Volvo B10M Driver Manual
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Volvo B10M Driver Manual

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Keith Yates
March 14, 2025

B10M no switch fitted to any doors but door symbol on dashboard comes on& won't turn off

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1 comments:
Mr. Anderson
May 14, 2025

If the door symbol remains on when no switch is fitted to any doors, the likely cause is a fault in the warning light circuit, such as a short or incorrect wiring that makes the system think a door is open.

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Summary of Contents for Volvo B10M

  • Page 1 Driver’s Manual...
  • Page 2 Keep this manual in the bus! Read it thoroughly. It contains important information for the driver.
  • Page 3 Technical data Technical data, construction details, descriptions and illus- trations were up to date when this manual was published. Volvo Bussar AB reserve the right to make changes to the Index bus specifications without prior notification. Volvo Bus Corporation...
  • Page 4 Driver’s responsibility – safety – As the driver of the vehicle, you are responsible for the safety and comfort of the passengers during the journey. Therefore, please do not drive the vehicle until you are familiar with and understand what the indicator lights, warning lights and instruments indicate and warn for.
  • Page 5 – Remember it requires special knowledge, access to information and special tools to be able to carry out reliable repairs. – Never crawl under the bus if it is only supported by a jack. Use approved vehi- cle supports or a solid pallet in case of punctures or wheel changes. Lifting device should stand on a horizontal surface.
  • Page 6 Pay attention to warning and indicator lights! Their purpose is to warn of danger.

  • Page 7: Table Of Contents

    Instruments and controls Dashboard – Lubricating oil, pressure/level ........17 – Left hand drive bus ............. – Coolant, temp/level ............ 18 – Right hand drive bus ..........Transmission Warning and indicator lights ........... – Transmission oil, temp ..........19 Controls on steering column Tachograph/Speedometer ..........

  • Page 8: Dashboard

    Instruments and controls Dashboard Left hand drive 13 14 25 26 6. Engine speed ............16 The illustrations show the most common switch loca- 7. Tachograph/speedometer ........20 tions, but there can be variations. Symbols and explana- 8. Temperature, ext./int..........31 tions of functions are, however, always accurate.

  • Page 9: Right Hand Drive Bus

    Instruments and controls Right hand drive 13 15 BROMS BRAK TILL FA ON OFF 13. Levelling control ............30 21. Starting heater ............14 14. Fire alarm system ............ 12 22. Emergency cut-out ..........12 15. Kneeling ..............30 23. Instrument lighting, rheostat ........15 16.

  • Page 10: Warning And Indicator Lights

    Instruments and controls Warning and indicator lights Description on page Door brake ..............26 Low air-pressure, handbrake ......... 23 Fire alarm ................ 12 Door- Fire- Slewing brake pressure, alarm, risk pressure, slewing warning (articulated bus) ........26 hand footbrake brake Low air pressure, footbrake ..........
  • Page 11 Instruments and controls Description on page Retarder ..........28 Retarder Direction Stop Indicator Gear indication G8 EGS, Gear indication Main beam G8 MGS ..........44, 48 Direction indicators ....... 10 Main beam ..........10 Stop ............33 Central warning lights Light up to indicate a warning Buzzer light has come on in lamp pan-...

  • Page 12: Controls On Steering Column

    Instruments and controls Controls on steering column Direction indicators Indicator lamp, Indicator lamp, Dipswitch and main beam direction main beam/main beam flash flash Push the direction indicator lever until resistance can be felt (1). The lever will spring back from this position when it is released.

  • Page 13: Windscreen Wipe/Wash, Headlamp Wipe/Wash

    Instruments and controls Windscreen wiper/washer Headlight cleaner Position (1) is intended for intermittent wiping. Used when driving in mist or fog for ex- ample. Intermittent wiping is fitted by the coach-builder and included in most bus models. Like the direction indicators, the wind- screen wipers have a spring loaded pressure point (2), in which position the wipers operate for as long as the lever...

  • Page 14: Fire Safety

    Instruments and controls Fire safety Fire alarm system When the spring-loaded switch for the alarm system is acti- vated, the warning lights for fire, high engine compartment temperature and the central warning light will come on and the buzzer will sound. This procedure will check that the fire alarm system is working.

  • Page 15: Start- And Lighting Controls

    Instruments and controls Start and light controls Starting switch Starting switch controls start/stop, voltage feed, indicator and warning lights. If there is a steering lock, this will be activated when the key is removed from the starting switch. Neutral position (steering lock and stop position) R Radio position Drive position Check position for indicator and warning lights...

  • Page 16: Supply Current Switch And Start And Stop Buttons

    Instruments and controls Feed switch and start/stop buttons Certain buses have pushbuttons for start/stop and a feed switch for the power supply instead of a starter switch and a light switch. The feed switch and start/stop buttons are locat- ed with the light switch at the bottom of the dashboard on the left-hand side of the steering column.

  • Page 17: Charging

    Instruments and controls Other electrical components and lights Charging The warning light is on when the generator is not charging. The light is on: If the light comes on while driving this means that there is a generator not charging! fault in the electrical system or that the generator belts are slipping.

  • Page 18: Engine

    Instruments and controls Engine Engine speed To achieve better performance with increased engine serv- ice life, it is wise to maintain correct engine speed. 1. The engine has less pulling power in the engine speed areas below the green zone. High load at low engine speeds increases fuel consumption and the risk of over- heating.

  • Page 19: Lubricating Oil, Pressure/Level

    Instruments and controls Lubricant pressure – Warm engine ..........300–500 kPa 3–5 kp/cm – Idling, minimum ........... 50 kPa 0.5 kp/cm Lubricating oil pressure gauge is optional. Low oil pressure The warning light comes on when the oil pressure in the engine goes below 50 kPa (0.5 kp/cm ).

  • Page 20: Coolant, Temp/Level

    Instruments and controls Coolant temperature Indicates the temperature in the engine coolant system and thereby the engine operating temperature. Under very hot conditions, the indicator may reach up to the edge of the red zone. The bus must not be driven with the indicator in the red zone.

  • Page 21: Transmission - Transmission Oil, Temp

    Instruments and controls Transmission High oil temperature This lamp is fitted on buses with automatic transmission. (Buses with G8 EGS gearboxes have a similar the same position on the lamp panel. Read about the func- tion of the lamp in the chapter ”If anything happens”.) The lamp will go on if the oil temperature in the gearbox gets too high.

  • Page 22: Tachograph/Speedometer

    Instruments and controls Tachograph/speedometer The tachograph automatically registers your driving time, Open tachograph speed, standstill time, number of stops and driven km (alt A Driver’s tachograph disc miles). On the display, you can also read the time and B Co-driver’s tachograph disc number of kilometres driven.
  • Page 23 Instruments and controls date, meter reading at end of journey and distance trav- Setting warning signal elled should be filled in. Open the tachograph. The level for the speed warning signal is set by turning the set screw (C), which is located just above where the speed Seven-day tachograph can be read (D), to the right or left.

  • Page 24: Handbrake - Controls

    Instruments and controls Handbrake Handbrake control The handbrake works on the drive wheels. When the hand control is in the forward position, with charged air pressure system and blocking valve depressed (see ”Blocking valve”) the handbrake is released. When the control is pulled backwards the handbrake is gradu- ally engaged and it is fully engaged when the control is in its rear locked position.

  • Page 25: Blocking Valve, Warning Light

    Instruments and controls Blocking valve, handbrake BROMS If for some reason the air brake system is empty, due to the BRAM bus being parked a long period of time for example, the handbrake can not be released until the blocking valve has been pushed in.

  • Page 26: Air-Pressure Gauge, Warning Light

    Instruments and controls Footbrake While driving, the indicators should Air-pressure gauge always be above Gauge1 indicates the pressure in the pressure chamber for the red zone! the first axle brake circuit and gauge 2 the pressure in the pressure chamber for the second axle brake circuit. While driving, the indicators should be above the red zone.

  • Page 27: Anti-Lock Brakes, Anti-Spin Control

    Instruments and controls Anti-lock brakes (option) This indicator light is connected if the bus has anti-lock brakes, ABS. The ABS-system is not at fault when the indicator light comes on when the starter key is turned to drive position. The indicator light will go out after a couple of seconds when the system has finished performing its tests.

  • Page 28: Brakes, Others - Anti-Slewing System

    Instruments and controls Brakes, others Anti-slewing system When reversing an articulated bus, the trailer coach may slew to such an angle that the chassis or gaiter may be dam- aged. There is a warning light and automatic brake system fitted to prevent this from occurring. Slewing warning Slewing warning This warning light goes on when the angle between the bus...

  • Page 29: Door Brake

    Instruments and controls Brakes, others Door brake The door brake is fitted by the coach-builder. This function is common on local buses and long-distance coaches. The door brake ensures that the bus cannot be driven with an open door. Lit warning light indicates that the brake is ap- plied due to an open door.

  • Page 30: Retarder

    Instruments and controls Retarder Buses with automatic transmission have the retarder inte- grated in the gearbox and manual buses can be fitted with an optional electromagnetic or hydraulic retarder. The retarder is a complement to the ordinary braking sys- tem. Correctly used, a retarder will increase the service life of the wheel brake linings many times over.

  • Page 31: Suspension - Suspension System

    Instruments and controls Suspension Suspension system The bus is equipped with electronically controlled air springs; ECS – Electronic Controlled Suspension. Function of indicator lights on buses with ECS: 1. Light goes on when starter key is turned to driver posi- tion.

  • Page 32: Levelling Control, Kneel

    Instruments and controls Levelling control (option) Levelling control raises or lowers the entire bus and should not be confused with kneeling. (See below). There are two versions of levelling control. One where the bus can be raised and lowered and another where the bus can be raised only.

  • Page 33: Other Instruments And Indicator Lights - Temperature Gauge, Clock, And Tripmeter

    Instruments and controls Other instruments and indicator lights Temperature gauge (option) Can be connected in two different ways. • Gauge in combination with switch. In one switch position, the exterior temperature will be displayed; in the other switch position, the interior tem- perature in the bus will be displayed.

  • Page 34: Bogie

    Instruments and controls Bogie Pressing the bottom of the switch will release compressed air from the bogie air bellows as long as it is depressed. The rear axle weight will then be transferred to the drive axle only, which is an advantage when pulling away on slippery surfaces.

  • Page 35: Open Door, Open Hatch Stop

    Instruments and controls Door open Rear fog lights The Indicator lamp comes on if The indicator light is on when a door is open. It is often neces- the rear fog lights are on. sary that the handbrake be ap- NOTE! The laws and regula- plied before a door can be tions concerning the use of rear...
  • Page 36 Follow our driving instructions! The manner in which the bus is driven has a great bearing on the bus’s reliability, economy and service life. The following chapter contains most of what is relevant to starting and driving.
  • Page 37 Driving Daily inspection ............... 36 Brakes ................51 Battery master switch ............37 – Footbrake ..............51 Steering wheel, driver’s seat .......... 38 – Exhaust brake ............52 – Safety belt ..............38 – Retarder ..............52 Starting the engine ............39 –...

  • Page 38: Daily Inspection

    For operational reliability, check the following before driv- ing off: 9. Engine oil level. 10. Coolant level. Always top up with a 50-50 mixture of Volvo coolant and water – all-year-round! 11. Oil level in hydraulic coolant fan and oil pump drive belt.

  • Page 39: Battery Master Switch

    Driving Battery master switch The battery master switch must be in the on position for the electrical system to work. A common coach-builder solution is to place the knob for the battery master switch by either the passenger door or by the drivers seat. Never break the current when the engine is running! After finishing a shift, especially when the bus is to be parked for longer periods (i.e.

  • Page 40: Steering Wheel, Driver's Seat

    Driving Steering wheel, driver’s seat Make sure you place yourself in a correctly seated position by adjusting the driver seat and steering wheel before start- ing your work shift. This is important, otherwise you may get tired unnecessarily. Through this action you will ensure your passengers a safe and comfortable journey.

  • Page 41: Starting The Engine

    Driving Starting the engine Before starting Check warning and indicator lights by turning the starter key (or the feed switch, see illustration on next page) to check position. All the indicator and warning lights, including the central warning lights, should go on and a buzzer sound when the starter key (or feed switch) is in check position.
  • Page 42 Driving Starting a cold engine To prevent exhaust smoke when starting the engine, the intake air should be heated if the ambient temperature is 10°C or below. Do this: Turn the starter key/feed switch to drive position and push the starting heater button (illustration on next page).

  • Page 43: Engine Shut-Down

    Driving Starting a warm engine Start directly by turning the key to the starter position (or turn the feed switch 0 Stop position to the drive position and push the start button on buses with feed switches). R Radio position The accelerator pedal does not normally need to be pressed when the engine 1 Drive position is warm.

  • Page 44: Automatic Gearbox

    Driving Automatic gearbox Start The engine can only be started with the gear selector in position N Cold engine should idle for 1–2 minutes so as to avoid dam- Gear selector. age to the gearbox. When changing from forward gears to reverse the neutral position N has to be engaged first.
  • Page 45 Driving Reverse gear Automatic neutral position NOTE! The bus should be at a standstill when ZF gearboxes are available – and Voith always has a func- selecting gear position R. tion – that enables the neutral position to be selected auto- matically in the following circumstances: Accelerator pedal released + footbrake pedal depressed + bus stationary.

  • Page 46: Gearbox G8 Egs

    Driving G8 EGS manual gearbox Volvo G8 EGS The G8 EGS is fully synchromesh with eight forward gears and one reverse gear. The gear lever has seven forward gear posi- tions and one pushbutton in the lever knob for the eighth for- ward gear, ”+ position”.
  • Page 47 Driving When changing down at high speed, especially when skip- ping one or more gear positions, the gear lever will lock in Warning! neutral temporarily to protect the shifting system from over- revving. Making regular use of this overrevving protection will strain Even though the gear lever can be move to a gear the gearbox controls and synchromesh and should there- position when engine is stationary, this does not mean...
  • Page 48 Driving Shifting program, alternative 2+ R and 1 Reverse gear and first gear are blocked and can be engaged only if the release ring is lifted towards the gear lever knob. First is used for ranging and pulling away on steep inclines.
  • Page 49 Driving Shifting program, alternative 7+ R and 1 Reverse gear and first gear are blocked and can be engaged only if the release ring is lifted to- wards the gear lever knob. First is used for ranging and pulling away on steep inclines.

  • Page 50: Gearbox G8 Mgs

    Driving G8 MGS manual gearbox Volvo G8 MGS G8 MGS is a fully synchromesh mechanical range gearbox with eight forward gears and one reverse gear. Reverse gear can be engaged in both low and high range but we recommend against attempting to reverse in high range due to the high gear ratio.
  • Page 51 Driving G8 MGS manual gearbox (3–4) Gently move the lever towards fourth position. ”Rest” when passing neutral. 2–4 Disengage second. Let the lever find neutral position before moving it to the right/down towards fourth posi- tion. 4–5 Move the toggle switch on the gear lever from low po- sition to high while still in fourth gear.

  • Page 52: Gearbox S6-85

    Driving S6-85 manual gearbox ZF S6-85 S6-85 is a fully synchromesh mechanical gearbox with six forward gears and one reverse gear. Lever movement is transferred to the gearbox by two control cables. Shifting The gearbox is fitted with a spring system that makes the gear lever seek a position between gear position 3 and 4 if a gear is not engaged.

  • Page 53: Brakes

    Driving Brakes Footbrake If the wheel brakes are used without caution when driving down steep and long inclines, they will heat up very quickly to extreme temperatures. As this is normally accompanied with low speeds, the brakes will not be cooled as efficiently as on level roads.

  • Page 54: Exhaust Brake

    Driving Exhaust brake (option) The exhaust brake is a complement to the wheel braking system. It is activated with a foot switch. The exhaust brake is included in the engine exhaust pressure regulator. Activating: – release the accelerator – then press down the foot switch Exhaust braking will cease when the foot switch is released.
  • Page 55 Driving Heat and cooling All braking develops heat. Warning! A hydraulic retarder is cooled by the engine cooling system. This applies to the hydraulic retarder (optional) together with manual gearboxes as well as the retarder integrated in The auxiliary braking systems described here (exhaust automatic gearboxes.
  • Page 56 Driving The green indicator light will go on when the retarder is ac- tive (illustration at bottom of next page). Braking with retarder. Retarder in automatic gearboxes: Braking with Retarder hand control is available as an option. The hand both retarder and control and foot control (brake pedal) both have three stag- wheel brakes.
  • Page 57 Retarder indicator light indicate a fault in the retarder. Depending on how serious the fault is, the result may be that the retarder works at re- duced effect or not at all. Contact a Volvo workshop for diag- nosis and repair.

  • Page 58: Parking

    Driving Parking Always apply handbrake when parking. Move control back to locked position to apply. Emergency brake The handbrake can be used as an emergency brake if the Warning! footbrake system should malfunction. When using as emergency brake: gradually move the con- trol back to parking position.

  • Page 59: Economic Driving

    Driving Economic driving Economic driving Correct driving techniques will considerably affect fuel con- sumption. There will also be less wear on the bus and the passengers will have a more comfortable ride. Avoid unnecessary and Only a fraction of the engine output is required when the bus rapid acceleration.

  • Page 60: Cruise Control

    Driving Cruise control Cruise Control The following description applies to buses with Electronic Diesel Control only. The EDC internal test must be performed before cruise con- trol can be engaged (see section ”Starting the engine” in this chapter). Max and min speed limits for cruise control depend on how the control unit is programmed.
  • Page 61 Driving Idle speed adjustment continued from previous page The stored speed will be cleared when the engine is stopped. Consequently, a previously set speed can not be restored once the engine has been turned off. Setting basic idling speed The following description applies to buses with Electronic Diesel Control only).

  • Page 62: Articulated Bus

    The difference between the outer turning radius (A) and the inner turning radius (B) is the turning breadth. The B10M articulated bus consists of a tractor coach, corre- sponding to a normal twin axle bus, and a trailer coach. The...
  • Page 63 Driving Reversing an articulated bus Use very small steering wheel movements when reversing with a steered trailer coach to prevent it from slewing. When reversing in a straight line, use the rear-view mirror to make sure the tractor coach and the trailer coach are standing in a straight line before starting to reverse.

  • Page 64: Steering

    Driving Steering/Tips Power steering Never try to turn the bus by pushing hard on the steering wheel if the front wheels are blocked sideways for any rea- son, against the kerb for example. High pressure on the steering wheel will increase pressure in the power steering system and cause overheating that may damage the oil pump.

  • Page 65: Tips For Winter Driving

    Driving Tips for winter driving Use winter fuel! It reduces the If abnormal exhaust smoke risk of deposits in the fuel sys- occurs, after-heat the en- tem. The build up of condensa- gine by pressing the cold tion in the fuel tank can be start button.
  • Page 66 This chapter is intended to increase your knowledge on the operation of the bus. If you are interested in reading a more detailed description of the bus’s de- sign, get a copy of Volvo Bus Service Manuals – contact your nearest Volvo dealer.
  • Page 67 If anything happens Volvo Action Service ............66 Electrical system – Changing batteries ............ 76 Towing ................67 Releasing handbrake ............. 68 – Rapid charging and start help ........77 – Changing bulbs in dashboard ........77 Change wheels ............... 70 –...

  • Page 68: Volvo Action Service

    When problems arise that you can not handle yourself, there is help at hand 24 hours a day, 365 days a year. This help is called Volvo Action Service and is available in many parts of the world. Contact your importer/ Volvo dealer for more information.

  • Page 69: Towing

    If anything happens Towing The power steering does not work when being towed. The steer- ing will be very heavy! Warning! When towing If the towing distance exceeds: – 100 m for bus with G8 manual gearbox The bus is heavy to steer when being towed! –...

  • Page 70: Releasing Handbrake

    If anything happens Releasing the handbrake Releasing the handbrake with compressed air from the bus tyre Warning! 1. Always start by blocking the wheels, or by connecting the drawbar to the tow truck so that the bus can not start rolling when the brake is disengaged.
  • Page 71 If anything happens Mechanical release of handbrake Warning! 1. Always start by blocking the wheels or by connecting the drawbar to the tow truck, so that the bus can not start roll- ing when the brake is released. Block the bus wheels or connect the drawbar to 2.

  • Page 72: Change Wheels

    If anything happens Changing wheels 9. Clean the mating surfaces and lift on the spare wheel. Preparations for a puncture 1. Make sure the bus is standing on a level, horizontal sur- 10. Screw on the wheel nuts. Then, lower the bus so that the face that is firm.
  • Page 73 If anything happens B Rear wheel puncture: 6. Make sure steps 1–5 have been carried out. (See previ- ous page.) 7. Use the rear hole in the air suspension member together with the adapter for the jack. This label on the side of the body marks the place.
  • Page 74 4. Tighten a further 90° in the same order. Dual mounted wheels To facilitate fitting dual mounted aluminium wheels, use two guide sleeves VOLVO no. 9996833. 1. Fit the guide sleeves (aluminium wheel). Lift the inner wheel onto the hub so that it centres on the hub centre shoulders.

  • Page 75: Control Tightening

    If anything happens Control tightening Tightening torque must not be below 670 Nm on any wheel Warning! nut. If the tightening torque should be below 670 Nm on any of the wheel nuts, all nuts must be loosened and the wheel Retighten the wheel nuts after approximately 200 km if retightened as instructed on the previous page.

  • Page 76: Tyre Choice

    If anything happens Profile ratio 0.8 Tyre choice (height divided by Load and speed indexes are stamped on the tyres. The index Seat diameter section breadth) indicates the highest permitted load and speed for the tyre. In in inches on rim Tubeless Radial the example below, (A) is:...

  • Page 77: Drive Belts

    HC38 x 1050 978522 4. A/C compressor Not supplied by Volvo Warning! Check belt tension twice after changing. First check after 500–1500 km and second check after 3000–5000 km. Turn off the battery master switch when working on the...

  • Page 78: Electrical System

    After connecting them, they must be treated with anti-corrosion agent. Battery boxes in various designs are available from Volvo. Battery installation may also have been carried out by the coach-builder. Battery box and rapid charge connector (see next page) may therefore be located and designed differ- ently to that illustrated.

  • Page 79: Rapid Charging And Start Help

    If anything happens Rapid charging and start help The bus has a connection for an external power supply. NOTE! The rapid charge connection can be positioned dif- ferentially than illustrated here since the bus can have a dif- ferent battery installation. When rapid charging, the battery master switch should be turned off so as to avoid overvoltage to the bus’s electricity consumers.

  • Page 80: Electrical Distribution Boxes

    If anything happens Electrical distribution boxes Circuit board for warning and indicator lights Fuse test Main circuit board 3028 3041 3063 3026 3026 354A 3005 3027 23 - 1 5A fuse for lamp check circuit...
  • Page 81 If anything happens Fuses on main circuit board Relays on main circuit board Fuse Amperage Circuit Relay Circuit 1–2 Parking lights, dashboard illum. Headlights, main/dipped beam 3–4 Main beam, main beam indicator Brake lights 5–6 Dipped beam Parking lights Indicator lights, Warning light Starting switch suspension, Reverse light S6-85, Start inhibitor, body (option)
  • Page 82 If anything happens Fuses and relays on EGS circuit board Fuse Amperage Circuit Control unit supply (EGS control system is supplied from fuse ”10” on the main circuit board) Relay Circuit 399A Safety relay, neutral position 399B Control unit supply 3038A Polarity reverse, start inhibitor 3038B...
  • Page 83 If anything happens Control units The electronic control units normally present on a B10M chassis are shown here in silhouette and to the same scale. 909 (ZF) 909 (Voith) Automatic gearbox 9002 ECS suspension system 9008 ABS (ASR) 9054 Hydraulic retarder...
  • Page 84 If anything happens Fuses and relay in junction box in front of core assembly ENGINE STOP Fuse Amperage Circuit 150A Starting heater 200A Electric retarder Reserve supply EDC Relay Circuit Starting heater Description Mechanical engine shut-down Fuses and relays in electrical distribution box in front end of battery box Applies to buses with original battery box (located under the driver’s position).

  • Page 85: Fault Tracing

    If anything happens Fault tracing General information The first measure to take when carrying out fault tracing of the electrical system is to check the fuses. Both fuses and circuit breakers are included in the bus’s electrical system. A tripped circuit breaker can be seen by the protruding red reset button.
  • Page 86 If anything happens Symptom: Check/rectify: – Is the battery master switch on? – Is the gear lever in neutral position or the clutch pedal depressed? Starter motor not cranking. (Does not apply to buses with S6-85 gearbox.) – Are the batteries charged? Turn on the headlights. If they do not come on or are dim, the batteries may be in poor condition.

  • Page 87: Edc Fuel Control

    (if fitted) but to avoid the risk of a complete power failure, which will charge air pressure cause the engine to stall, we recommend allowing a Volvo charge air temperature garage to rectify the fault as soon as possible.
  • Page 88 ”emergency control”. The engine can be started but it will have a reduced output and a lower maximum engine speed! Contact your Volvo- garage as soon as possible. Fault indication! See next page.
  • Page 89 If anything happens Flashing (continued): Have the starter key/ supply current switch in the drive posi- tion, press in the diagnostic switch. Release the switch after a few seconds and count the number of flashes from the di- agnostic lamp. Note the number. The number of flashes cor- responds to the fault codes.
  • Page 90 If anything happens Clearing fault codes after performed measures – Turn the starter key to position ”0”. – Keep the diagnostic switch pushed in while at the same time turning the starter key to the drive position. Do not release the switch. –...

  • Page 91: Clutch

    If anything happens Clutch Symptom: Check/rectify: No declutch when pedal depressed. – Check the level in the clutch fluid reservoir. – If low, fill to correct level. Depress the clutch pedal and watch for leaks in the hydraulic lines. – Keep the clutch pedal depressed for two minutes.

  • Page 92: Diagnose, Egs System

    If anything happens Gearbox G8 EGS Fault in EGS system The EGS system is powered via fuse ”10” on the main circuit board (see page 78) and fuse ”43” on the EGS circuit board (see page 80). The EGS diagnostic lamp will go on for one second when the engine is started.
  • Page 93 If anything happens Fault codes Fault codes are grouped as follows: 11–13 Service information 21–45 Faults affecting the gearbox Faults affecting the declutch sensor 61–66 Faults affecting engine speed, vehicle speed and gear lever carrier. Diagnostics lamp Clearing fault codes Once a fault has been rectified, the stored fault codes are cleared in the following way.
  • Page 94 If anything happens Integral emergency operation system The first emergency operation system to be engaged is the one that is integrated with the ordinary control unit. It can be engaged with the emergency operation switch. The engine must be running and the bus must be stationary when en- gaging.

  • Page 95: Suspension

    If anything happens Suspension Suspension system The bus is equipped with ECS, Electronic Controlled Sus- Warning! pension, The ECS system compares preprogrammed values in the control unit with signals from level sensors fitted between the bus chassis and the wheel axles. Aided by these signals Crush risk! and any other signals from levelling control and kneeling Remember that kneeling reduces ground clearance.
  • Page 96 If anything happens Continued from previous page The suspension system is powered via fuse no. 15. Fault tracing is normally carried out with a computer (PC). A simpler form of diagnosis can be performed with a few cable ends only. Locate the 9-pin connector marked ”DIA” hang- ing on the cable harness from the suspension control unit.
  • Page 97 No.of Fault Check/Rectify flashes Solenoid valves Valve block with electric connections/leads Voltage to Voltage on pins 27-9/26-28/30- level sensor 31/14-29 should be 5 V Tachograph signal Tachograph speed signal w. connect./leads Level sensor Level sensor with levers, connections and leads Control period Air leaks, pressure, pressure sensor, solenoid valves, speed...
  • Page 98 Remember... – Regular service is needed to keep the bus in perfect working order and to maintain a high standard of passenger safety. – The correct choice of oil, regular oil level checks and changing oil and fil- ters in accordance with recommendations is crucial for the lifetime of the components.
  • Page 99 Service and Maintenance Maintenance and warranty ........... Front wheel hub ............118 Engine, lubricating oil ........... Clutch fluid ..............118 Hydraulic cooling fan operation ........102 Rear axle gear .............. 119 Coolant ................103 Steering – Coolant filter ............105 –...

  • Page 100: Maintenance And Warranty

    The oil and fuel must fulfil the re- quired standards. Warranty A condition of the Volvo warranty is that the bus should be maintained according to our recommendations. Instructions can be found in the Volvo service manual ”Service and Maintenance”.

  • Page 101: Engine, Lubricating Oil

    If oil change intervals exceed 30,000 km, the ”Long life” full- flow filter, part no. 478736, must be used. Using oil complying with VDS-2 (Volvo Drain Specification 2): – Urban and suburban traffic ....max 25 000 km –...
  • Page 102 Service and Maintenance There are three plugs for draining. One on the bottom edge of the dry sump, one by the oil pocket on the inspection Filling engine oil hatch and one on the bottom of the oil reservoir. The engine oil reservoir is located in the rear right corner of the bus.
  • Page 103 Service and Maintenance Temperatures refer to constant ambient temperatures. 3. Moisten the rubber gaskets on the new filter elements with oil. Screw on the elements by hand until the gaskets -30 -20 -10 20 30 make contact with the sealing surfaces. Then, turn a fur- ther 1/2 to 3/4 of a revolution.

  • Page 104: Hydraulic Cooling Fan Operation

    Oil change volume Approx. 33 l including oil filter. Oil grades ATF Dexron IID (Volvo part. no. 1161282 for 208 l package and 1161934 for 20 l package). Oil filter Check oil level The oil level should be in close to the top of the level glass.

  • Page 105: Coolant

    Never use coolant with less than 40% anti-freeze. This also applies when topping up. Anti-freeze protects the system against rust and freezing. Volvo coolant is recommended even when coolant is not The plug is located in required to protect against frost. It provided good protection the engine block close against corrosion.
  • Page 106 Service and Maintenance Filling and level control of coolant Before filling: prepare a mixture of anti-freeze and pure wa- Filling ter. Fill coolant through the filler neck in the expansion tank. The expansion tank is accessible through the rear engine cover.

  • Page 107: Coolant Filter

    Service and Maintenance Coolant filter A coolant filter is optional. It filters the coolant and adds anti- corrosion agent. To avoid adding too much anti-corrosion agent, the filter must not be changed at the same time as the coolant but six months after the first coolant change and then every 6 months.

  • Page 108: Fuel System

    Service and Maintenance Fuel system Fuel Always observe cleanliness when refuelling and working with the fuel system. Always use a diesel fuel of high quality supplied by a well known oil company. In low winter temperatures, use a special winter fuel sup- plied by these well known oil companies.

  • Page 109: Hand Pump

    Service and Maintenance Hand pump After working on the fuel system (e.g. when changing a fuel filter) or when the fuel tank has been run dry, the fuel needs to be pumped in manually. Approximately 15 pumps with the hand pump is usually sufficient. The fuel system does not usually require bleeding after run- ning out of fuel, but it is wise after changing the fuel filter to open the air nipple on the filter console and pump a few...

  • Page 110: Automatic Gearbox Zf

    Automatic gearbox ZF HP-series Changing oil and filter – Oil and filter should be changed every 30,000 km. Alter- natively every 90,000 km when using Volvo ”Synthetic oil”. (See page 111 Oil grades.) – But at least once a year.
  • Page 111 Service and Maintenance Oil change volume Approx. 17 l. Check oil level Warm gearbox (80°–90°C oil temperature) The check is performed with the engine at a low idling speed, approx. 500–600 rpm. The oil level should remain in the area marked ”hot” on the dipstick.

  • Page 112: Automatic Gearbox Voith

    Alternatively every 120 000 Filter housing km when using Volvo “Synthetic oil”, or at least every third year. (see next page, Oil grades) 1. Drain the oil in the oil pan by removing the plug in the middle of the pan.
  • Page 113 Service and Maintenance Oil grades Change 60 000 km: ATF Dexron IID. Must comply to Volvo standard 1273,35 specification 97335. (Volvo part. no. Filter housing (cap) 1161282 for 208 l package and 1161934 for 20 l package). Change 120 000 km: Volvo ”Synthetic oil”. Complies to Vol- vo standard 1273,31 specification 97331.

  • Page 114: Manual Gearbox G8-Egs/Mgs

    Change gearbox oil and oil filter – every 120,000 km to Volvo STD 1273,05 specification 97305. (Example: SAE 80W/90 part no. 1161933 for 20 litre pack. 1161280 for 208 pack.) – or at least once a year.
  • Page 115 2000 m above sea level, a note 3: transmission fluid with viscosity SAE 85W/140 or SAE 140 is – Volvo ”Synthetic oil” (part no. 1161904 for 20 litre pack, recommended. 1161906 for 208 litre pack). 3. Volvo ”Synthetic oil” is recommended at low temperatures.

  • Page 116: Manual Gearbox Zf S6-85

    Service and Maintenance Manual gearbox ZF S6-85 Check oil level Check the oil level at every basic service. Unscrew the plug in the level/filler hole. The oil level should reach the bottom of the hole. Level/filler Change gearbox oil – every 90,000 km Drain –...
  • Page 117 Recommended at low temperatures, see viscosity 68 86 104 scale: – Volvo ”Synthetic oil” (part no. 1161904 for 20 litre pack, Temperatures refer to constant ambient temperatures. 1161906 for 208 litre pack). 1. When driving in temperatures above 30°C or when driving long...

  • Page 118: Hydraulic Retarder

    Service and Maintenance Hydraulic retarder Check oil level 1. Check the oil level when the retarder oil is warn (min. 60°C). The bus must be level. 2. Activate the retarder fully (stage 5) for about 5 seconds. Repeat twice. Shut off and allow the oil to settle (approx. 5 minutes).
  • Page 119 Service and Maintenance Change retarder oil The oil should be changed every 120,000 km if single- grade oil is used, 180,000 if synthetic oil is used. 1. Activate the retarder fully (stage 5) for about 5 seconds. Repeat twice. Disengage the retarder and turn off the battery master switch.

  • Page 120: Front Wheel Hub

    Fluid Use brake fluid complying with DOT 4 (SAE J 1703) require- ments. Volvo part. no 1381074. Change hydraulic fluid in good time! When under great strain or driving at high altitudes, heat radiation from the engine and gearbox may cause steam bubbles in the hydraulic fluid if it is old.

  • Page 121: Rear Axle Gear

    Oil change interval for rear axle. Drain RAEV 80/85 Oil change when using Volvo 97312* transmission fluid ..Max. 180,000 km But at least once a year Oil change when using standard oil ........Max. 120,000 km Temperatures refer to constant ambient temperatures.

  • Page 122: Steering Servo

    The filter (inside the reservoir) should be changed every 90 000 km or at least once a year. Oil grades ATF Dexron IID (Volvo part. no. 1161282 for 208 l package and 1161934 for 20 l package). Check oil level Check the level in the oil reservoir with the dipstick.

  • Page 123: Periodic Inspection

    Service and Maintenance Periodic inspections Air cleaner, filter insert If the pressure drop indicator shows red, this means that the filter insert is blocked and needs to be changed. Vibrations can cause cracks in the filter insert which is why we recom- mend changing the filter every 18 months even if there is no cleaner reading from the indicator.

  • Page 124: Draining Compressed Air System

    Service and Maintenance Draining compressed air system The compressed air tanks are equipped with manual drain valves. The valves are opened by pulling the ring sideways. The primary tank should be drained regularly to enable in- spection of the compressor and air dryer. When the primary tank is drained regularly there is less risk of damage or ac- cidents due to defects in the compressor or air dryer.

  • Page 125: Air Dryer

    Service and Maintenance Cover on drying agent cartridge Air dryer The compressed air system is equipped with an air dryer. It separates damp from the air, which prevents valves in the system from freezing. Depending on the bus model, the air dryer has either ”one tower”...

  • Page 126: Charging Time - Braking System

    Service and Maintenance Charging time – braking system Pump the brake pedal a number of times until the pressure goes under 200 kPa (2kp/cm2) Run the engine at approx. 1000 rpm. Increase of pressure from 200 till 400 kPa (2–4 kp/cm should be reached in 1 to 2 minutes.

  • Page 127: Tyres, Air Pressure

    Service and Maintenance Tyres Axle load Observe that the air pressure in the diagram applies to cold tyres. Already after a couple of kilometres driving, the tem- 315 / 80 R22.5 perature in the tyres, and therefore even the air pressure, 13 000 has risen to a value approximately 0.8–1.9 kp/cm (80–190...

  • Page 128: Lubrication Schedule

    = Lithium based grease with EP additive and consist- – Engine Oil and filter changed at ence to NLGI no. 2. Volvo part. no 1161315. least every lubricating serv- (depending = High temperature grease Volvo part no. 1161251. grade) See page 99.
  • Page 129 Service and Maintenance Brake cam Belt transmission Brake cam Propeller shaft – front spider Spindle bolt bearing – front spider – top cover x 2 – bottom cover – rear spider Hinge battery box Steering axle Brake cam Brake cam –...
  • Page 130 Remember... When contacting your Volvo garage or when ordering spare parts, the type designation and serial number of the chassis (and the components) must be specified.
  • Page 131 Technical Data Type plates ..............130 Specifications, Data ............132...
  • Page 132 * YV3 1M A4 1 8 * Example: * X A 56789 * Hydraulic retarder serial number and version where YV3 is manufacturer (= Volvo Bussar AB, Sweden) Stamped on rear left side of retarder housing. 1M chassis version (= B10M) A4 engine version (= DH10A245)
  • Page 133 Technical Data Identification plate The identification plate is divided into a regulated section, inside the inner frame of the plate, and three boxes for chas- sis type, drive and wheelbase. The latter are not used for buses, only for trucks. On buses, the identification plate is located by the driver’s TYPE DRIVE...
  • Page 134 Technical Data Engine THD102KF Output kW (hp) ............ 180 (245) 6-cylinder 4-stroke turbocharged diesel engine with over- at rps (rpm) ............37 (2200) head valves and direct injection. Torque Nm (kgf m) ..........1050 (107) at rps (rpm) ............21 (1250) Cylinder bore .............
  • Page 135 Gear Gear ratio 7.72:1 4.42:1 Manual gearboxes 2.85:1 1.91:1 VOLVO G8 EGS (Easy Gear Shift) 1.30:1 Mechanical 8-speed fully synchromesh gearbox. Lever 1.00:1 movement transferred to gearbox through an electropneu- Reverse 7.09:1 matic shifting system. For a description of the difference between the two G8 EGS gearbox variants: 2+ and 7+, see the chapter ”Driving”.
  • Page 136 Technical Data Automatic gearbox Automatic gearbox ZF 4HP500/590, 5HP500/590/600 Allison MT 647 Fully automatic gearbox with retarder. Shifting points are Fully automatic 4-speed gearbox. Shifting points are con- controlled by an electronic unit. trolled hydraulically. Gear Gear ratio Gear Gear ratio 4HP500 5HP500 5HP600...
  • Page 137 Technical Data Rear axle All final drives are single gear hypoid type with denomina- tion EV85. The speed of the bus at any given engine speed depends on the type of gearbox, rear axle ratio and tyre dimension. For comparison, the speed at 2000 rpm and 295/80-22.5" tyres is shown here for various gearboxes and rear axle ra- tios.
  • Page 138 Technical Data Braking system Steering gear Dome nut type power steering with integrated servo unit. Pneumatic brakes complying with EG braking system with Approx. 4.7 steering wheel turns between lock. separate circuits for front and rear wheels. Air dryer. Auto- matic brake adjustment.
  • Page 139 Capacity ............2 x 150 litres Capacity ............3 x 150 litres Vehicle documents (type certificate) specifies permitted weights for your bus and its wheel/tyre equipment! The tanks above are supplied by Volvo. Other tanks may be fitted by the coach-builder.
  • Page 140 Register ABS ..........25 Chassis number ......130 Emergencies ........65 Air cleaner ........121 Clamping strips ....... 27 Emergency brake ......56 Air dryer ......... 123 Clearing, fault codes ....... 88 Emergency cut-out ......12 Air pressure, tyres ......125 Clock ..........
  • Page 141 Levelling control, fault tracing ..93 Speed limiter ........20 Voltmeter ......... 15 control ...... 30 Speedometer ........20 Volvo Action Service ....... 66 Light switch ........ 13, 14 Start help ......... 77 Warning ..........2 Lubrication ........126 Start of engine ......... 39 Warning lights ........
  • Page 142 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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  • Page 147 Notes ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 148 Volvo Bus Corporation TP 9273/1 (English)

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