tp15947 2 PDF

Service Manual
Buses
Section 3(37)
Electrical system
B12 with D12 engines
Component Wiring Diagrams
TP 15947/1
Contents
Electrical system, B12 with D12 engines
Page
Introduction .................................................................. 1
How to read our electrical schematic diagrams ............ 1
Component symbols ..................................................... 3
Centralised relay and connector locations .................... 4
Test socket .................................................................... 6
Main printed circuit board interconnections
schematic diagram .................................................... 7
Body connections ......................................................... 8
Warning and indicator lamps printed circuit board ...... 9
Wire numbering ............................................................ 10
Colour coding ............................................................... 10
B12/D12 cable harness wiring table ............................. 12
Safety ............................................................................ 13
Fuses ............................................................................. 14
Chassis and cable harness ground connections ............ 16
Schematic diagrams, circuit descriptions

and component locations
Page
1 Battery circuit breaker, emergency
cut-out switch .................................................... 18
2 Keystart switch, lighting switch, high/low
beam switch ....................................................... 20
3 Engine start ............................................................ 22
4 Combination relay, starting heater, G8 MGS
range lock, exhaust gas pressure regulator
and windscreen wash/wipe switch circuits ........ 26
5 Alternators ............................................................. 30
6 Engine stop ............................................................ 32
7 Central warning lamps and buzzer, instrument
panel lighting ..................................................... 34
8 Indication and warning lamps ............................... 38
9 Fire warning .......................................................... 42
10 Instrument gauges (Combi 1) ................................ 44
11 Instrument gauges (Combi 2) ................................ 48
12 Speedometer, tachograph ...................................... 50
13 Reversing lights, brake lights ................................ 52
14 Hazard warning lights, direction indicators, horn . 54
15 Differential lock, bogie.......................................... 56
16 Volvo G8 EGS transmission system ..................... 58
17 Electrical retarder .................................................. 62
18 Voith hydraulic braking retarder ........................... 64
19 ABS and ASR systems .......................................... 68
20 ABS connections, trailer ....................................... 74
21 Electronically Controlled Suspension (ECS) ........ 76
22 Fuel Injection Control (FIC) system, 24V ............ 80
Indexes
Component number index ....................................... 82
Component name index ........................................... 86
Order number: TP 15947/1

Electrical system,
B12 with D12 engines
Introduction
This Service Manual describes the chassis-mounted The physical location of the components in and around
electrical system for B12 buses equipped with D12 the B12 bus body and chassis depends in many cases on
engines. the requirements of the coachbuilder. This means that
the photographs in this Manual can only be relied on to
The division of the electrical circuits into separate func- show typical locations. In other Volvo buses their loca-
tional areas follows the same principles as in other tions are generally determined during final assembly of
Volvo Bus Electrical System Manuals. the chassis at Volvo
How to read our electrical schematic diagrams
24V Battery positive The “+” line on the schematic diagrams represents a
direct connection to the battery, protected by an 80A
fuse. This line is used for electrical items which must be
permanently supplied with voltage, such as clocks,
hazard warning lights, communications radio etc.
The “+” line supplies the “+” connection on the electrical

centre printed circuit board.
The “+30” line is supplied with voltage whilst the

electrical battery master switch is closed, to connect it to
the “+” line.
The “+30” line supplies the “+30” connection on the

electrical centre printed circuit board.
Current The “+15” line is relay-controlled via relay (3026A)
paths contact and only supplied with voltage from the “+30”
and line when the keystart switch (150) is in the RUN
components position, to energize relay (3026A).
The “+15” line supplies the “+15” connection on the

electrical centre printed circuit board.
Chassis ground Current flows down through the components from the
(Battery negative) appropriate “+” line to the chassis ground, represented
by a thick line at the bottom of the diagram.
1
Current path reference number
A double line indicates a connection

to a printed circuit board.
Detachable connection, (empty circle)
*Permanent connection (black dot)
Wire number and colour (refer to “Colour coding” on

page 10 for the colour coding descriptions).
Pin 7 of the 9-pole connector marked “EP”
The continuous sequence of current path reference num-

bers at the top of the schematic diagrams makes it easier
to cross-refer from one connected current path to an-
other, and each cross-reference is shown on the diagram
by a “#” symbol.
A component, in this case number 144, the battery

master switch. Every component has a unique compo-
nent number, which is clearly shown in the diagram by
underlining. “CF” stands for the component location at
the front of the chassis (refer to the “Component location
codes” table below).
Ground connection, direct to the chassis, which acts as

the main ground return line.
* Note: Ultrasonic welded connectors are indicated by Other types of permanent connection are indicated by
large black dots. In this example permanent welded smaller black dots.
connector “13” indicates that the connection is sup- Turn to the fuse diagram and list on pages 14/15 to see
plied from fuse “13”, and it may be necessary to check which circuits are supplied by which fuses (in this case
other circuits connected to this fuse during fault dia- the other circuits supplied via fuse “13” are in current
gnosis. paths 12, 20, 221 and 261).
.
Component location codes
Code Location Code Location

ABS ABS printed circuit board E Electrical centre front
B Battery box EGS EGS printed circuit board
CC Chassis centre ER Electrical centre rear
CF Chassis front I Instrument panel
CR Chassis rear M Engine/transmission area
CV Chassis at battery box P Pedal plate area
2
Component symbols
These are the principal electrical symbols used in this Service Manual.
Connectors
Battery Km/h
Body K
Circuit beakers Speedometer
Detachable
Fast charging Automatic or fuse
socket
Grounding tags Solenoid-operated

Permanent
30a 30 Tachograph
Switch contacts Km/h
With holding coil
Cam operated
Dual, centre 31 86 Electronic components
sprung
Relays and solenoids Amplifier
Relay
Foot
pedal AND gate &
Solenoid valve
micro-
sw. Solenoid valve, Buzzer
dual coil
Mechanically
operated 30 50 Converter, 24 V
Microswitches d.c. to d.c. 12 V
5(30) 2(56)
Starter motor M Converter,
Multi- sine wave
31
pole to pulses
3(56a) 4(56a) 1(56b)

Diode
Horn
Electronic
Multi- control unit
position,
B+ D+
rotary
D+ WL
Pulse
Alternator generator
Pressure operated P<540kPa B- D- Relay, level

switching
Push-button, Lamps
normally closed
Indicator, Battery
steady lit
Push-button, 2-pole
Rocker, 1 pole Panel

Clock
Rotary, Warning, flashing
manually operated
Sprung, centre off Gauges Heater element
Sprung, one way Instrument

FUEL
panel
Temperature t>110 C
operated
Two way with detent
With built-in
electronic C
With built-in lamp switch
3
Centralised relay and connector locations
KD KB KA J I H G
KC
3028 308 300 3063 309
CA
3066 903
3026 3026 354 396 345 315 3005 3027 398 354B BUNDLED
B A A DIODES
”23”
CD
CC
F E D I B A
FUSE
389 TEST
AT EH EJ EK RET STE ER EI ET EG TC KG
INT GA EB ED ECS EL EM EN EO EP GBX KE KF KH
Front electrical centre
Notes:
Relay
socket Circuit and function
This list of relays and circuit functions refers to the relays
300 Headlamps high/low beam relay located in the front and rear electrical centres. The other
308 Brake lights relay relays that are not listed here are identified in their
309 Parking lights relay respective schematic diagrams and descriptions.
315 Starting switch relay
315R Engine start solenoid relay Electrical connectors are identified by letter codes, such
345 Start inhibit relay as A, AA, RET etc. Main power connections are labelled
345R External start inhibit relay “+”, “+30” and “15”.
354A Starting position relay (alternator sensed)
354B Auxiliary starting position relay (in socket The FUSE CHECK socket labelled “TEST” is an empty
labelled 3029) (hold-in when cranking) fuse socket connected to a green light-emitting diode.
389 Starting heater indicator lamp relay This socket may be used to check any of the circuit
396 Transmission in neutral relay breakers, and the green LED will light if the breaker is
398 VEB inhibit on cold engine relay (option) serviceable. Any circuit breaker or blade-type fuse may
3005 Parking brake off warning relay be exchanged for any other with the same rating.
3014 ECS diagnostic indicator lamp
relay (option) Refer to page 6 for a description of the 35-pole test socket
3026A “+15” supply relay to chassis circuits, located between the relays.
via keystart switch
3026B Aux. “+15” supply relay to body circuits, Some diodes are wired directly on to the printed circuit
via keystart switch boards, while others are bundled in the cabling on the
3027 Fire warning lamp and buzzer relay right of the electrical centre.
3028 Reversing lights relay
3063 Engine stop relay
3066 Combination relay
4
ABS printed
circuit board
EGS G7A G7D G7B G7C DIA7 JMP EAB ABS

printed
circuit
board “43” 3045 3046
5A 399A 399B 3038B 3038A
3044 3025 3024-1 3024-2
TA AXL1
ABS/ASR TB AXL2
CONTROL UNIT
TD AS R
(if ABS is fitted)
VOITH RETARDER 9008 MF SW
CONTROL UNIT
9054 DIA KK
308X 379B 379A “45” “44”

10A 5A
3014 354B 379A 308B 3023

ECS
CONTROL UNIT
9002
This illustration shows a typical set of components as coachbuilder, and the actual items supplied depend on
they are delivered with the chassis to the coachbuilder. the bus specification; some may not be present, others
These components may be re-positioned in the bus by the may be added.
Accessory group
Rear electrical centre

The rear electrical centre is shown with the door open inside the cabinet. The starting heater relay (312) is
and the door-mounted components at the left. Heavy- located on the outside of the cabinet, to its left.
current fuses are normally fitted to a distribution panel 5
Test socket
The test socket allows the voltages at certain

1 35 important points within the electrical systems to
be monitored. This is a fault tracing aid. The test
socket is a 35-pole AMP minitimer connector,
type 527439.
Pin Test conditions Pin Test conditions

1 Not used 13 (+) during starting while engine is cranking
2 Ground 14 (+) if parking lights are switched on via
4 Not used relay (309)
5 (+) during starting if relay (354A) is de- 19 Not used
energized (alternator not charging) 20 (+) if reversing lights are switched on via
6 (+) during starting if transmission in neutral relay (3028)
and alternator not charging 21 Not used
7 (+) during starting if relay (345) is de- 22 Not used
energized to confirm that there is no start 23 Not used
inhibit from body circuits 25 (+) when brake lights activated via relay
8 (+) during starting if all start conditions are (308)
fulfilled and start sequence is activated 26 (+) when dipped headlights selected via
9 (+) if engine running and parking brake is relay (300)
not set on (parking warning condition) 28 (+) when battery is being charged
10 (+), connected to “+15” supply fuse “8” 29 Not used
11 Grounded to light fire warning lamps (544) 33 Not used
and (559) 35 (+) when relay (3063) energises to stop the
12 VEB inhibit due to cold engine if relay engine
(398) is energised
Adapter 999-8177 for connection to test socket

in electrical centre
Test box 981-3190, Adapter 9998360,

Volvo Digital Multimeter 951-0060
6
Main printed circuit board interconnections schematic diagram
"B+"
"+" 3 x M8 F3
M6
"+30" "+15"
"21" "12" "13" "16" "23" "11" "14" "18" "22" "20" "17" "15" "7" "9" "10" "8" "19"
25A 8A 8A 8A TEST
8A 8A 8A 15A 8A 15A 15A 8A 8A 8A 8A 8A 8A
1k2
10
3026B
3026A
F1 D1 F9 F2 KB3 M6 F6 F7 C8 C1 D8 C3 KB6
M6 F4 F8 KB1 "+15"
"+"
KA1 H3 KA9 KA6 KA5

G9 I9 I2 I6 I5 KB8 E2 E9 E7 E3 E1 KB4 KA4 KA3 KA2 H2 H6 KA8 J1
28
354A
(3008) (3013)
396 5
309 300 308 3028 6 345

29 22 (3014)
(3009)
315 7
14 26 25 20 4 21 23 19 1
8
I7 KB7 I8 I1 KB9 E6 E8 E4 E5 KB2 F5 J3 H4 J6 J8 J9 J5 H1 J7 H5 KA7 J4 J2
2 B7 B8 B9 B3 C7 C9 C2 D3 G8 G1 G2 I4
A8 A6 A5 B2 2 x M6
GND
"31"
354B 398 3027 3005 3063 (381)

"1" "2" "3" "4" "5" "6"
8A 8A 8A 8A 8A 8A
13 12 11 9 35 33
A7 A9 A3 A2 A1 A4 B5 B4 D4 B1 B6 D7 C5 C4 D9 D2 C8 D6 G5 G7 G4 I3 G3 G6
The numbers in squares refer to pins in the test socket In general, relays (381), (3008), (3009), (3013) and
(see “Test socket” list on page 6). (3014) are not used in B12 buses with D12 engines.
This is a standard Volvo Bus printed circuit board and Note that the ECS diagnostic indicator lamp relay (3014)
some of the the sockets for relays may be fitted with described in Schematic 21 is not the relay (3014) shown
jumper links or remain empty, depending on the bus on this diagram.
specification.
7
Body connections
KC KD 30 + 15 KB KA KE KF KG KH
Ref. Function Ref. Function

+ Direct battery (+) connection KE1 Parking lights (fuse “1”)
+30 Battery (+) connection via electrical KE2 Parking lights (fuse “2”)
battery master switch (342A) KE3 Headlights, high beam (fuse “3”)
+15 (+30) via relay (3026B) contact KE4 Headlights, high beam (fuse “4”)
KE5 Headlights, low beam (fuse “5”)
KA1 Not connected KE6 Headlights, low beam (fuse “6”)
KA2 Not connected KE7 Headlights “+”, to control wash/wipe
KA3 Not connected KE8 Not connected
KA4 Not connected KE9 Not connected
KA5 Not connected
KA6 Not connected KF1 Not connected
KA7 Ground KF2 Not connected
KA8 Not connected KF3 Direction indicators, “49” supply from
KA9 Not connected blinker circuit
KF4 Direction indicators, “49”
KB1 Fuse “16” (+) KF5 Direction indicators, “15”
KB2 Start inhibit signal input (–) KF6 Direction indicators, “L”;
KB3 Fuse “22” (+30) KF7 Direction indicators, “30”;
KB4 (+) while starting KF8 Direction indicators, “49 a/c”
KB5 Not connected KF9 Direction indicators, “R”;
KB6 Fuse “19” (+15)
KB7 Brake lights (relay 308 pin 87) KG1 Buzzer, reversing lights (+)
KB8 Reversing lights (relay 3028 pin 30) KG2 Buzzer, hazard warning lights (+)
KB9 Reversing lights (relay 3028 pin 87) KG3 Combination relay (3066) pin 16
KG4 Spare buzzer input (+)
KC1 Warning lamp, door brake (–) KG5 Buzzer, doors (–)
KC2 Warning lamp, rear fog lights (+) KG6 Windscreen wipers, “53a”
KC3 Warning lamp, next stop sign (+) KG7 Windscreen wipers, “53b”
KC4 Warning lamp, turn indicators (+) KG8 Windscreen wipers, “53”
KC5 Warning lamp, engine hatch/luggage door open, KG9 Windscreen wipers, main switch
no buzzer (–)
KC6 Warning lamp, engine hatch/luggage door open, KH1 Not connected
with buzzer (–) KH2 Not connected
KC7 Warning lamp, doors open (–) KH3 (+) when emerg. switch (180) operated
KC8 Warning lamp, parking brake off (–) KH4 Not connected
KC9 Warning lamp, perambulator (–) KH5 Direction indicators, main switch
KH6 Horn (grounded via steering column)
KD1* Not connected KH7 Not connected
KD2* Not connected KH8 Not connected
KD3 Buzzer activating input (–) KH9 Not connected
KD4 Extra buzzer supply (100 mA)
KD5* Not connected KK2 ECS control unit (9002) pin 1
KD6 Extra lamp test “+” output (1A) KK4 Ground
KD7* Not connected KK6 ECS control unit (9002) pin 20
KD8 Not connected KK8 ECS control unit (9002) pin 6
KD9 Not connected
* These connections must not be used to supply current without
8 permission from the Volvo Bus Corporation.
Warning and indicator lamps printed circuit board
The warning and indicator lamps printed circuit board
KD has three functions:
• to receive control lamp activation signals and deter-

KC mine, according to the signal priorities, whether to
activate the central warning lamp and/or warning
buzzer
CA
• it carries the electronic circuits for monitoring cool-
ant level
“F1”
5A • to carry out the lamp test function in its electronic
circuits
RE1
This board carries two solid-state relay circuits; RE1 to
RE2 control the lamp test switching, and RE2 to control the
engine oil pressure low warning buzzer. Note that the 5A
CD lamp check circuit fuse “F1” is also located here.
CC
CA CC Output signal to CD
Connection indicator/warning Sensor input signal
pin pin pin
lamps
1 “+” supply from fuse “9” 1 Perambulator 1 Perambulator
2 Lamp check ground 2 Retarder engaged 2 Retarder engaged
3 Electronic ground 3 Brake wear 3 Brake wear
4 G8 EGS input to buzzer 4 ABS engaged 4 ABS engaged
5 G8 EGS input to central 5 Engine compartment fire 5 Engine compartment fire
warning lamps 6 Service brakes low press. 6 Service brakes low press.
6 Lamp check “+” input via 7 Coolant temperature high 7 Coolant temperature high
keystart switch 8 Coolant level low 8 Coolant level low
7 Buzzer switching 9 Door brake 9 Door brake
connection 10 Alternator charging 10 Alternator 1 charging
8 Coolant level sender warning warning
input 11 Oil pressure 11 Oil pressure
9 Central warning lamps 12 G8 EGS transmission 12 G8 EGS transmission
switching connection warning/diagnosis warning/diagnosis
13 Rear fog lights 13 Rear fog lights
14 Next stop sign 14 Next stop sign
15 Direction indicators 15 Direction indicators
16 Engine preheater 16 Engine preheater
17 Air susp. pressure low 17 Air susp. pressure low
18 Door open 18 Door open
19 Engine hatch/luggage 19 Engine hatch/luggage
door open door open
20 High beam 20 High beam
21 Alternator 2 charging 21 Alternator 2 charging
warning warning
22 Parking brake off 22 Parking brake off
23 Eng. compt. temp. high 23 Eng. compt. temp. high
24 Not used 24 Not used
25 Not used 25 Not used
9
Wire numbering
The chassis wiring is easy to trace due to its colour Ground wires are labelled 37, 37A, 37B etc. Indirect
coding and wire numbering. ground wires are labelled with the numbers of the com-
ponents they are connected to, for example 216A.
A wire is given the same number as the component it is
connected to, with the exception of wires connected to If several wires lead to the same component, each wire
ground (earth) and indirect ground wires (on the ground carries the same number, but with the suffix A, B, C, D
side of the circuit but connecting between components). etc. If a wire is further split, it is marked with “double
letters”, such as 2AA, 2AB etc.
Colour coding
The electrical wiring is normally colour-coded accord- exceptions to these “rules” where the use of the same
ing to the components or areas to which it is connected, colour could cause confusion. The schematic diagrams
as shown in the following table. There ma,y howeve,r be are labelled with the actual colours used.
Wire colours Colour Type of circuit

Primary Tracer code
RED NONE R “+” (battery direct) or “+30” (via battery master switch)
GREEN RED GN/R “+15” (“+30” line via relay controlled by keystart switch)
YELLOW RED Y/R Positive from charging alternator
WHITE RED W/R Indirect positive (between components)
GREEN OR NONE GN or GR Switch connection where a colour code has not been
GREY defined, e.g. wiring from a switch to a fuse.
BLUE NONE BL Relay connection “87”
BLUE BLACK BL/SB Relay connection “30”
BLUE RED BL/R Relay connection “86”
BLUE GREEN BL/GN Relay connection “87a”
YELLOW NONE Y Signal, e.g. speed signal
YELLOW BLACK Y/SB Indicator lamps that are positive-activated
WHITE YELLOW W/Y Indicator lamps that are negative-activated
WHITE GREEN W/GN Warning lamps that are negative-activated
WHITE NONE W Ground
WHITE BROWN W/BN Indirect ground (between components)
BLACK NONE SB External systems with their own cabling, such as auto-
matic transmissions
BLUE YELLOW BL/Y Equipment installed by the body builder
BLUE WHITE BL/W Indicator lamps installed by the body builder
LIGHT NONE LBN Spare wiring
BROWN
10
PRIMARY COLOUR ONLY PRIMARY COLOUR WITH TRACER
How the colours appear on the wiring
(+) 86
87a 87
8
30
9 7
6 85
3
8
5
2 87
7 86
4 87a 85
1
30
9-pin connector and socket numbering Relay markings
11
B12 buses with D12 engines Cable Harness Wiring Table
Cable Harness Identification Part No
Instruments 9518315
G8 EGS 9521652
G8 EGS control unit 9518318
AT-reg 9521535
AT-reg with rang (MGS) 9521534
Allison WT 9523065
Allison GEA 9523196
Programming 9520342
Tachograph 3962958
El distribut unit 9520369
Fuel cut off 9520964
Instrument 9523692
U. I-instrument 9519074
Voith retarder 9520370
Sensor 9522529
Emergency switch 3034334
ECS 9955255
Control unit 9523075
Boggie 9515250
F-battl 9521847
U-battl 9521848
El-switch 3113996
Stelem 9519078
Fire warning 9520366
Alternator 9519076
Alternator 9519075
Feed 24 V 9520364
Exhaust brake 9520371
Telma Focal 516029
Telma 9517645
Telma Focal 9516065
Radiation shield 9517405
ABS-4-chann 9515844
ABS 3036104
ASR 9515846
ABS-trailer 9517492
ABS-lamp 9517668
12
Safety
Always follow the prescribed safety rules when working The advanced electronic circuits in modern buses can be
on a bus electrical system. Open the battery master destroyed instantly by incorrect connection, and special
switch before beginning repair work. Because some care must be taken when testing and repairing this type
circuits are connected directly to the battery, bypassing of component and circuit.
the battery master switch, the battery cables must be
disconnected to be absolutely sure that no current can If welding is to be carried out, care must also be taken to
flow. avoid damage to the electrical and electronic compo-
nents installed in the bus.
Remember that the batteries in a bus store a large amount
of energy, which can cause severe burns if a short-circuit
occurs.
13
14
Fuses
Fuse Rating Circuit protected by fuse
“1”/“2” 8A Parking lights (KE1)/(KE2), Panel lamps
“3”/“4” 8A Headlamps, high beam (KE3)/(KE4)
“5”/“6” 8A Headlamps, low beam (KE5)/(KE6)
“7” 8A G8 MGS reversing lights relay, Differential lock,
Bogie, ECS diagnostic lamp
“8” 8A Engine stop, VEB inhibit, Starting heater
“9” 8A Warning panel lamps, Instrument gauges,
Speedometer,
Tachograph, Central warning lamps,
Coolant level warning
“10” 8A Volvo G8 EGS system, ABS logic system for 3026 3026
B A
trailer
“11” 8A Fire warning control system
“12” 8A Emergency fuel cut-off
“13” 8A Battery circuit breaker control, Tachograph clock, “23” 3026B 3026A “1”
Clock/odometer
“14” 8A Keystart switch, Engine start/stop, Buzzer,
Voltmeter
“15” 8A ECS, ABS/ASR, EPG, G8 MGS, Electrical retarder,
Voith hydraulic retarder
“16” 8A “+” to body circuits (via KB1)
Fuses “1” to “23” and relays 3026A/B in the electrical centre
“17” 15A Starting control circuit
“18” 15A Headlamps, Parking lights and Panel lamps “41” 342A
“19” 8A +15 to body circuits (via KB6)
“20” 15A +15 to body circuits, via relay (3026B) “46”
“21” 25A “+” to body circuits
“23” 8A Brake lights, Voith hydraulic retarder
“34” 80A “+30” line main fuse
“35” 80A “+” line main fuse
“40” 8A ABS control unit feed 1
“41” 8A ABS control unit feed 2
“45” 15A FIC system main feed
“46” 10A FIC system back-up feed
“F1” 5A Lamp check circuit “35”
No. Component “34”

3026A Keystart switch relay
3026B Auxiliary keystart switch relay Fuses in the rear electrical centre 342B Starter motor circuit breaker
“41” ABS Control unit feed 2 “34” +30 line main fuse
“35” + line main fuse
“46” EDC backup feed fuse
15
16
Chassis and cable harness ground connections
NOTE: The grounding cable numbered 37 connecting 1 on the electrical centre to the welded nut on the chassis frame must provide a solid ground.
BATTERY BOX Welded nut near battery box
“31” M6 screw in electrical centre printed circuit board.
“P4” Ultrasonic welded connector in electrical centre cable harness

Schematic diagrams,
circuit descriptions and
component locations
17
18
1 Battery circuit breaker, emergency cut-out switch
Fuse Rating Circuit protected by fuse 342A
“13” 8A Battery circuit breaker control system
“34” 80A “+30” line main fuse
“35” 80A “+” line main fuse 144
No. Component
30 Batteries
85 Fast charging socket
144 Battery master switch
180 Emergency cut-out switch
342A Battery circuit breaker
903 Diode
342A Battery circuit breaker 144 Battery master switch
Circuit descriptions
Battery circuit breaker (current paths 5 to 12)

When the master switch (144) in current path 12 closes, the battery
circuit breaker (342A) is energized, opening its lower contact and
closing its upper contact. A holding winding in (342A) keeps it ener-
gized. When the engine starts, voltage from the alternator (see Schem-
atics 3 and 5) keeps the holding winding energized.
180
The upper contact of the battery circuit breaker (342A) supplies the
“+30” line via fuse “34” to the distribution rail in the rear electrical
centre, providing excitation voltage from the batteries to the alternator(s)
and starter motor when starting, and charging current (in the opposite
direction) to the batteries from the alternator(s) when running.
180 Emergency cut-out switch 85 Fast charging socket
Emergency cut-out switch (current paths 13 to 24)
The battery circuit breaker (342A) section of this circuit operates in the
same way as described above.
If the emergency cut-out switch (180) in current path 20 is operated, the

supply to the circuit breaker (342A) holding winding is removed and it
de-energizes, to remove the supply from the “+30” line distribution rail.
Simultaneously the engine stop circuits (described in Schematic 6) are
energized via the emergency cutout switch (180), which when it is
pressed also supplies “+” to the body connector KH3.
In buses equipped with a fuel cut-off system, operation of the emergency

cut-out switch is sensed by the fuel cut-off control unit (9063) (see
Schematic 6) and shuts off the fuel supply. 30 Batteries
19
20
2 Keystart switch, lighting switch, high/low beam switch
“1” 8A Parking lights (KE1)
“2” 8A Parking lights (KE2)
“3” 8A Headlamps, high beam (KE3)
“4” 8A Headlamps, high beam (KE4)
“5” 8A Headlamps, low beam (KE5)
“6” 8A Headlamps, low beam (KE6)
“14” 8A Keystart switch
“16” 8A Body circuits (via KB1)
“18” 15A Headlamps, parking lights and panel lamps
“19” 8A “+15” to body circuits (via KB6) 150 101/147
100
“20” 15A “+15” body circuits, via relay (3026B)
109
“21” 25A “+” to body circuits
No. Component 150 Keystart switch 100 Ligting switch
100 Lighting switch 101/147 High/low beam switch
315 300
101/147 High/low beam switch
150 Keystart switch 309
300 Headlamps high/low beam relay
309 Parking lights relay
504 High beam indicator lamp
903 Diode
3026A Keystart switch relay 300 Headlamps high/low
3026B Auxiliary keystart switch relay beam relay
309 Parking lights relay
Circuit descriptions 3026A Keystart switch
Keystart switch (current paths 51 to 58) relay
The keystart switch is used to both start and stop the engine, by 3026B Auxiliary keystart
switch relay
controlling the current flow to the starting switch relay (315). The
3026B 3026A
keystart switch (150) positions are: “0”, neutral and steering lock; “R”,
radio only; “1”, the driving position; “2”, lamp checking and “3”, starting
(positions “2” and “3” being spring-loaded). Position “1” connects B+ S
to D, energizing relays (3026A) and (3026B); “2” connects switch

terminal 30 to 19, supplying the combination relay and lamp check 80 100 1/2
60
120
40 E F
504
circuits (see Schematics 4 and 8 respectively); “3” connects B+ to 50,
energizing relay (315) in the starting circuit.
2 4 4
Lighting switch circuits (current paths 59 to 70) 6 2 6
8 8
0 10 0 10
The lighting switch (100) energizes relay (300) for headlamps and relay
(309) for panel lamps and parking lights. The high/low beam switch
(101/109/147) then controls the headlamp beam switching. 504 High beam indicator lamp
21
(Continued on page 27)
22
3 Engine start (Sheet 1 of 2)
41 345R
“17” 15A Starting control circuit
“41” 15A Engine start/stop
No. Component
160B Engine stop button at bus rear
185B
185B Engine start button at bus rear
186 Engine rear start enable switch
315R Engine start solenoid relay
345 Start inhibit relay
345R External start inhibit relay 160B 315R
186
354A Starting position relay (alternator sensed)
354B Auxiliary starting position relay
396 Transmission in neutral relay 160B Engine stop button 41 Fuse Engine start stop
654 Starter motor 185B Engine start button 345R External start inhibit relay
903 Diode 186 Engine start enable switch 315R Engine start solenoid relay
Starting from the driver’s seat
When the keystart switch (150) (see Schematic 2) is turned to the start
396 345
position, or the rear start button (185B) is pressed, the starting switch
relay (315) is energized. Its contact completes the circuit to the engine
start solenoid relay (315A), and this provides current to the starter motor
solenoid (654) if the following conditions are met:
(a) The engine has not already been started, so that no current is being
generated by the alternator and the starting position relay (354A) is
de-energized.
(b) Neutral gear is selected, so the transmission in neutral relay (396)
is energized. In buses with the G8 MGS transmission this relay is
replaced by a link between terminals 30 and 87a to simulate a closed
contact.
(c) There is no start inhibit (ground connection) from body connectors
KB2 or F5, so that the start inhibit relay (345) is not energized.
354B
Alternatively, relay (345) has been replaced by the optional link
between terminals 30 and 87a that simulates a closed contact. 354A 315
(d) The rear engine start button (185B) is not pressed and the engine 354A Starting position relay
hatch microswitches have not grounded the body connection so that 354B Auxiliary starting position relay
the external start inhibit relay (345R) is not energized. 396 Transmission in neutral relay
(e) The engine start enable switch (186) in the rear electrical centre is
set to ENABLE.
23
24
3 Engine start (Sheet 2 of 2)
41 345R
(Continued from page 23)
If all the above conditions (a) to (e) are met, the starter solenoid connects
the starter motor (654) to the battery + supply via the battery circuit
breaker (342A) closed contact (see Schematic 1).
If the alternator begins to deliver current before the engine has started
properly, the starting position relay (354A) will energize and its contact
185B
will open. However, by this time the auxiliary starting position relay
(354B) will have energized and acts as a holding relay. The current via
relay (354B) and (315) closed contacts keeps (354B) energized and
provides an alternative path to keep the engine start solenoid relay
(315R) energized, even though relay (354A) contact is now open.
186 160B 315R
Starting from the rear of the bus
Pressing the rear start button (185B) energizes the starting switch relay
(315), which then completes the circuit via (315A) and (654) as de- 160B Engine stop button 41 Fuse Engine start stop
scribed above, providing conditions (a), (b), (c) and (e) listed above are 185B Engine start button 345R External start inhibit relay
all met. This means that the engine hatches can be open when starting the 186 Engine start enable switch 315R Engine start solenoid relay
engine from the rear.
After the engine has started

When the engine starts properly, the alternator current energizes the
starting position relay (354A), its contact switches over and de-energizes 396 345
the starter solenoid circuit, since the keystart switch (150) or rear start
button (185B) have been released, de-energizing relay (315) to break the
relay (354B) holding circuit.
354B
354A 315
354A Starting position relay
354B Auxiliary starting position relay
396 Transmission in neutral relay
25
26
4 Combination relay, starting heater, G8 MGS range lock, exhaust gas pressure regulator
and windscreen wash/wipe switch circuits (Sheet 1 of 2)
“8” 8A Starting heater
“15” 8A Exhaust gas pressure regulator, G8 MGS range lock
No. Component
119/120 Windscreen wash/wipe switch
312 Starting heater relay
389 Starting heater indicator lamp relay
614 G8 MGS range lock solenoid valve
626 Exhaust gas pressure regulator solenoid valve
756
756 Engine coolant temperature sender
800 Starting heater element
903 Diode
3066 Combination relay 756 Engine coolant temperature sender 528 Starting heater indicator lamp
Combination relay (3066)

This is an electronic unit combining several functions that in previous 800
buses were performed by separate components.
312
Starting heater
When the keyswitch (150), see Schematic 2, is turned to start the engine,
if the engine coolant temperature sender (756) detects that the coolant
temperature is below 10°C the combination relay (3066) sends a signal
to energize the starting heater relay (312). This switches on the starting
heater element (800), which remains energized for a period of up to 55
seconds if the coolant temperature is below -10°C. The length of time is 800 Starting heater element 312 Starting heater relay
determined by the circuit inside the combination relay (3066). A signal
from this circuit also lights the engine preheater on indicator lamp (528),
see Schematic 8. Note that there is no cold start button on these buses,
since the preheating circuit operates automatically.
G8 MGS transmission range lock

The range lock circuit is used in buses equipped with the manual
G8 MGS gearbox. If the road speed (received as a signal from the
speedometer (700) or tachograph (701) on Schematic 12 is greater than
35 km/h, the range lock relay (614) is energized by a ground signal at
terminal 3 of the combination relay (3066). This prevents low range from
being selected.
614
614 G8MGS range lock solenoid valve

27
28
4 Combination relay, starting heater, G8 MGS range lock, exhaust gas pressure regulator
and windscreen wash/wipe switch circuits (Sheet 2 of 2)
Exhaust gas pressure regulator 626
When the engine is running and the parking brake is set on, a signal is
received by the combination relay (3066) from the parking brake
pressure switch (200), see Schematic 7. This causes terminal 4 of the
combination relay (3066) to be grounded and energize the exhaust gas
pressure regulator solenoid valve (626). This remains connected, until
either the coolant temperature has reached +70∞C or the parking brake
has been released.
Wash/wipe circuit
The windscreen washer pump and wiper motor are operated by stalk
switches (119/120) on the steering column, being supplied from the body
electrical system via KG6. The delay interval and wiper parking connec-
tions are handled by the combination relay (3066) via terminals 6 and 13 626 Exhaust gas pressure regulator solenoid
respectively. KG7 is connected to the wiper motor normal speed contact, valve
KG8 to the slow speed contact, and KG9 to the washer pump. The wiper 3066
motor connections are shown in the diagram at the right of the schematic.
The table on the schematic provides information to the coachbuilder as

to the maximum permissible current and inductive loading that can be
connected to the switch terminals listed in the table. This applies to the
washer and wiper motors, and the limitations are set to ensure that the
contacts in the switches (119/120) will not be damaged by sparking.
389
119/120
3066 Combination relay 119/120 Windscreen wash/wipe switch

389 Starting heater indicator lamp relay
29
30
5 Alternators
“9” 8A Alternator charging warning lamp(s)
No. Component
505 Alternator 1 charging warning lamp
506 Alternator 2 charging warning lamp
660 Alternator(s)
Circuit description
The bus charging system may be equipped with either one or two
alternators (660). Where two alternators are fitted they are connected in
parallel and each alternator has its own charging warning lamp (505) and
(506).
When the alternator is at rest and during starting, the charging warning 660 Bosch alternator connections 660 CAV alternator connectors
lamp (505) is lit, as it is grounded via the battery negative connection.
When the bus engine starts, the alternator begins to generate current,
which flows from the battery positive connection to the batteries. The
generated voltage also appears at the charging warning lamp connection
to equalize the “+15” line voltage at the other side of the charging
warning lamp (505) and, where appropriate, (506). The lamp thus goes
out, to confirm that the alternator is charging.
The battery positive connection on Alternator 1 also supplies maintain-

ing current to:
– the starting position relay (354A), see Schematic 3.
– the engine stop circuit, see Schematic 6.
– the parking warning buzzer circuit, see Schematic 7.
Note:
BRAKE
Bosch and CAV alternators have different labelling for their connec- “9”
P
tions, as follows: “9” Alternator charging warning lamps fuse
OIL
Bosch CAV 505
Battery positive B+ D+
506
Charging warning lamp output D+ WL
P
Battery negative B– D–
505/506 Alternator charging warning lamp
31
32
6 Engine stop
“8” 8A Engine stop
“12” 8A Emergency fuel cut-off 9063
No. Component
903 Diode
3063 Engine stop relay
6023 Emergency fuel cut-off solenoid valve
9063 Emergency fuel cut-off control unit
Engine stop circuit
With the engine running, relay (3063) is de-energized, its contact
sending a signal to pin 6 of the fuel injection control unit (9070) to permit
the engine to run (see Schematic 22 or 22A as appropriate). 9063 Emergency fuel cut-off control unit 6023 Emergency fuel cut-off solenoid valve
If the emergency cut-out switch (180) (current path 20, Schematic 1) or

the engine stop button at the bus rear (160B)(current path 90, Schematic
3063
3) are pressed, or the keystart switch (150)(current path 56, Schematic
2) is set to off, relay (3063) energizes and breaks the signal to the fuel
injection control unit (9070). This in turn switches off the fuel injectors
(6072) to stop the engine.
If fuse “8” blows, the alternator D terminal continues to supply voltage

to the engine stop circuit, via connector D3 (see Schematic 5).
Emergency fuel cut-off circuit

During normal engine running, a voltage input is present at pin 3 of the
emergency fuel cut-off control unit (9063). This voltage is fed via
terminal 4 to energize the fuel cut-off solenoid valve (6023), since
terminal 5 is normally grounded.
If the emergency cut-out switch (180) (see Schematic 1) is pressed,

terminal 2 of the control unit (9063) receives a positive signal that 3063 Engine stop relay
initiates a pulse to the fuel cut-off solenoid valve (6023) and thereby
shuts off the flow of fuel to the engine, which then has to stop.
33
34
7 Central warning lamps and buzzer, instrument panel lighting (Sheet 1 of 2)
Fuse Rating Circuit protected by fuse 547
547
“9” 8A Central warning lamps; coolant level warning
BRAKE
3 4 5 90 110 P
2 70 150
1 6 170
“14” 8A Buzzer 0 7 50
OIL
F 555
P
mph
125 km / h
6
8 r / min x 100 km
No. Component 10 2 1
0 0 0 0 0 0 0
200 Parking brake pressure switch

431 Instrument panel lamps R
508 Parking brake off warning lamp

805
547 Central warning lamps
555 Engine coolant level low warning lamp
759 Coolant level sender 547 Central warning lamps 555 Engine coolant level low warning lamp
805 Panel lamps rheostat (dimmer) 508 Parking brake off warning lamp
853 Buzzer
3005 Parking brake off warning relay
Central warning lamps and buzzer 759
When a sensor sends a warning signal to the lamp’s circuit it passes via
a diode matrix (see Schematic 8) which ensures that the instrument panel
central warning lamps (547) light. These flash at a fixed frequency,
regardless of the supply voltage, i.e. the frequency does not alter during
engine starting. The signal similarly starts the warning buzzer (853) for
those circuits which use the buzzer as a warning.
The lamp flashing circuit is based on an astable multivibrator built into
an integrated circuit. When an alarm is activated, the signal pulls down 853
the base voltage of transistor T2 to ground. This starts the multivibrator
switching at a steady frequency, determined by the values of R9, R10 and
C7. The multivibrator controls transistor T3 which switches the warning
lamps on and off.
Coolant level warning (current paths 150 and 151) 759 Coolant level sender 853 Buzzer
This function is also based on an integrated circuit, which sends an
alternating current signal to the coolant level sensor (759). The signal
amplitude is continuously monitored by the integrated circuit, and if the
amplitude reaches a certain level the circuit activates the coolant level
warning lamp (555).
35
36
Central warning lamps and buzzer, instrument panel lighting (Sheet 2 of 2)
Parking brake off warning and interlock to exhaust brake

3007
system
The parking brake off warning relay (3005) is connected both to the
warning buzzer circuit and the fuel injection system control unit
(9070), see Schematic 22 or 22A as appropriate.
If the engine is stopped without setting the parking brake on, the
buzzer will sound. Relay (3005) contact is connected to buzzer
(853) terminal 4, which is normally at alternator voltage but will be
grounded if the engine stops. Setting the parking brake will close the
contact (200) (in current path 159), and energize relay (3005), thus
200A
opening the line to terminal 4 of the buzzer (853). Hence the buzzer
will not normally sound, but if the engine stops and terminal 4 is 200A Parking brake pressure switch 3005 Parking brake off warning relay
grounded because relay (3005) has not been energized via the
parking brake pressure contact, the buzzer will sound.
Instrument panel lighting (current paths 162 to 166)

These five lamps (431) are supplied from fuse “2” via the parking
lights relay (309) contact (see Schematic 2) and a dimming rheostat
(805).
Changing instrument panel light bulbs

To change a panel lamp (431), unscrew the panel bezel, unplug and
remove the appropriate instrument, open the casing at the rear and
change the bulb.
805
805 Panel lamps rheostat (dimmer) 431 Instrument panel lamps
37
38
8 Indication and warning lamps (Sheet 1 of 2)
BRAKE
“9” 8A Warning panel lamps
“F1” 5A Lamp check circuit P
No. Component
200 Parking brake pressure switch 542 508 559 558 507
214 High range indicator lamp contact
500 Indicator lamp, direction indicators (via KC4)
503 Warning lamp, engine oil pressure low OIL
504 Indicator lamp, high beam
505 Charging warning lamp, alternator 1
506 Charging warning lamp, alternator 2
507 Warning lamp, service brakes pressure low
505 503 544 555 540
508 Warning lamp, parking brake off
514 Splitter gear indicator lamp
526 Indicator lamp, retarder engaged
528 Indicator lamp, engine preheater on
536 Indicator lamp, rear fog lights (via KC2)
541 Indicator lamp, EGS diagnostics 546 543 541 554 506
542 Warning lamp, door brake
543 Warning lamp, engine hatch/luggage doors open P
(via KC5 and KC6)
544 Warning lamp, engine compartment temperature high
545 Indicator lamp, next stop (via KC3)
546 Warning lamp, door open (via KC7)
554 Warning lamp, engine coolant temperature high 5009 528 536 561 562
555 Warning lamp, engine coolant level low
559 Warning lamp, engine compartment fire Warning and indicator lamps panel
561 Warning lamp, perambulator (via KC9)
562 Warning lamp, air suspension pressure low
3027 Fire warning lamp and buzzer relay
5009 Indicator lamp, ABS engaged
RE1 Lamp check relay
RE2 Engine oil pressure low buzzer activating relay
Note that not all the indicator and/or warning lamps may be connected 526 500 545
on a particular bus; the lamp fit depends on the particular bus specifica-
tion, e.g. jack-knifing only appears on trailer buses. S
504
Indicator lamp group
39
40
8 Indication and warning lamps (Sheet 2 of 2)
Circuit description
Every sensor in the chassis is connected to its indicator or warning lamp
via a connection in CD. The signals pass through a diode matrix which
determines whether the central warning lamps and/or buzzer should be
activated.
When the keystart switch (150) (in current path 58, Schematic 3) is
turned to the lamp check position, all the indicator and warning lamps
should light. Those which light from a voltage input receive it from the
switch, via CA6 and the diode matrix, and those which light from ground
are grounded (via the diode matrix and CA2) by RE1, which is energized
from the switch lamp check position. 200A
“FI” 5A lamp check circuit fuse location on 200A Parking brake pressure switch
If the engine oil pressure falls low enough to light warning lamp (503) printed circuit board in electrical centre
in current path 177, relay (RE2) will also be energized (if the engine is
running) and cause the buzzer to sound.
Warning lamps lit by grounding

503, 505, 506, 507, 508, 514, 526, 541, 542, 543, 544, 546, 554, 555, 558,
559, 561, 5009
Warning lamps lit by positive voltage LAMP

+30 CHECK
500, 504, 528, 536, 545, 562
150
214
F1
CA6
5A
RE1
CA2
Lamp check system 214 High range indicator lamp contact
41
42
9 Fire warning
“9” 8A Fire warning lamps
“11” 8A Fire warning control system
No. Component
254 Engine compartment thermal contact
544 Engine compartment temperature high warning lamp
559 Engine compartment fire warning lamp
1116 Fire warning test switch
3027 Fire warning lamp and buzzer relay 544 559
Circuit description
254
The fire and high temperature warning lamps (544 and 559) are wired in
parallel, so that both lamps will light if any of the thermal break contacts
(254) opens and de-energizes relay (3027). The warning condition is 544 Engine compartment temperature high
254 Engine compartment thermal contact
shown in the schematic. Normally this relay will be energized, but if the warning lamp
test switch (1116) is pressed, it will de-energize and the lamps should 559 Engine compartment fire warning lamp
light, confirming that they are serviceable.
1116
3027
1116 Fire warning test switch 3027 Fire warning lamp and buzzer relay 254 Engine compartment thermal contacts
43
44
10 Instrument gauges (Combi 1) (Sheet 1 of 2)
“9” 8A Instrument gauges S
“13” 8A Clock/odometer 709

80 100 1/2
60
120
No. Component 40 E F
507 Warning lamps, service brakes air pressure low

554 Warning lamp, engine coolant temperature high
702 Combi 1 instruments
706 707
703 Gauge, engine rpm
704 Gauges, service brakes air pressure (1 and 2) 2 4 4
6 2 6
8 8
0 10 0 10
706 Gauge, engine coolant temperature r / min x 100
707 Gauge, fuel
709 Clock/odometer 703
753 Engine speed sender
754A Sender, front wheel brake circuit air pressure (1) 704 (1) 704 (2)
754B Sender, rear wheel brake circuit air pressure (2) 702 Combi 1 instruments
756 Sender, engine coolant temperature
757 Sender, fuel level Fuel tank sender (757)
Circuit descriptions Float Electrical

height resistance
Gauges and warning lamps
FUEL TEMP (Empty) 180 ohm
The electronic gauges (704) and (706) have built-in electronic switches
controlling their warning lamps. If the sender signal exceeds a preset 13 1 Res 163–165 ohm
TACHO- 25 14
limit, the electronic switch will operate and ground the lamp negative METER
line, so that the lamp will light. At 102°C ± 3°C the transistorized circuit 1/2 88 ohm
in the engine coolant temperature gauge (706) lights the warning lamp (Full) 11 ohm
(554). The gauge indication is controlled by a separate circuit.
Sender characteristics
The fuel tank sender (757) has approximate resistance values in a 10-step Combi 1 wiring diagram Coolant temperature sender
(756)
ladder successively connected by reed switches, as listed in the table. If
the circuit fails, the gauge will indicate either full tank (open circuit) or Combi 1 plug connections Temperature Electrical
empty tank (grounded circuit). 1 Sensor water temperature 15 Warning contact air pressure 1 resistance
2 Retarder 16 Warning contact air pressure 2
3 Warning contact water temperature 17 Sensor air pressure 2
4 Split (–) 18 31 terminal (–) 60°C 109 ohm
The service brakes air pressure gauges indicate pressure in (1) the front 5 Direction indicators (+) 19 Sensor inductive
brake tank and (2) the rear brake tank. The warning lamps for these are 6 High beam 20 Not used 80°C 58 ohm
7 Next stop (+) 21 Tripmeter switch or display data
lit if the pressure falls below 0.49 MPa. 8 +30 terminal 22 Display clock
9 Tripmeter signal or display switch 23 Warning control light red (+) 100°C 33 ohm
NOTE: An electrical open circuit will cause the affected pressure 10 Instrument illumination (+) 24 Warning control light (–)
gauge(s) to read maximum. 11 +15 terminal 25 Battery minus (31)
12 Sensor fuel gauge
13 Warning contact (upper left)
14 Sensor air pressure 1
45
46
10 Instrument gauges (Combi 1) (Sheet 2 of 2)
Clock and odometer
The combined clock and odometer (709) is electronic, and the displayed
function is selected by the right hand button above the display, which
switches alternately between the clock and odometer functions. The left
hand button either resets the odometer to zero or sets the clock time, BRAKE
depending on which function has been selected. Further details of the
clock setting procedure are given in the Operator’s Manual.
756
507 Warning lamps, service 554 Warning lamp, engine

brakes air pressure low coolant temperature high 756 Sender, engine coolant temperature
754B
753
753 Engine speed sender 754B Rear brake cct. air pressure sender
702 Combi 1 instruments
757
754A
757 Fuel level sender 754A Sender front wheel brake circuit air
pressure sender
47
48
11 Instrument gauges (Combi 2)
“9” 8A Instrument gauges
“14” 8A Voltmeter
No. Component
202 Engine oil pressure low contact
503 Warning lamp, engine oil pressure low
705 Gauge, engine oil pressure
713 Voltmeter
705 7005
7002 Interior and ambient temperature gauge
7005 Turbocharger pressure gauge
7061 Engine oil pressure sender
7063 Turbocharger gauge pressure sender
Circuit description
The electronic engine oil pressure gauge (705) has a built-in electronic 7002 713
switch controlling the warning lamp (503). The gauge indication is
controlled by a separate circuit. The engine oil pressure low warning
lamp (503) will be lit if contact (202) closes. Note that either (202) or Combi 2 instruments
(7061) will be fitted, not both on the same bus.
503 Warning lamp, engine oil pressure low Combi 2 plug connections
1 Sensor upper right
2 Warning contact upper right
3 Not connected
4 +15 terminal
5 31 terminal (–)
7061 6 Not connected
7 Sensor oil pressure upper left
8 Warning contact oil press. upper left
9 Warning contact lower right
10 Sensor lower right
11 Warning contact lower left
12 Sensor lower left
13 Not connected
14 Not connected
8 15 91
15 Instrument illumination (–)
7061 Engine oil pressure sender Combi 2 wiring diagram 202 Engine oil pressure low contact
49
50
12 Speedometer, tachograph
“9” 8A Speedometer, Tachograph
“13” 8A Tachograph clock
No. Component
700 Speedometer
701 Tachograph
805 Panel lamps rheostat (dimmer)
7052 Transmission speed sender
Circuit description
The speedometer (700) and tachograph (701) are fully transistorized,
and supplied with a speed signal consisting of square wave pulses from
the sender (7052), mounted on the transmission.
The sender (7052) includes a Hall element which is influenced by the

magnetic field of the rotating core. The output pulse repetition frequency
depends on the core rotation speed.
The C1 output provides distance travelled signals to the odometer (709),

A1 +30 supply from fuse “13” B1 Positive feed to sender (7052)
see Schematic 10. The C3 output provides bus road speed signals to the A2 Lighting supply from rheostat (805) B2 Ground to sender (7052)
electrical or hydraulic retarder circuit (see Schematics 17 or 18 as A3 +15 supply from fuse “9” B3 Positive pulses from sender
A4 Not used B4 Negative pulses from sender
appropriate), the exhaust gas regulator section of the combination relay A5 Ground B5 Ground
(see Schematic 4), the ECS circuit (see Schematic 21), the Volvo G8 A6 Ground B6 Ground
transmission system (see Schematic 16) and the fuel injection control A7 Not used B7 Speed signals to ECS system
A8 Not used B8 Distance travelled signals to odometer
circuit (see Schematics 22 or 22A as appropriate). (709)
The tachograph includes a light-emitting diode (LED) shown in path

701 Tachograph and connections
260, lit via an internal tachograph switch when the bus speed reaches a
preset level, which can be set by an adjustment screw in the tachograph.
805
701 Tachograph 700 Speedometer 7052 Transmission speed 805 Panel lamps rheostat
sender (dimmer)
51
52
13 Reversing lights, brake lights
“7” 8A G8 MGS gearbox reversing lights relay
“23” 8A Brake lights
No. Component
216 Brake lights closing contact
217 Reversing lights contact (manual gearbox)
308 Brake lights relay
3028 Reversing lights relay 216A 217
Reversing lights (current paths 290 to 293)
The reversing lights, wired on the body from KB8 and KB9, are relay-
controlled from relay (3028), which is energized by a closing contact,
either (217) on the Volvo G8 MGS gearbox or relay (3038B) in the Volvo 216A Brake lights closing contact 217 Reversing lights contact
G8 EGS transmission circuit (see Schematic 16). Relay (3028) is
energized when reverse gear is selected.
Brake lights (current paths 296 to 300)

The brake lights are controlled by the contact of relay (308), which
applies voltage to the body-mounted brake lights via KB7 when the
KA J I H G
contact (216) closes due to brake pressure being applied, or alternatively
when the electrical (Schematic 17) or hydraulic (Schematic 18) retarder
system signals that retardation is being applied. Brake application is 3028 308 300 3063 309
signalled to the fuel injection control system (see Schematic 22).
396 345 315 3005 3027 398 354B
E D I B A
308 Brake lights relay

3028 Reversing lights relay
53
54
14 Hazard warning lights, direction indicators, horn
No. Component
101/109/147 Hazard warning lights and direction
indicators switch
149/223 Horn switches/ring
Both circuits on this schematic diagram are connected to body wiring via
connectors KF and KH.
Hazard warning lights/direction indicators

These are operated by stalk switches (101/109/147) on the steering 101/147 100
column. The direction indicators use the “+15” supply, via KF5, and the
hazard warning lights us the “+” supply, via KF7. The body-mounted
109
lights are connected via KF6 (left indication) and KF9 (right indication).
The other connections are via KF3 (direction indicators “49”), KF5 109 Hazard warning lights
(direction indicators “15”), KF7 (direction indicators “30”), KF8 (direc- 101 High/low beam switch
tion indicators “49 a/c”), and KH5 (direction indicators main switch). 147 Direction indicators switch
Horn
The horn is grounded via the horn switches (149), the ring contact (223)
and connector KH6. If two or more horns are installed, the extra horns
are controlled via a relay (fitted by the coachbuilder).
149/223
149/223 Horn switches/ring
55
56
15 Differential lock, bogie
“7” 8A Differential lock, Bogie
No. Component
126 Differential lock switch
133 Bogie switch
207 Differential lock indicator lamp closing contact
601 Differential lock solenoid valve 601
648A Bogie solenoid valve
648B Auxiliary bogie solenoid valve
9001 Bogie air pressure sender 126 Differential lock switch
Differential lock (current paths 324 to 326)
When differential lock is selected by the driver using switch (126), 601 Differential lock solenoid valve
solenoid valve (601) energizes to send compressed air to a membrane in
the differential lock actuator. A mechanical switch in the differential
lock closes contact (207) to indicate by means of the lamp in the switch
(126) that differential locking is actually engaged.
Bogie (current paths 327 to 329)

When the bogie switch (133) is pressed, solenoid valves (648A and
648B) are energized and release air pressure from the bogie air suspen- 133 Bogie switch
sion. When the pressure falls low enough to release the bus weight from
the bogie, the sender (9001) contact closes to light the lamp in the switch
(133).
648A
9001
207 648B
207 Differential indicator lamp closing contact 9001 Bogie air pressure sender
648A Bogie solenoid valve
648B Auxiliary bogie solenoid valve
57
58
16 Volvo G8 EGS transmission system (Sheet 1 of 2)
Fuse Rating Circuit protected by fuse KV
“10” 8A Volvo G8 EGS transmission system Control unit (9059) K 1 connections
“43” 5A Volvo G8 EGS transmission control unit 1 +24 V supply via (399A) or (399B)
2 (–) signal to activate buzzer
7052B
No. Component 7052 5 (–) to energize relay (3038B)
172 “Limp-home” switch 6 Signal from speedo/tachograph
8 (–) for “limp-home” switch/lamp (172)
399A G8 EGS safety neutral relay 9, 12, 14, 15, 16 , 25, 27, 28, 30
399B G8 EGS control unit feed relay (–) signals from gear selector
1121 G8 EGS diagnostic switch microswitches
1124 G8 EGS gear selector microswitches 10 “Ground” signal from (2063); approx. 0.8
V with clutch pedal deppressed
1124X G8 EGS extra gear switch 11 (–) signal to activare central warning
2063 Clutch position inductive switch 17 Signal to activare MS solenoid valve
3038A G8 EGS start inhibit polarity switching relay 18 Control unit ground
3038B G8 EGS reversing lights polarity switching relay 20 (–) to energize relay (3038A)
G
21 (–) to energize relay (399A)
7052B Transmission speed sender 22 +24V supply to MS, (399A)
9059 G8 EGS transmission control unit and (172)
N 23 Permanent (+) from fuse “10
Volvo G8 EGS solenoid valves and switch contacts R 1 3 LRV
NV 2 4 HRV 24 (–) signal to diagnostic switch (1121)
1 First gear solenoid valve HR 32 (–) signal to light warning lamp (541)
ROK 33 Common (+) for gear switches (1124)
2 Second gear solenoid valve
3 Third gear solenoid valve
EGS components mounted on G8 transmission
4 Fourth gear solenoid valve
G Gear engaged switch contact
HR High range switch contact
HRV High range solenoid valve
LRV Low range solenoid valve
MS Gear lever inhibit cylinder solenoid valve
N Neutral switch contact
NV Neutral solenoid valve
R Reverse gear solenoid valve
ROK Planet gears engaged switch contact
Circuit description Control unit (9059) K2 connections
Feed relay (399B) energizes when the engine is switched on. Its closed 1 (+) supply to gear solenoid valves
contact then supplies current from the +30 line via fuse “43” to terminal 1124X 2, 3, 4, 5, 20, 21, 22, 24
172 (–) gear changing signals
1 of the control unit (9059). Terminal 22 of (9059) then energizes relay 10, 11, 26, 28
(399A), since terminal 21 is grounded. When the engine is switched off, 1121 Gear switch contacts, (–) when closed
or if the supply from the “+15” line is broken, relay (399A) remains 13 +24V to transm. speed sender
energized and the currently selected gear remains selected until the control 14 (–) to transm. speed sender (7052B)
15 Ground for gear switch contacts
unit (9059) detects that the driver has selected neutral. If the road speed at 17 (+) supply to NV solenoid valve
this time is less than 3 to 5 km/h, the control unit sets the gear selector and 30 Transmission speed pulses, input transm.
the transmission to neutral regardless of the driver’s actions. In this speed sender (7052B)
1124 32 Engine speed signal input
condition the control unit breaks the ground connection at pin 21 and relay
(399A) de-energizes to remove the supply from the control unit. G8 EGS operating switches
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60
16 Volvo G8 EGS transmission system (Sheet 2 of 2)
The inductive sender (2063) in current path 340 provides a low signal to
pin 10 of the control unit (9059) when the clutch is fully depressed, i.e.
when the metal of the clutch pedal comes within the sensing range of the
inductive circuit in the sensor. This signal confirms to the control unit
(9059) that the clutch has been released.
2063
The computer program in the control unit includes fault diagnosis and
warning functions; the output at pin 32 lights lamp (541) on the
instrument panel (see Schematic 8) for fault diagnosis, or in the case of
a warning, causes the lamp to flash.
When the gear lever is set to neutral microswitches (1124) send a “–”
EGS 5A
signal via “K1” terminal 12 to the control unit. Physical confirmation FUSE
that the transmission is in neutral is given by switch contacts N (Neutral) 399A 399B 3038B 3038A
and G (Gear engaged). Contact N presents a “–” signal to “K2” terminal 2063 Clutch position inductive switch G8 EGS board
26, while contact G opens, so approx. +24V is present at “K2” terminal
10. The diagram shows these contacts in the neutral gear position. If
these two signals do not appear when the gear selector is set to neutral,
the control unit places a “–” signal on “K1” terminals 2 (activating the
buzzer), 11 (activating the central warning lamps) and 32 (lighting the
EGS warning lamp (541)).
All the solenoid valves are closed when they are de-energized.
To ensure that relay (396) (see Schematic 3) will energize to permit
engine starting, the control unit sets “K2” pin 20 to “–” once switches N
and G have confirmed that neutral is selected (as described above), or the
clutch is depressed, as indicated by the clutch position sensor (2063),
thereby energizing the polarity switching relay (3038A). In either case
the engine speed, as reported by the engine speed sensor (7052B) to “K2”
terminal 30 must be below 300 rpm.
The “limp-home” emergency switch (172) on the G8 EGS gear lever Pin numbering on G8 EGS connectors K1 and K2
housing permits 5 of the gears to be selected if the system has partially
failed. Gear changing will however be slower than usual if the switch is
used. Only the clutch position sensor (2063) input remains connected.
In the case of a total failure, the “limp-home” card located on the side of
the control unit (9059) can be plugged into the 35-way connector instead
of the control unit, allowing a limited gear-changing function.
The system can be reprogrammed via a DIP switch located beneath the
control unit (9059) to suit different engine and gearbox combinations.
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62
17 Electrical retarder
“15” 8A Electrical retarder 331 526
5A
“37” 200A Electrical retarder coils
— 5A Electrical retarder control system
“F1” - “F4” 50A Electrical retarder coil 1
A B C D 151 811
No. Component
151 Electrical retarder foot control switch
331 Electrical retarder relay box
526 Retarder engaged indicator lamp
37
807F Retarder foot pedal microswitches
9064
811 Electrical retarder hand control
903 Diode A
950 Electrical retarder coils BC D 807
9064 Electrical retarder control unit
950
Circuit description
The retarder system consists of a hand control (811) selecting the
required degree of retardation via a control unit (9064) that applies
current to the retarder coils (950) via relays in a relay box (331). The relay 15
box (331) contains a separate 5A fuse to protect the light current control
circuits inside the control unit (9064). The 200A retarder fuse “37”
protects the relatively long high-current cable to the retarder coils.
The hand control (811) has three activating positions. The first position
switches in two retarder coils (8 electromagnets), the second position
switches in a further retarder coil (total 12 electromagnets) and in the
third and fourth positions all four coils (16 electromagnets) are switched 151 Electrical retarder foot control switch
in. The retarder coils are grounded via a tag bolted direct to the chassis 331 Electrical retarder relay box
frame. The control unit (9064) automatically disengages the retarder 526 Retarder engaged indicator lamp
when the speed signal at pin 9 of the control unit falls below 6 pulses per 807F Retarder foot pedal microswitches
second, equivalent to 2–3 km/h. Application of the retarder switches on 811 Electrical retarder hand control
950 Electrical retarder coils
the brake lights (see Schematic 13).
9064 Electrical retarder control unit
The driver may alternatively choose to select foot-controlled retardation 15 Fuse
with switch (151). Operation of the footbrake pedal then closes micro-
switches (807F) that consecutively switch in the retarder coils as the
pedal is pressed harder, in a similar way to the hand control.
Current passing through the retarder coils generates a powerful magnetic
field. Since the coils are rotating, opposing magnetic fields and thus eddy
currents are also generated, resisting the motion of the rotating parts to
slow them down. This braking energy is dissipated as heat.
63
64
18 Voith hydraulic braking retarder, electrical system (Sheet 1 of 2)
“15” 8A Voith hydraulic braking retarder electrical system
“23” 8A Voith hydraulic braking retarder electrical system
No. Component
182 Retarder switch
216X 25% retardation pressure switch
397A Hydraulic retarder speed hold relay
807F Retarder foot pedal microswitches
807H Hydraulic retarder hand control
903 Diode
6018A Hydraulic retarder solenoid valve block
7060A Hydraulic retarder coolant temperature sender
7060B Hydraulic retarder oil temperature sender
807H Hydraulic retarder 807F Retarder foot
9054 Voith hydraulic retarder control unit hand control pedal microswitches
Circuit description
This retarder is available as an option on buses with mechanical gear-
boxes. The hand control (807H) has 5 positions, the first being for
constant speed operation. Positions 2 to 5 provide fixed braking levels,
at 25%, 50%, 75% and 100% of the maximum braking torque. The
footbrake option has 3 microswitches (807F) which provide 25%, 50%
and 75% retardation. Retarder switch (182) can be used to switch the foot
pedal system (807F) on and off, but the hand control (807H) is always
connected.
Warning lamp (526) lights and remains lit if the system detects a fault, 182
but flashes if retardation is limited by overheating. The same lamp is
used to show fault diagnosis blink codes.
182 Retarder switch
Fuses “15” (“+15 line”) and “23” (“+30” line) supply the control unit 9054
(9054). When the “+15” supply is first switched on lamp (526) lights for 9054 Voith hydraulic retarder control unit
5 seconds during self-test. Road speed signals are received from the
speedometer (C3) or tachograph (B7) as appropriate, and a signal from
the ABS unit can inhibit retardation during ABS operation.
65
66
18 Voith hydraulic brakeing retarder, electrical system (Sheet 2 of 2)
The hand control (807H) is supplied with voltage direct from the control
unit (9054), but the foot pedal microswitches (807F) are fed via the
retarder switch (182). As an optional alternative to (807F) a brake
pressure closing contact (216X) can be used to apply the first (25%) level 2063
of retardation. This contact is located between the footbrake valve and
the brake circuit, and is only installed in buses with the extreme low
driving position. 2063
216x
Controls (807F) and (807H) apply gradually increasing retardation by
successively sending signals to the control unit (9054) inputs. The dual
retarder solenoid valves in the valve block (6018) are controlled directly
by the control unit (9054) and determine the amount of retardation by
allowing controlled amounts of compressed air into the hydraulic
retarder system. 7060B Hydraulic retarder oil temp sender. 216X 25% retardation pressure switch
7060A Hydraulic retarder coolant temp sender
If the retarder coolant temperature reaches 98°C the control unit (9054)
begins to reduce the amount of retardation, and if the temperature
continues to rise and reaches 113°C, the retarder is switched off com-
pletely. The retarder engaged indicator lamp (526) on the instrument
panel will flash, indicating excessive retarder temperature. Signals from
the oil temperature sender (7060B) have a similar effect, beginning at
180°C and completely switching out the retarder at an oil temperature of
210°C. 3014 354B 397A 308B
In the constant speed mode the engine control unit (9070) (on Schematic
22 or 22A) controls the amount of retardation by energizing relay (397A)
3023
only when its system permits retarding or exhaust braking, i.e. if the road
speed downhill increases by more than 7 km/h above the selected
constant speed. Relay (397A) contact switches the hand control (807H)
position 1 contact to “X1” 6 on the control unit (9054) and keeps 25%
retardation applied until the selected speed is regained.
Stored fault codes can be read out as blink codes on lamp (526), with a
6018A Hydraulic retarder soleniod valve block 397A Hydraulic retarder speed hold relay
long flash for every 10s unit and a short flash for single digits.
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68
19 ABS and ASR systems (Sheet 1 of 2)
JMP AEB ABS
3046
“15” 8A ABS/ASR control system
“40” 8A ABS control unit feed 1 “41”
“41” 8A ABS control unit feed 2 3045
“42”
No. Component
601L Anti-slip solenoid valve, left 3044 3024-2
601R Anti-slip solenoid valve, right
3024-1 ABS control unit feed 1 relay 7057
3024-2 ABS control unit feed 2 relay
3025 ABS engaged indicator lamp relay 3025
3044 Automatic transmission lock-up inhibit relay
3045 Auxiliary automatic transmission lock-up inhibit relay
3024-1
3046 Retarder inhibit relay
5009 ABS engaged indicator lamp Printing circuit
ABS control unit and printing circuit
6013 Wheel brake ABS solenoid valves
7057 Road wheel rotation ABS senders
9008 ABS/ASR system control unit
ABS system
The ABS system is independent of normal braking and only comes into
operation if one or more wheels begins to lock during braking. The ABS
system then takes over control of braking, using its wheel sensor (7057)
signals to the four-channel control unit (9008) to determine when and
how much brake pressure is to be applied to the wheel (or wheels) which
have stopped rotating.
The relays and fuses for the ABS system are mounted on a special printed
7057
circuit board next to the control unit (9008). The JMP1 and JMP3
connectors on this board are connected together by a plain jumper,
plugged into the connectors.
5009 Control lamp ABS 7057 Road wheel rotation ABS senders
The system includes a self-testing procedure which is automatically
carried out each time the bus is started, and the result is shown by the
indicator lamp (5009), (see Schematic 8), on the instrument panel. If
there is no fault in the system, the lamp switches off as soon as the speed
exceeds 7 or 8 km/hr.
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70
19 ABS and ASR systems (Sheet 2 of 2)
ASR system
The Anti-Slip Regulation (ASR) section of the ABS control unit (9008)
controls the two anti-slip solenoid valves (601L) and (601R). If a drive
wheel starts to spin, and its speed exceeds that of the other drive wheel
by more than 4 km/h, the control unit (9008) energizes the solenoid valve
for this wheel. The valve opens to allow compressed air to apply the
6013
brake on that wheel. The braking pressure is modulated by the appropri-
ate ABS solenoid valve (6013) to prevent the wheel from being locked
to a standstill. When the difference in speed between the drive wheels
becomes less than 4 km/h, the braking is released by de-energizing the
ASR solenoid valve (601L) or (601R) as appropriate.
The speed signal from the fuel injection control unit (9070), at pin 28 of ABS control unit and printing circuit 6013 Wheel brake/ABS solenoid valves
the ABS/ASR control unit (9008), is used to prevent the braking control
function from operating at speeds exceeding 35 km/h. Above this speed,
the engine power is reduced instead, as described below.
At speeds above 35 km/h, if the control unit (9008) detects that one drive
wheel is beginning to rotate faster than the other, it communicates with
601L
the fuel injection control unit (9070) via pins 28 and 29 to reduce the
engine power. Pulse-width modulated signals are used, output on pin 29
and input on pin 28.
A signal from pin 11 of the control unit (9008) is sent via the ABS printed
circuit board to the electrical or hydraulic retarder (see Schematic 17 or
18 as appropriate) and fuel injection system (see Schematic 22 or 22A
as appropriate) to prevent retardation or exhaust braking while ABS is
in operation.
601L/601R Anti-slip solenoid valve, left
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72
20 ABS connections, trailer
“10” 8A ABS logic system for trailer
No. Component
216 Brake lights closing contact
308B Trailer brake lights relay
3023 Trailer ABS logic unit 3014 354B 397A
5010 ABS indicator lamp, trailer
308B
5017 ABS signal control lamp, trailer
216A
3023
Circuit description
If the bus is towing a trailer, the logic unit (3023) warns the driver by
means of the ABS indicator and control lamps (5010) and (5017) of the
following circumstances: 216A Brake lights closing contact 308B Trailer brake lights relay
(5010) ABS indicator lamp, (5017) ABS signal con-

trailer (RED) trol lamp, trailer
Fault in bus LIT NOT LIT
ABS circuits
Fault in trailer LIT LIT
ABS circuit
Trailer not NOT LIT LIT continuously
equipped or
with ABS LIT only when breakes
applied
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74
21 Electronically Controlled Suspension (ECS) (Sheet 1 of 2)
“7” 8A ECS diagnostic lamp 7064
“15” 8A ECS system
No. Component
175 Level control switch
ECS ECS feed relay, alternator-controlled
1102 Kneeling switch
3014 ECS diagnostic indicator lamp relay 354B
9002
6035F ECS front solenoid valve block
6035R ECS rear solenoid valve block
3014
7064 Air suspension pressure low contact
7072 ECS chassis height senders
9002 ECS control unit 9002 ECS control unit 7064 Air suspension pressure low contact
562 WCS level control indicator lamp 354B ECS feed relay, alternator-controlled
3014 ECS diagnostic indicator lamp relay
Circuit description
During normal driving
The air suspension pressure low contact (7064) must be closed, ground-
ing pin 25 on the ECS control unit (9002), to signal that there is sufficient
pressure (more than 7.5 bar) in the suspension compressed air system to
permit the ECS system to operate. In the front and rear solenoid valve
blocks, solenoid valves Z (41) are both energized, supplying compressed
air to the other solenoid valves in their blocks.
The four chassis height senders (7072) keep the control unit (9002)
informed of the chassis height, and the program decides whether one or
more corners of the bus need to be raised or lowered to keep the chassis
height level and at the correct ride height. If necessary, signals are sent
from the control unit (9002) to the front and/or rear solenoid valve blocks
(6035) to admit or exhaust air from the air bellows to keep the ride height 6035R ECS rear solenoid valve block
7072 ECS chassis height senders
constant.
Level control
Before the bus can be raised:
– The keyswitch must be in position 1 (normal driving position), and
the system air pressure must be high enough to permit raising. P
– Note that the raise system will operate with the entrance/exit doors
open or closed and the bus can be driven without any speed restriction
when in the raised position.
562 ECS level control indicator lamp
75
76
21 Electronically Controlled Suspension (ECS) (Sheet 2 of 2)
If the level control switch (175) switch is now set to its “raise” position, When the bus has been lowered by 80% of the total kneeling movement, 7072
it grounds pin 8 on the control unit (9002). This supplies the appropriate a +24V signal is made available at pin 20 of the control unit (9002) for
signals to the solenoid valves in both the solenoid valve blocks (6035) a coachbuilder’s connection via body connector KK2. This could for
to cause the suspension air bellows to inflate further than normal, raising example operate a door brake (if one has been fitted by the coachbuilder).
the bus above the normal ride height. Signals from the chassis height When the program receives signals from the chassis height senders that
senders (7027) inform the control unit when the pre-programmed ferry match the memorised kneeling height, the solenoid valve exhaust(s) are
lift height has been reached, and the solenoid valves then close to prevent closed to stop the kneeling.
further raising.
On pressing the “raise” section of the kneeling switch (1102) pin 6 on the
At any time during raising, or when the bus has reached raise height, the control unit (9002) is grounded. To raise the bus from the kneeling level,
level control switch (175) can be switched back to its normal position. the control unit opens valves in the solenoid valve blocks (6035F and
This opens the ground connection to pin 8 on the control unit (9002), 6035R) to allow air to inflate the bellows, raising the bus to its normal
which exhausts the air from the air bellows via the solenoid valves until height. This process cannot be stopped by the driver.
the height senders (7027) signal that the normal ride height has been 7072 ECS Chassis height senders
resumed. Diagnostic connector
The 7-pole ECS diagnostic connector “DIA” can be connected for
Kneeling servicing to a personal computer for more extensive diagnosis. A
Operation of the kneeling switch (1102) permits either the front corner separate Service Manual describes the fault tracing methods for the ECS
or the whole side (depending on the bus specification) to be lowered to system in detail.
aid passenger entry and exit. The kneeling height is programmed at the
factory, and may be reprogrammed depending on local requirements and
the final step height after coachbuilding.
Before the bus can be kneeled:

– The keyswitch or feed switch must be in position 1 (normal driving 6035F
position), preferably with the engine running, the bus must be at its
normal ride height, the road speed must be less than 3 km/h, the system
air pressure must be high enough to permit raising the bus again after
kneeling, and depending on the coachbuild specification, the entrance/
exit doors may have to be closed. 1102
– Note that: the kneeling system will not operate if sensitive edges that
175
the coachbuilder may have installed sensitive edges below the doorstep(s)
to stop kneeling or return the bus to normal height if the edges sense an
obstruction.
When the “lower” section of the kneeling switch (1102) is pressed,

terminals 8 and 24 on the control unit (9002) are grounded. Depending
on the type of kneeling (front corner or whole side), the program sends 175 Level control switch 6035F ECS front solenoid valve block
kneel signals to either the front or to both solenoid valve blocks (6035). 1102 Kneeling switch
The appropriate bellows are deflated by exhausting through the solenoid
valve(s) (42 and/or 43) to begin kneeling.
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78
22A Fuel Injection Control (FIC) system, 24V (Sheet 1 of 3)
“8” 8A VEB inhibit 600A
“44” 5A FIC cruise control 6072
“45” 10A FIC system main feed
No. Component
24 FIC terminal block
125 Exhaust brake switch
239 Engine coolant temperature switch for VEB
308X Braking signal relay for 12V FIC 125
379A FIC feed relay
6072 Fuel injector solenoid valves 600A EPG exhaust braking 125 Exhaust brake foot switch
379B FIC back-up feed relay
solenoid valve
398 VEB inhibit on cold engine relay
600A EPG exhaust braking solenoid valve
600B VEB solenoid valve
753A FIC engine crankshaft speed sender CHECK
753A
753B FIC camshaft speed sender
756B FIC engine coolant temperature sender
901 FIC 24V/12V d.c. converter
903 Diode 1142
FIC diagnostic
1135 FIC cruise control 753B
switch
1142 FIC diagnostic switch
2007 Clutch pedal switch 1135
2008 Brake pressure switch
6072 Fuel injector solenoid valves (6)
7065 Accelerator pedal position sender 1135 FIC cruise control 753B Engine camshaft speed sender 753A Engine crankshaft
7066 Turbocharger pressure sender speed sender
7067 Charge air cooler temperature sender
9070 FIC (fuel injection) control unit
398 7066
Circuit description
The FIC system controls the timing and amount of fuel injected into the
engine by sending signals from the control unit (9070) to the six fuel
injector solenoid valves (6072). These signals result from a program that 7067
takes into account engine values (such as crankshaft and camshaft
speeds, turbocharger pressure and temperature etc.), and other inputs 2008
such as the accelerator pedal position. A special terminal block (24) can
be used to program and fault trace the system, using a set of connections
to SAE standard 1587.
2008 Brake pressure switch 398 VEB inhibit on cold 7066 Turbocharger pressure sender
engine relay 7067 Charge Air cooler temp sender
79
80
22 Fuel Injection Control (FIC) system, 24V (Sheet 2 of 3)
Normally relay (379B) is energised via fuse “45” and supplies +24V Pin 30A is grounded by the parking brake contact (200) to permit
from the “+30” line to the d.c. converter (901). This in turn sends high idle to be set with the cruise control when the bus is parked.
+12V to the control unit (9070), which then enrgises relay (379A),
with the main +12V feed to the control unit being fed to pins 11A and The Volvo Engine Braking (VEB) function is controlled from pin
12A via relay (379A) closed contact. If fuse “45” blows, relay 2A. This is a “+” signal to enable VEB if the engine speed is
(379B) de-energises, maintaining a back-up +24V supply from the greater than 1 000 rpm and the accelerator pedal is released and
battery circuit breaker (342A) (Schematic 1) via fuse “46”. The cruise control is not activated. VEB is also enabled during cruise
engine stop function via relay (3063) is described on Schematic 6. control if the road speed exceeds the set cruise speed by more than
7 km/h. The VEB function is however inhibited by relay (398) if
The system includes a cruise control (1135) with SET+, RESUME the engine coolant temperature is lower than 40°C as detected by
and ON positions. The usual SET- position is not present, but the temperature switch (239). If the oil is cold, the VEB system may
RESUME mode can be used to obtain the SET- function while cruise not work properly.
control is in operation. Otherwise the RESUME function is similar
to that for buses equipped with EDC. A “+” input at pin 31A when Engine power will be reduced by the control unit (9070) if:
braking is applied switches off the cruise mode. – the turbocharger pressure (7066) is low
– the engine coolant temperature (756B) is high
The accelerator position sender is a potentiometer, with a switch – the charge air temperature (7067) reaches 91°C (and the EDC
contact that closes when the accelerator is released (idle position). lamp will be lit in this case).
FIC control unit (9070) pin connections

A= top row on diagram (chassis plug socket)
B = bottom row (engine plug/socket)
2A VEB signal output 32A RESUME input from cruise control (1135)
3A Ground signal to energize (379A) 33A ON input from cruise control (1135)
4A FIC diagnostic switch (1142) connection 34A Supply to accelerator pedal position sender (7065)
6A +12V supply confirmation input 35A Accelerator pedal position signal input from (7065)
9A, 10A Ground
11A, 12A +12V input Connected to terminal block (24) pin 4 3B Common connection for fuel injectors 4, 5 and 6 (6072)
Engine speed reduction during ASR, pulsewidth moculated signal 4B Common connection for fuel injectors 1, 2 and 3 (6072)
from ABS control unit (9008) 6B Fuel injection signal to injector 4 (6072)
17A Programming input, connected to terminal block (24) pin 4 7B Fuel injection signal to injector 6 (6072)
18A Brake pressure switch (2008) input, +12V when brakes applied 8B Fuel injection signal to injector 5 (6072)
19A Clutch pedal switch (2007) input, +12V when clutch pedal fully 10B Fuel injection signal to injector 2 (6072)
depressed 11B Fuel injection signal to injector 3 (6072)
20A SET input from cruise control (1135) 12B Fuel injection signal to injector 1 (6072)
21A Idle validation input, +12V when (7065) idle contact is closed 13B Coolant temperature sensor (756B) connection for power reduction
22A Supply to accelerator pedal position sender (7065) 14B Charge air cooler temperature sender (7067) connection
24A Road speed signal input from speedometer (C3) or tachograph (B7) 15B Charge air cooler temperature sender (7067) connection
25A Programming input, connected to terminal block (24) pin 2 17B Engine speed sender connection (753A)
26A Programming input, connected to terminal block (24) pin 3 18B Engine speed sender connection (753B)
27A Engine speed pulsewidth modulated input from ABS control unit 25B Charge air cooler pressure sender connection (7066)
(9008) 27B Charge air cooler pressure sender connection (7066)
28A ABS inhibit VEB signal input 28B Charge air cooler pressure sender connection (7066)
30A Parking brake set input, grounded by parking brake switch (200) 29B Coolant temperature sensor (756B) connection for power reduction
contact 30B Engine speed sender connection (753A)
31A Braking signal input from (308X) 31B Engine speed sender connection (753B)
81
82
22 Fuel Injection Control (FIC) system, 24V (Sheet 2 of 3)
“8” 8A VEB inhibit 2007
“44” 5A FIC cruise control 24
No. Component
24 FIC terminal block
125 Exhaust brake switch 239
239 Engine coolant temperatire switch for VEB
379A FIC feed relay
379B FIC back-up feed relay 24 FIC terminal block 239 Engine soolant temperature 2007 Clutch pedal switch
398 VEB inhibit on cold engine relay switch for VEB
600A EPG exhaust braking solenoid valve
600B VEB soleoid valve
753A FIC engine speed sender
753B FIC auxiliary engine speed sender
756B FIC engine coolant temperature sender
1135 FIC cruise control
1142 FIC diagnostic switch
2007 Clutch pedal switch
2008 Brake pressure switch
6072 Fuel injectors (6)
7065 Accelarator pedal postition sender 756B
7066 Charge air cooler pressure sender
7067 Charge air cooler temperature sender 600B VEB solenoid valve 600B VEB solenoid valve 756B FIC engine coolant
9070 FIC (fuel injection) scontrol unit connection temperature sender
Cicuit description
This circuit is almost identical to the 12V system described in Schematic
22, with the following exceptions:
– Pin 24A recieves a road speed signal from teh speedometer (C3) or 7065
tachograph (B7).
– There is no need for a 24V/12V d.c. converter, nor for a relay to
provide the braking signal input to the control unit(9070) at pin 31.
– Pin 27A receives a pulsewidth modulated signal representing engine
speed to the ABS control unit (9008), see Schematic 19.
– Pin 16A receives a pulsewidth modulated signal from the ABS control
unit (9008), Schematic 19, to inform the FIC control unit (9070) when
the engine speed must be reduced during ASR operation.
Note that B12 buses with D12 engine that are not equipped with ASR do
not need to have a jumper connected between pins 16A and 17A; this is
only necessary on buses with EDC. 7065 Accelarator pedal position sender
83
Component number index
Abbreviations:
ECS Electronically-Controlled Suspension system
EGS Volvo G8 EGS Electrical Gear Shifting system
EPG Exhaust Pressure Governor system
FIC Fuel Injection Control system
MGS Mechanical Gear Shifting system
VEB Volvo Engine Brake system
Location area codes

ABS ABS printed circuit board EGS G8 EGS printed circuit board
B Battery box ER Rear electrical centre
CC Chassis centre I Instrument panel
CF Chassis front M Engine/transmission area
CR Chassis rear P Pedal plate area
E Front electrical centre
Component Schematic Shown on

No. Area Name No. Path(s) page(s)
24 I FIC terminal block 22 544

30 B Batteries 1 5, 13
85 B Fast charging socket 1 6, 14
100 I Lighting switch 2 61
101/ High/low beam switch,
109/ hazard warning
147 I and dir. indicators switch 2, 14 69, 307
119/ Windscreen wash-wipe
120 I switch 4 103
125 I Exhaust brake foot switch 22 541
126 I Differential lock switch 15 326
133 I Bogie switch 15 329
144 CF Battery master switch 1 12, 20
149/ Horn switches
223 I and ring 14 310
150 I Keystart switch 2 58
151 I Electrical retarder foot control switch 17 423
160B ER Engine stop button at bus rear 3 90
172 CF G8 EGS “limp-home” switch 16 366
175 I Level control switch 21 531
180 I Emergency cut-out switch 1 21
182 I Retarder switch 18 439
185B ER Engine start button at bus rear 3 89
186 ER Engine rear start enable switch 3 90
200 P Parking brake pressure switch 7, 8 159, 171
202 M Engine oil pressure low contact 11 230
207 CR Diff. lock ind. lamp closing contact 15 325
214 M High range indicator lamp contact 8 191
216 P Brake lights closing contact 13, 20 299, 507
216X P 25% retardation braking press. switch 18 439
217 M Reversing lights contact 13 291
239 M Engine coolant temp. switch for VEB 22 540
254 M Eng. compt. thermal contact 9 202
261 P Trailer brake lights closing contact 20 507
300 E Headlamps high/low beam relay 2 59
308 E Brake lights relay 13 299
308B E Trailer brake lights relay 20 507
308X E Braking signal relay for 12V FIC 22 556
84
309 E Parking lights relay 2 60

312 CC Starting heater relay 4 95
315 E Starting switch relay 2, 3 54, 80
315R ER Engine start solenoid relay 3 90
331 CR Electrical retarder relay box 17 425
342A B Battery circuit breaker 1 7, 15
345 E Start inhibit relay 3 85
345R ER External start inhibit relay 3 90
354A E Starting posn. relay (alternator sensed) 3 81
354B E Auxiliary starting position relay 3 83
354B* E ECS feed relay, alternator controlled
379A E FIC feed relay 22 558
379B E FIC back-up feed relay 22 562
389 E Starting heater indicator lamp relay 4 97
396 E Transmission in neutral relay 3 83
397A E Hydraulic retarder speed hold relay 18 447
398 E VEB inhibit on cold engine relay 22 540
399A EGS G8 EGS safety neutral relay 16 358
399B EGS G8 EGS control unit feed relay 16 356
431 I Instrument panel lamp bulbs 7 161-166
500 I Direction indicators indicator lamp 8 194
503 I Engine oil press. low warning lamp 8, 11 177, 230
504 I High beam indicator lamp 2, 8 64, 192
505 I Alternator 1 charging warning lamp 5, 8 111, 119, 176
506 I Alternator 2 charging warning lamp 5, 8 113, 181
507 I Brake pressure low warning lamp 8, 10 175, 225
508 I Parking brake off warning lamp 7, 8 160, 170
514 I Splitter gear indicator lamp 8 191
526 I Retarder engaged indicator lamp 8, 17, 18 190, 425, 432
528 I Engine preheater on indicator lamp 8 197
536 I Rear fog lights on indicator lamp 8 196
541 I G8 EGS diagnostic indicator lamp 8 182
542 I Door brake warning lamp 8 171
543 I Hatches/doors open warning lamp 8 186
544 I Eng. compt. temp. high warning lamp 8, 9 174, 200
545 I Next stop indicator lamp 8 193
546 I Door open warning lamp 8 180
547 I Central warning lamps 7 151, 152
554 I Eng. coolant high temp.warning lamp 8, 10 184, 222
555 I Eng. coolant level low warning lamp 7, 8 150, 179
559 I Engine compt. fire warning lamp 8, 9 173, 201
561 I Pram disembarking warning lamp 8 188
562 I ECS level control indicator lamp 8 195
600A M EPG exhaust braking solenoid valve 22 542
600B M VEB solenoid valve 22 541
601 CC Differential lock solenoid valve 15 324
601L CR Anti-slip solenoid valve, left 19 469
601R CR Anti-slip solenoid valve, right 19 470
614 M G8 MGS range lock solenoid valve 4 98
626 M Exh. gas press. regulator sol. valve 4 98
648A CR Bogie solenoid valve 15 327
648B CR Auxiliary bogie solenoid valve 15 327
654 M Starter motor 3 87
660 M Alternator 5 110, 112, 118
700 I Speedometer 12 252
701 I Tachograph 12 262
85
702 I Combi 1 instruments 10 223

703 I Engine rpm gauge (tachometer) 10 221
704 I Service brakes air pressure gauges 10 225, 227
705 I Engine oil pressure gauge 11 232
706 I Engine coolant temperature gauge 10 223
707 I Fuel gauge 10 224
709 I Clock/odometer 10 228
713 I Voltmeter 11 239
753 M Engine speed (tachometer) sender 10 221
753A M Engine crankshaft speed sender 22 559
753B M Engine camshaft speed sender 22 560
754A CF Front brake cct. air pressure sender 10 225
754B CR Rear brake cct. air pressure sender 10 227
756 M Engine coolant temperature sender 4, 10 96, 222
756B M FIC engine coolant temp. sender 22 555
757 M Fuel level sender 10 224
759 CC Coolant level sender 7 150
800 M Starting heater element 4 95
805 I Panel lamps rheostat (dimmer) 7, 12 163, 250, 259
807 P El. ret. footbrake pedal microswitches 17 423
807F P Retarder foot pedal microswitches 17, 18 421, 437
807H I Hydraulic retarder hand control 18 443
811 I Electrical retarder hand control 17 420
853 I Buzzer 7 154
903 E Bundled diodes in front el. centre 1, 4, 6, 18, 22 23, 95, 135, 136,
139, 140, 444, 552
903 CC Diode in chassis centre 4 95
903 I Diodes in instrument panel 2, 6 56, 137
903 E Diodes wired into front el. centre pcb 1, 2, 3, 13, 11, 19, 59, 83, 298,
17, 18 426, 431
950 C Electrical retarder coils 17 424
1102 I Kneeling switch 21 530
1116 I Fire warning test switch 9 202
1121 CF G8 EGS diagnostic switch 16 365
1124 CF G8 EGS gear selector microswitches 16 363
1124X CF G8 EGS extra gear switch 16 367
1135 I FIC cruise control 22 548
1142 I FIC diagnostic switch 22 546
2007 P Clutch pedal switch 22 546
2008 P Brake pressure switch 22 547
2063 P Clutch position inductive switch 16 340
3005 E Parking brake off warning relay 7 159
3014 E ECS diagnostic indicator lamp relay 21 518
3023 E Trailer ABS logic unit 20 504
3024-1 ABS ABS control unit feed 1 relay 19 454
3024-2 ABS ABS control unit feed 2 relay 19 456
3025 ABS ABS indicator lamp relay 19 452
3026A E Keystart switch relay 2 51, 55
3026B E Auxiliary keystart switch relay 2 52, 56
3027 E Fire warning lamp and buzzer relay 8, 9 174, 202
3028 E Reversing lights relay 13 292
3038A EGS G8 EGS start inhibit pol. sw. relay 16 351
3038B EGS G8 EGS rev. lights pol. switching relay 16 353
3044 ABS Auto. transm. lock-up inhibit relay 19 464
3045 ABS Aux. auto. transm. lock-up inhibit relay 19 465
3046 ABS Retarder inhibit relay 19 460
86
3063 E Engine stop relay 6 136

3066 E Combination relay 4 95
5009 I ABS engaged indicator lamp 8, 19 189, 453
5010 I ABS indicator lamp, trailer 20 502
5017 I ABS signal control lamp, trailer 20 503
6013 C Wheel brake ABS solenoid valves 19 451-465
6018A M Hydraulic retarder solenoid valve block 18 434
6023 C Emergency fuel cut-off solenoid valve 6 143
6035F CF ECS front solenoid valve block 21 519
6035R CR ECS rear solenoid valve block 21 522
6072 M Fuel injector solenoid valves (6) 22 545
7002 I Interior and ambient temp. gauge 11 237
7005 I Turbocharger pressure gauge 11 234
7052 M Transmission speed sender 12 254, 263
7052B M Transmission speed sender 16 367
7057 C Road wheel rotation ABS senders 19 450-464
7060A M Hydraulic retarder coolant temp. sender 18 436
7060B M Hydraulic retarder oil temp. sender 18 437
7061 M Engine oil pressure sender 11 232
7063 M Turbocharger gauge pressure sender 11 234
7064 CR Air suspension press. low contact 21 533
7065 P Accelerator pedal position sender
and idle validation switch 22 551
7066 M FIC turbocharger pressure sender 22 553
7067 M Charge air cooler temperature sender 22 557
7072 CF/R ECS chassis height senders 21 524-532
9001 CR Bogie air pressure sender 15 329
9002 E ECS control unit 21 523
9008 E ABS/ASR system control unit 19 460
9054 E Voith hydraulic retarder control unit 18 435
9059 CF G8 EGS transmission control unit 16 354
9063 E Emergency fuel cut-off control unit 6 147
9064 E Electrical retarder control unit 17 420
9070 E D12 FIC (fuel injection) control unit 22 552
RE1 Lamp check relay 8 199
RE2 Engine oil pressure low buzzer relay 8 177
87
Volvo Bus Corporation
Göteborg, Sweden
TP 15947/1 English 2500.02.97 Printed in Sweden by Novum Grafiska AB, Gbg 96.22106

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Service Manual

Schematic diagrams, circuit descriptions

Order number: TP 15947/1

How to read our electrical schematic diagrams

The “+” line supplies the “+” connection on the electrical

The “+30” line is supplied with voltage whilst the

The “+30” line supplies the “+30” connection on the

The “+15” line supplies the “+15” connection on the

A double line indicates a connection

Detachable connection, (empty circle)

*Permanent connection (black dot)

Wire number and colour (refer to “Colour coding” on

Pin 7 of the 9-pole connector marked “EP”

The continuous sequence of current path reference num-

A component, in this case number 144, the battery

Ground connection, direct to the chassis, which acts as

Component location codes

Code Location Code Location

Grounding tags Solenoid-operated

3(56a) 4(56a) 1(56b)

Pressure operated P<540kPa B- D- Relay, level

Rocker, 1 pole Panel

Sprung, centre off Gauges Heater element

Sprung, one way Instrument

INT GA EB ED ECS EL EM EN EO EP GBX KE KF KH

Front electrical centre

EGS G7A G7D G7B G7C DIA7 JMP EAB ABS

308X 379B 379A “45” “44”

3014 354B 379A 308B 3023

Rear electrical centre

The test socket allows the voltages at certain

Pin Test conditions Pin Test conditions

Adapter 999-8177 for connection to test socket

Test box 981-3190, Adapter 9998360,

KA1 H3 KA9 KA6 KA5

309 300 308 3028 6 345

354B 398 3027 3005 3063 (381)

Ref. Function Ref. Function

• to receive control lamp activation signals and deter-

Wire colours Colour Type of circuit

How the colours appear on the wiring

9-pin connector and socket numbering Relay markings

Cable Harness Identification Part No

No. Component “34”

BATTERY BOX Welded nut near battery box

“31” M6 screw in electrical centre printed circuit board.

“P4” Ultrasonic welded connector in electrical centre cable harness

Battery circuit breaker (current paths 5 to 12)

If the emergency cut-out switch (180) in current path 20 is operated, the

In buses equipped with a fuel cut-off system, operation of the emergency

to D, energizing relays (3026A) and (3026B); “2” connects switch

After the engine has started

Combination relay (3066)

G8 MGS transmission range lock

614 G8MGS range lock solenoid valve

The table on the schematic provides information to the coachbuilder as

3066 Combination relay 119/120 Windscreen wash/wipe switch

The battery positive connection on Alternator 1 also supplies maintain-

505/506 Alternator charging warning lamp

If the emergency cut-out switch (180) (current path 20, Schematic 1) or

If fuse “8” blows, the alternator D terminal continues to supply voltage

Emergency fuel cut-off circuit

If the emergency cut-out switch (180) (see Schematic 1) is pressed,