ................... 111 – Intercooler ................... 112 – Pressure-drop indicator ................ 112 Starting pre-heater – Troubleshooting................... 113 – Replacing heating coil ................. 114 Turbocompressor – Description DH10A, 345, 350, 360 ............. 115 –...

  • Page 112: Description

    Description The intake system for the air is entirely separated from the fuel system. It consists of four main parts: – air intake with inlet pipe – air cleaner – turbocompressor – inlet manifold with starting pre-heater (including intercooler on engines with intercooler). The start- ing pre-heater is optional, so it may not be fitted on some engines.

  • Page 113: Intercooler

    Intercooler All the DH10A-engines have the single-circuit type in- tercooler with a separate cooling circuit, radiator and pump. The intercooler lowers the temperature of the inlet air and this has a better effect on engine power. The sys- tem cools the inlet air down to approx. 60°C. Concern- ing pressure testing and description of the coolant cir- cuits, refer to “Cooling system”.

  • Page 114: Troubleshooting

    Starting pre-heater Troubleshooting An indicator lamp lights when the starting pre-heater is engaged. Should it light during testing, the fault is in the power supply circuit or in the operating circuit. But first check the fuses and also relay 312. If cable failure or short-circuit is suspected, carry out the following checks: Engage the starting pre-heater and feel with the...

  • Page 115: Replacing Heating Coil

    Switch off the electric circuits when about to replace the starting pre-heater! Intercooler housing Gasket Heating coil Starting pre-heater housing Replacing heating coil Remove the intercooler housing and starting pre-heater housing as a complete unit. Separate these housings on the work bench in order to get at the coil. This procedure makes it easier to align correctly the in- tercooler assembly with the starting pre-heater housing gasket.

  • Page 116: Turbocompressor

    Turbocompressor General Use is made of the engine exhaust gases to drive the The turbine wheel and compressor wheel are mounted turbocompressor turbine wheel. on the same shaft. When the compressor wheel rotates, it sucks air in from the air cleaner, the turbocompressor compresses it and presses it through the intercooler to the engine.

  • Page 117: Servicing Dh10A, 345, 350, 360

    Installing Fit new gaskets on the – exhaust manifold – delivery oil pipe – return oil pipe – coolant connections (DH10A, 245, 285). Sealant 591247-2 Sealant 591 247-2 between turbine housing and diffusor Servicing turbocompressor, DH10A, 345, 350, 360 Special tools: (998) 7600 Adapter (999) 9708 Torque wrench Always line-up mark the position for the turbine hous-...
  • Page 118 NOTE! L-H thread 7600 Circled digits refer to previous page. Cleaning Some parts are sensitive to corrosive cleaners. Such cleaners should therefore be avoided. Make sure all areas adjacent to wheels and housings are free from deposits, are clean and smooth. Let the parts seep in the cleaner until deposits drop off.
  • Page 119 Checking, cont. A damaged shaft with scored bearing surfaces must not be refitted. Minor scratches are acceptable. A damaged turbine or compressor wheel must always be replaced. Do not try to straighten out a deformed blade. The housing should be replaced if it has cracks or has been exposed to overheating.

  • Page 120: Description Dh10A, 245, 285

    Turbocompressor To intercooler DH10A, 245, 285 From air cleaner To exhaust system From exhaust manifold The turbocompressor on engine DH10A, 245 and 285, has a wastegate function that limits charge pressure at high power output. The wastegate-shutter functions as a by-pass valve for the exhaust turbine. The shutter is activated by a pressure box that, together with a hose connection, senses the charge pressure in the compres- sor housing.

  • Page 121: Wastegate

    Wastegate Pressure box Lube oil Coolant Wastegate, checking opening pressure Remove the hose from the pressure box at the compressor housing and connect nipple 999 9314 to the hose. Connect pressure tester 999 6662 to Special tools: the nipple. Always check to make sure the pres- (999) 6662 Pressure gauge 9324 Nipple sure gauge is correctly calibrated.

  • Page 122: Servicing Dh10A, 245, 285

    Turbocompressor, repairs Important! Refers to repairs to turbo on DH10A, 245, 285. The wastegate with pressure box and bracket is not to be removed from the turbine housing. Nor is the lock nut on the push rod to be released. But, if it has to be released, the push rod must be adjusted, in which case refer to Checking wastegate opening pressure.
  • Page 123 – Observe due care when removing the compressor Cleaning housing/turbine housing not to damage the blades Corossive cleaners can damage certain parts and on the wheels. should therefore be avoided. Make sure all surfaces adjacent to the wheels and hous- ings are free from deposits and are clean and smooth.
  • Page 124 Repair kit 1. Lock nut 2. Circlip 3. O-ring 4. Piston ring seal 5. Oil guide plate 6. Axial bearing 7. Retaining rings 8. Bearing bushings 9. Piston ring seal 10. Screw Installing – Use straight engine oil and oil the bearing parts and the piston ring seals.
  • Page 125 – Line-up the balance mark on the oil guide plate – Align the line-up marks on the bearing housing with the mark on the axial bearing (6) and the and the turbine housing. Tighten the screws (10) to mark on the shaft end. 14 Nm.

  • Page 126: Exhaust Pressure Governor

    Exhaust Pressure Governor (EPG) The engine has been fitted with an exhaust pressure governor (EPG) the function of which is to provide cleaner exhaust gases while the engine is warming up.When the parking brake is on and coolant temper- ature is below 70°C, the governor shutter closes off the exhaust gases so that the engine works against a certain backpressure and this reduces hydrocarbon emissions and white smoke.

  • Page 127: Servicing

    Exhaust pressure governor, servicing Special tool: (999) 6068 Drift Tightening torque 10–11 Nm (1.0–1.1 kpm) Cover O-ring Piston Sealing ring Cylinder Spring (Evacuation hole) Bearing housing Spacer washer Bushings Scraper ring Stopp ring Piston rod Shutter housing cover Shutter Disassembling Assembling Remove 5.
  • Page 128 Group 26 Cooling System Contents – Description ..................128 – Main thermostat, checking ..............130 – Pressure valve ..................131 Coolant pump – Disassembling/assembling ..............131 Intercooler – Pressure-testing ................... 135 Cooling fan – Description ..................137 – Pressure-testing cooling system ............139 High coolant temperature •...

  • Page 129: Description

    Cooling system – description The function of the cooling system is to cool the en- the engine oil temperature. Two piston type main ther- gine, and if the bus has a separate hydraulic retarder or emostats regulate the engine coolant temperature. The retarder built into the gearbox, also the oil for the re- system also has two other thermostats: a heating sys- tarder or gearbox.
  • Page 130 Cooling system vent lines, B10M Better use of cooling system heating To prevent air from getting into the cooling system a capacity vent line from the radiator lies in the bottom of the ex- Check valve between intercooler and expansion pansion tank, that is, below coolant level.

  • Page 131: Main Thermostat

    Main thermostat The thermostat housing contains two thermostats for maintaining temperature in the engine cooling circuit and one thermostat for the bus interior heating system. If the bus does not have an hydraulic retarder or auto- matic transmission with oil cooler, their connections 2 and 3 on the thermostat housing are inter-coupled with a pipe elbow and the housing has only one vent hose.

  • Page 132: Coolant Pump

    The pressure valve, which is placed in the tube be- tween the thermostat housing and the coolant pump, increases the pressure in the inner circuit when the main thermostat is closed, especially at low engine speed. This improves circulation in the heating system circuits.
  • Page 133 Tap out the seals. Press a new bearing into the bearing cage. 2268 Remove the circlip. Fit the circlip. Press out the outer bearing and the deflector ring. Tap on the deflector ring. 8113 Press the shaft out of the bearing cage. Mark the shaft 37 mm from its end.
  • Page 134 9. Tap the inner bearing into the bearing housing. 12. Tap down the unit seal. 8039 8039 10. Press in the shaft, bearing and bearing cage. 13. Press the impeller about 10 mm down on the shaft. First use counterhold 2269 as a counterhold. Then continue with drift 8113, using the handle as a counterhold.
  • Page 135 15. Check the distance. 18. Fit the O-ring and the outer cover. NOTE! The marks on the intermediate cover and the outer cover must coincide. 16. Tap the seal into the intermediate cover. NOTE! With the sealing edge facing down. 17.

  • Page 136: Intercooler

    Connect the pressure gauge to the nipple and test Intercooler the pressure. It must not drop during one minute. If it does, replace the intercooler! Pressure-testing For single-circuit system Special tools: (999) 6662 Pressure gauge 6815 Connection washer 6816 Sealing washer For two-circuit system Special tool: 6815...
  • Page 137 Disassembling Use a standard puller and pull out the intercooler tubu- lar sleeves. Assembling Tighten the screws in two stages in the sequence shown below. Stage 1: Tighten the screws until the screw head makes contact with the block. Stage 2: Tighten the screws to 20±2 Nm (2±0.2 kpm). Check-tightening screws difficult to access on the in- tercooler requires a special tool with P/N 1158239.

  • Page 138: Cooling Fan

    Cooling fan pin (4) transfers the bi-metal washer movements to a Up front the temperature-controlled cooling fan has spring-loaded valve (5) in the fan hub. two temperature-sensitive bi-metal plates that regulate fan engagement. A thermostat-controlled fan should always be in The bi-metal plates start to bend when the cooling air the vertical position.
  • Page 139 Cooling fan speed B10B Checking Expensive testing equipment is required to do a complete check on the thermostat-regulated cool- ing fan. One of the reasons for this is that it is diffi- cult to measure the air temperature round the bi- metal plates.

  • Page 140: Pressure-Testing Cooling System

    Coolant Place or hang up the pressure tester gauge above the The mixture in the Volvo coolant should be between radiator to prevent coolant from getting into it. 40% and 60%. Less than 40% will not provide protec- Slowly raise the pressure to above 40 kPa (0.4 kp/cm...
  • Page 141 Radiator, removing/installing Special tool: (999) 9954 Component lift Close the taps for the bus heating system. Drain the coolant. Take off the drive belts and remove the fan. Remove… – the hoses for the coolant and intercooler – the engine rear plate on the inside of the air cleaner –...

  • Page 142: High Coolant Temperature

    High coolant temperature Radiator Check the radiator for clogging and for deformed fins or for poor coolant flow to the radiator pipes. If neces- sary clean the radiator. NOTE! Observe great care not to damage the fins when cleaning the radiator. Do not use high-pressure flushing.

  • Page 143: Coolant Temperature Sensors

    Coolant temperature sensors 1, 3 Temp. sensor EDC P/N 1619819 (2-pin) max. test current 1mA Ω C° 615±62 255±29 119±15 Temp. sensor, temp. gauge P/N 1619819 (2-pin) max. test current 1mA between pins 1–3 between pins 2–3 Ω Ω C° C°...

  • Page 144: Fan Drive With Drive Belts

    Fan drive with drive belts B10B Adjusting drive belts Check to make sure that the tension on the fan Check-tighten the drive belt tension twice: Check 1 af- drive belts is correct: 13–14 mm deflection at 50 N ter 500–1500 km; check 2 after 3000–5000 km. (5 kp) midway between the pulleys.

  • Page 145: Fan Drive

    Hydraulic fan drive An alternative to the mechanical fan drive is the hy- draulic version, which is to be found on both the B10M and B10B. Fan drive, B10M System layout, hydraulic fan drive 1. Pump 2. Fan motor 3. Thermostat valve 4.
  • Page 146 Group 27 Engine Controls Contents – Description ..................146 – Sensor function, driver area ..............147 – Sensors on engine ................147 EDC–components in electrical distributor unit – Relay box ..................... 148 – Control unit ..................149 Fault diagnosis – Activating fault diagnosis ..............150 –...

  • Page 147: Description

    EDC – Electronic Diesel Control Compared to a conventional fuel system, the advant- EDC is an electric system for regulating and monitor- ing the engine fuel injection. ages of the EDC is that it has greater opportunities to control fuel flow. The electromagnetic governor reacts Characteristic of the system is that it works with an more rapidly and provides a more precise fuel control electromagnetic governor mounted on a standard injec-...

  • Page 148: Sensor Function, Driver Area

    Function of sensors, driver area Clutch pedal position breaker A speed signal is despatched as information to the con- Controlled mechanically by the clutch pedal. When the clutch pedal is depressed, this position breaker disen- trol unit from the speedometer/tachograph. gages the cruise control.

  • Page 149: Edc-Components In Electrical Distributor Unit

    EDC-components in electrical distributor unit Relay box 3060 Fuse 45 for Fuse 44 for Control unit 9058 normal voltage cruise control feed stalk Relay box Relay box 3060 contains relays for voltage feeding the TR2 circuit is wired to the automatic transmission and system and three small electronic circuits, which main- parking brake.

  • Page 150: Control Unit

    Control unit Control unit 9058 houses the electronics for regulating fuel flow. The electronic system has two microproces- sors, a main processor M1, that normally looks after all engine and vehicle control, and another microprocessor that takes care of fault diagnostics, communication with the other control units, that is, ABS/ASR and EST 18.

  • Page 151: Fault Diagnosis

    Signals to/from control unit 9058 Speed signal from relay box 3060 Sensor earth. Voltage feed 17/13 Accelerator pedal position from position sensor, accelerator pedal (7065). In the EDC-system, 18/12/30/5 Signals from “cruise control” (1125). In series the kick-down breaker for automatic transmis- between pin 5 and the cruise control stalk there sion is housed in the position sensor.

  • Page 152: Fault Codes

    Probable fault(reaction) Fault code/ Check/action Diagnosis The control unit is not programmed (engine Program the control unit with the data statement speci- will not start) fied for the engine, see further page 9. Brake indication faulty or not checked (cruise Turn the start key to the drive (feed selector switch) control does not function) position.
  • Page 153 Fault code/ Probable fault(reaction) Check/action Diagnosis Check voltage in connector TB“7”. Should be 5V. Accelerator pedal indicates abnormally low Voltage in TB“6” should be 0.5V with accelerator ped- voltage (does not react to throttling, remains al released. at low idle) Check for earth failure, pin TA“3”.
  • Page 154 Injection pump governor Compressed-air cylinder for The governor adjuster device (1) is placed in the gov- emergency stop ernor housing end and consists of an electromagnet that For safety reasons, there is a compressed-air cylinder works directly against the injection pump control rod. for emergency engine switch-off.

  • Page 155: Troubleshooting

    Accelerator pedal, adjusting Obs!. Vridverktyg 999 6956 finns inte under Special- At full throttle or kick-down position, the stop screw verktyg och på sid. 97 nämns 998 8068? Översättarens for the accelerator pedal should be able to stop pedal anm. movement precisely before the throttle control reaches the max.

  • Page 156: Connecting-Up

    Connecting-up Switch off the power with the battery main switch. NOTE! Never pull out or plug in the control unit cable contact when the power supply (ignition) is Disconnect the connector to the EDC-control unit and connect it to the test box. Connect the other connector to the EDC-control unit.
  • Page 157 cont. … Test box Pin+ Pin– Nominal value Component Remarks Battery voltage Exhaust brake, activated 0.3–0.6 V Control rod travel, accelerator pedal released 2.8–3.5 V Control rod traval, accelerator pedal depressed 2.1–2.5 V Position signal to automatic transmission and ASR 2.1–2.5 V Without ASR approx.
  • Page 158 The following measurements are made with the engine started Pin+ Pin– Nominal value Component Remarks 9.7 V ~ (300 Hz) Speed sensor, engine low idle 5 9.4 V ~ (840 Hz) Speed sensor, engine 1650 rpm 5 1.3–2.5 V ~ (70 Hz) Speed signal, C3 30 km/h 6 2.2–3.3 V ~ (150 Hz)

  • Page 159: Remarks

    Remarks If the bus has automatic transmission, the relay Signal to control unit for ABS/ASR and automatic box earths pin 27 when the transmission is in neu- transmission. It is the socalled “pulse wide modu- tral and the parking brake on or if speed exceeds 3 lated signal”...
  • Page 160 Pulse signals from the engine speed sensor, so- Signal from ABS/ASR (pulse wide modulated) called “square” signal (but not a pulse wide modu- that indicates if dethrottling is necessary. When lated signal). Frequency increases with increased dethrottling is not required, the signal should have speed.
  • Page 161 9. Turbopressure sensor. To be able to compare the measured voltage value for max. turbo pressure with the value given in the specifications for the engine in question, it is necessary to correct the value with a view to the fact that the reference voltage can vary.
  • Page 162 Volvo Bus Corporation Göteborg, Sweden TP 16031/1 English 2500.06.97 Printed in Sweden by Novum Grafiska AB. 97.24296...

This manual is also suitable for:

Dh10a 285Dh10a 345Dh10a 350Dh10a 360

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