Volare Marcopolo Owner's Manual
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Volare Marcopolo Owner's Manual

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Summary of Contents for Volare Marcopolo

  • Page 3: Table Of Contents

    EXTERNAL COVER AND HATCHES ............61 PREVENTIVE PERIODIC MAINTENANCE CHART ........26 BUS BODY PAINTING ................62 PREV.PERIOD.MAINT.CHART - VOLARE W8 AND W9 - ENGINE MWM ..27 EXTERNAL CONSERVATION ..............64 PREVENTIVE PERIODIC LUBRICATION AND RE-TIGHTENING CHART ..32 INTERNAL CONSERVATION ..............
  • Page 4 DAILY INSPECTION .................. 70 Fuel Filter Drainage .................. 86 IMPORTANT RECOMMENDATIONS FOR DRIVER ........71 Low Pressure Fuel System Bleeding ............87 ECONOMICAL DRIVING ................. 73 Injection System ..................87 INSTRUCTION FOR BREAKING-IN ............73 Fuel Tank ....................88 ENGINE STARTING AND STOPPAGE ............

  • Page 5: Introduction

    Whenever you need technical assistance, always contact a Volare Representative. Some stay, others Volare! He will be pleased to help you maintain and preserve your Volare and is ready to offer you all technical assistance you may need. Finally, we take the opportunity to congratulate you on your choice of the Volare product, and assure you that we hold a maximum interest in keeping you satisfied.

  • Page 7: Warranty Term

    3.1. The warranty covers the Volare Product’s parts and components that have 2.2. The Product Volare warranty is valid since the emission of the tax invoice e defects or faults in accordance with item 2 (two), except for the described in effective delivery to the first customer.

  • Page 8: Conditions For Full Warranty

    3.4. The warranty applies to the necessary repairs or replacement of 4.7. Use only adequate fuel and lubricants recommended by MARCOPOLO S.A. components with proved material, assembly or workmanship defects. UNDER – Volare Division. NO CIRCUMSTANCES SHALL THE PRODUCT BE REPLACED.

  • Page 9: Warranty Limitations

    5.3. Any fault in the electronic system (electronic module, sensors and actuators) occurred because of non-observance of the measures mentioned 5.8. List of the parts considered as normal wear parts and assemblies: in the Volare Owner’s Manual, and/or the replacement of the electronic module Pneumatic: Tyres, protectors and air chamber.
  • Page 10 5.11. The expenses for transportation of the Volare Representative or Service 5.16.2. Hydraulic steering system, limited by the warranty for 12 (twelve) months Station to the vehicle and from the vehicle to the site of the Volare Representative or 100 000 (hundred thousand) kilometers, herewith dominates occurrence of or Service Service are not covered by the warranty.

  • Page 11: Warranty Termination

    7.2. Some options should be required during the sale of the vehicle, and 6.3. The warranty for the structure of the product will cease: MARCOPOLO S/A – Volare Division reserves the right to alter the cost, chart of offers, specifications, serial equipments and/or any other options of the products, 6.3.1.

  • Page 12: General Information

    • The WARRANTY TERM comprises the contract information that ensures you the access to any Volare Representative. It refers to the maintenance of parts and service within the terms under WARRANTY, established in it. 7.5. The figures given in this manual are merely illustrative. MARCOPOLO S/A –...

  • Page 13: Inspection Check Lists

    INSPECTION CHECK LISTS To preserve the right to the vehicle’s warranty, it is obligatory to perform periodic inspections at the Volare Representatives in the specified intervals. The check of the maintenance chart execution is made by virtue of the authentification by the executive Representative of the respective check of periodical inspections.
  • Page 14 14 14...

  • Page 15: Delivery Check List - Copy To Be Send To The Manufacturer

    City: State: e-mail: Delivery Date: Trade Note No.: Volare Volare Representative’s Code: Representative’s Code Person responsible for Technical Delivery (Name and Signature): Volare Representative’s Stamp: Volare Representative’s Stamp Herewith I declare that this vehicle has been delivered to me, this day, completely inspected and in perfect external and operating conditions.

  • Page 17: Delivery Check List - Customer Copy

    City: State: e-mail: Delivery Date: Trade Note No.: Volare Volare Representative’s Code: Representative’s Code Person responsible for Technical Delivery (Name and Signature): Volare Representative’s Stamp: Volare Representative’s Stamp Herewith I declare that this vehicle has been delivered to me, this day, completely inspected and in perfect external and operating conditions.

  • Page 19: Inspection At 5.000 Km

    City: State: e-mail: Overhaul Date: Trade Note No.: Volare Volare Representative’s Code: Representative’s Code Person responsible for Technical Delivery (Name and Signature): Volare Representative’s Stamp: Volare Representative’s Stamp I hereby declare that I have been assisted in every item of the 5,000 Km Overhaul contained in the Periodical Preventive Maintenance Chart of the Owner`s Manual.

  • Page 21: Inspection At 15.000 Km

    City: State: e-mail: Overhaul Date: Trade Note No.: Volare Volare Representative’s Code: Representative’s Code Person responsible for Technical Delivery (Name and Signature): Volare Representative’s Stamp: Volare Representative’s Stamp I hereby declare that I have been assisted in every item of the 15,000 Km Overhaul contained in the Periodical Preventive Maintenance Chart of the Owner`s Manual.

  • Page 23: Technical Delivery Instructions

    TECHNICAL DELIVERY INSTRUCTIONS .7 Passenger and Load Capacity Limit; The TECHNICAL DELIVERY is primarily intended for giving to the Volare owner the 1.8 The Owner’s Manual Usage; following orientations and for checking the items indicated in the check list. 1.9 Safety precautions concerning electronic module, sensors and actuators;...
  • Page 24 3.4 Oil from the fuel tank; 2.8 Traction (differential gear – oil and antifriction replacement); NOTE: The plant recommends to use mixture of water and 2.9 Brake System (compressor, brake shoe lining and/or pads, air lubricants. reservoir and dry air filter); 4.
  • Page 25 4.11 Cooling System – water indicator; 5.12 Towing Pin; 5. Orientations on the Execution 5.13 Emergency Hammers; 5.1 Driver’s, second driver’s and passenger seats (adjustments) and 5.14 Internal and External Conservation; safety belts; 6. General Safety Regulations; 5.2 Internal and External Lighting; 7.Daily Inspection –...

  • Page 26: Preventive Periodic Maintenance Chart

    The warranty will be valid only if all the inspections are performed and authorised Fuel tank, side, battery and spare tyre hatches: Check oxidation, locks with the respective signature and seal by a Volare Representative, service functioning, articulations, handles and latches.

  • Page 27: Prev.period.maint.chart - Volare W8 And W9 - Engine Mwm

    8- Series 2100 Automatic Gearbox, oil volume - 16 litres. Change oil at the first 8 000 km, then every 160 000 km or 48 months, depending on what happens NOTES – MODELS VOLARE W8 and W9 first. The notes given below cover the lubrication and maintenance points that should 9- Never perform bleeding-off of the electro injectors, when the engine is in be exactly fulfilled according to the Preventive Maintenance Chart.
  • Page 28 PREVENTIVE MAINTENANCE CHART - Volare W8 and W9 DESCRIPTION ENGINE Antifreezer Note 4 Compressed-air Pump Note 4 Check / Inspect Ventilator Funnel Note 4 Vibration Supressor Note 4 Belt Tightener Bearing Note 4 Turbo-compressor Check gap of the rotor axle and frame state...
  • Page 29 DESCRIPTION INTAKE SYSTEM Replace Primary Element Replace when the restriction warning light starts glowing on the panel Air Filter Replace Secondary Element At every 5th replacement of the primary element or anually (depending on what occurs first) Air filter, tubes and hoses Air Cooler Check / Inspect Air Filter –...
  • Page 30 DESCRIPTION GEARBOX Change oil - FSO 4405 5,3 litres Note 7 Gearbox Change oil and filter - Series 2000 16 litres Note 8 Check for leakage TRACTION Check Level and Fill up Diferential Gear Change oil 4 litres Chart 1 Check for leakage Rear Wheel Bearings Lubricate with grease...
  • Page 31 DESCRIPTION SUSPENSION Re-tighten the fixing brackets of the springs and stabilizing rods Check degree of the bushing wear Re-tighten the screws and nuts fixing the springs and stabilizing rods STEERING SYSTEM Check level and fil up 1,7 litres Chart 1 Steering Hydraulic Sector and Hydraulic Oil Reservoir Re-tighten fixing screws...

  • Page 32: Preventive Periodic Lubrication And Re-Tightening Chart

    PREVENTIVE PERIODIC LUBRICATION Trust the lubrications and re-tightening service only in a Volare Represen- tative. AND RE-TIGHTENING CHART The torque of the main screws and nuts are indicated in the re-tightening The items given in the following charts are related to the points of lubrication chart.
  • Page 33 LUBRICATION CHART Lubricant ITEMS TO BE LUBRICATED (type) • • • • • Battery Cable Connections Grease • • • • • • • Windshield Wiper Assembly • • • • • Windows Sliding Mechanism Graphite • • • • •...

  • Page 34: Specifications

    VOLARE IDENTIFICATION POINTS Identification Plate The Identification Plate is fixed on the interior part of your Volare on a visible place, next to driver, and contains the following data: Chassis Number, Model/ Year, Engine, Front Axle Maximum Capacity, Rear Axle Maximum Capacity, Total Gross Weight (TGW) and Traction Maximum Capacity.
  • Page 35 V.I.N. Numbers – Sequential Production Number V.I.N. - Vehicle Identification Number Manufacturer Construction Technical Information Plant/Factory/Serial Number 1. On the Structure 1.1. On the column of the hood. To reach it: open the hood and check on the column under the hood coupling. 1.2.
  • Page 36 Air Conditioner The Air Conditioner’s serial number is situated on the air condenser or also in the Air Conditioner’s manual that accompanies the Volare. To identify the number on the air condenser, position the vehicle on a ramp.

  • Page 37: Commands, Controls And Maintenance

    COMMANDS, CONTROLS AND MAINTENANCE VOLARE PANEL Automatic Gearbox PANEL IDENTIFICATION Panel Indicators Air Conditioner Control Switches Electric Switchboard Starting Switch Multifunctional Switch Parking Brake Selector Switch Master Switch Comands and Controls Speed Selector Lever Tachograph Air Diffusers...

  • Page 38: Optical Warning Indicators

    To alter the odograph and watch functions, just press one time the button that is OPTICAL WARNING INDICATORS situated on the lower part of the speed recorder. To null, press and keep the button during a few seconds. The time must be adjusted on the tachograph.
  • Page 39 If this red light of the brake indicator starts glowing when the vehicle is in motion, 7 - Alarm Light – Activated High Beam park your car in a safe place and find out the reason of the pressure drop. The blue light, when starts glowing, indicates that high beam is switched on.
  • Page 40 12- Brake Light – Engine started “Cooling System”. IMPORTANT: Check the hoses and radiator for the leakage and splits This light starts glowing only when the engine brake interrupter is regularly. activated. 13- Water in the Fuel System 17 – Oil Temperature Light (Automatic Gearbox) It indicates that the clutch oil is at abnormal temperature what, in When this light starts glowing, it means that the filter separating fuel this manner, may cause any abnormality in the system.
  • Page 41 The tachometer also indicates when the engine is operating with rotations above the maximum recommended. TACHOMETER 24 - Fuel-level Indicator Indication Volare W8 and W9 Green band 1.200 to 1.800 rpm This indicator shows fuel level in the tank. Apart from the Yellow band 1.801 to 2.500 rpm...
  • Page 42 When its hand is in the red band, light 16 starts glowing, indicating that the vehicle In normal operating conditions, the hand should be in the centre of the should be fuelled as soon as possible. scale. IMPORTANT: When the hand approaches the red band, stop you engine NOTE: See item “Fuel Tank Capacity”.

  • Page 43: Panel Switches

    PANEL SWITCHES Fog Lamp Steps/Gangway Lightening Panel Switches Symbols Low Beam Headlamp Maintenance Light Driver’s Light Route Sign Light Night Light (passenger compartment) Engine Brake Defroster (anti-fog) Nest Stop Request Button Ventilator Rotating Light Taillight Windshield Washing Blower/exhauster Front Door Windshield Wiper Alert Flickering Lamp Reading Light...

  • Page 44: Interruptors

    Switches Operation Signal Lights and Headlights Interrupter The headlights and signal lights interruptor has three positions: a) Headlights and signal lights are switched off; b) Panel instruments lights and rear signal lights start glowing; c) Low-beam headlights start glowing. Position 1 Position 2 Position 3 Switched off...

  • Page 45: Starting Switch

    systematic use of the engine brake saves the service brake, ensuring its full ANTI-FOG COMMAND efficiency in case of emergencies. To activate and disactivate the engine brake, just switch on the interruptor. IMPORTANT: Every time when bending the accelerator pedal or clutch pedal, the engine brake stops operating, reactivating as soon as the pedals return in their initial positions.

  • Page 46: Air Conditioner Command

    Air Diffusers on the Panel Air Conditioner Functions Set-Point Increment Switch* Set-Point Decrement Switch* * Set-point: Desired Temperature. NOTE: For more information and instructions, consult the air conditioner manual that accompanies the vehicle. The air diffusers are situated on the panel. They are activated by means of the ventilation switch and ensure IMPORTANT: The air conditioner is calibrated by the device’s airflow to the driver´s seat through their flaps.
  • Page 47 4- After the cloth drying, reinstall the air filter; 5- House the electric switchboard cover. In the models Volare W8 and W9 there is the Defroster with Air Conditioner for the driver. It is situated on the panel and provides air directing to the driver and his auxiliary.

  • Page 48: Sound System

    SOUND SYSTEM Radio and CD player The radio and/or CD player, when required, are installed on the panel. For adequate operation of the radio, check the perfect fixing of the ground cable of the antenna, fixed on the first front ceiling light. NOTE: See also the electric diagram at the end of the manual.

  • Page 49: Electric Switchboard

    Set the volume of the device in 60% capacity and adjust the sound volume The electric switchboard is located on the panel, near the driver’s station. To by means of the selector switch. This procedure will prevent from acoustical access the electric switchboard, remove the panel’s cover plate. distortions in the ambient medium.

  • Page 50: Multifunctional Switch

    ATTENTION: Before replacing a fuse, turn off the switch of such a • After opening of the compartment (front cover plate), remove the socket/lamp circuit. assembly and replace the burned-out lamp carefully, avoiding contact of its bulb with your skin. A burn-out fuse can be visually identified by its internal broken filament.

  • Page 51: Speed Select Lever - Gearbox

    ROUTE PLATE positions are shown below: Coventional Route NOTE: The Volare gearbox is equipped with a coupling inhibit device that prevents accidental change from the 4th gear to reverse one. The front route plate is located at the driver’s station.

  • Page 52: Parking Brake

    Having parked your vehicle, always use the parking brake Parking Brake Steering Wheel The Volare steering system is hydraulic and hydrostatic, providing easy operation and less physical depreciation. Clutch Pedal The coupling clutch is activated hydraulically, providing easiness and flexibility.

  • Page 53: Driver's Site

    Accelerator Pedal NOTE: The vehicles are equipped with adjustments of the driver’s seat according to the required at the act of purchase. Operating the pedal sends an electric signal to the control module that adjusts The seat back adjustment may be dispensing of the fuel sent to the injectors and, therefore, acceleration.
  • Page 54 Maximum Authorized Capacity Identification Sit down, pull totally, adjust the inclination of the back seat with the body and return the lever. Your Volare maximum authorized capacity identification is located near the Adjust the height in accordance with your head position. driver.

  • Page 55: Passenger Compartment

    PASSENGER COMPARTMENT Seat Belts Seats Correctly-buckled seat belts keep their occupants in the correct position and significantly reduce the kinetic energy. Executive Bus Seat Reclined Microbus Seat The passengers wearing their seat belts correctly benefit greatly, as they allow the kinetic energy to be absorbed in an optimized manner. IMPORTANT: Seat belts should always be fastened before moving off.
  • Page 56 NOTE: The abdominal seat belt shall run over the pelvic region and not over the abdomen and shall always be well attached to the body. If necessary, IMPORTANT: The tongue must re-tighten the seat belt strap. be inserted into its correct buckle, if not, the protection efficiency may be To Shorten the Seat Belt compromsed.
  • Page 57 Individual Panel The air inlet features 4 (four) positions of use, allowing air renewal and/or ventilation of air in the passenger compartment. Button activating the reading lamp on the Ventilation/Renewal individual panel. Adjustment of the reading lamp focus. Natural Air Inlet Bus Front Part Totally open Equipped with two natural air inlets for air renewal in the passenger compartment,...
  • Page 58 Emergency Exit Seal Reposition Emergency Mechanism The seal of the assembly contains the information concerning its operation. To open it: Spring Shaft We recommend that you check the emergency 1- Open the exit at its total-open position; exit every 6 (six) months to make sure it is operating properly. 2- Break the safety seal;...

  • Page 59: Heating System

    HEATING SYSTEM Detail of the heating system on the panel Booster The heating system activation key Hot air Bus body front IMPORTANTE: The heating Left Side system activation should be switched off Convector when the engine is not in operation. Cool air Convector Defroster...

  • Page 60: Rear-View Mirrors

    REAR-VIEW MIRRORS The vehicle is equipped with two external articulated mirrors (on the left and right sides) and one internal rear-view mirror (on the internal lining – near the driver) facing the passenger compartment. Internal Rear-View Mirrors, front and rear External Mirrors The door activating valve is located on the panel, on the driver’s left side.

  • Page 61: External Cover And Hatches

    EXTERNAL COVERS AND HATCHES Battery Compartment Hatch Sedan Door Urban Door Lock To open the battery compartment hatch, insert the key into the lock and turn clockwise. Valve on the External Side Pantografic Door Rear Hatch Door emergency valve: To open the rear hatch, insert the key into the lock eye, turn and remove the key, press the lock eye with a finger and open the hatch.

  • Page 62: Bus Body Painting

    Front Hatch and Maintenance Lamp BUS BODY PAINTING Painting Conservation For cleaning use only neutral soap. Avoid washing in the sun and when the sheeting is hot. Do not use solvents or similar products. Do not put the washing roles directly on the vehicle when it is very dirty.
  • Page 63 BASIC COLORS Color Identification Code Pattern Line Producer White Royal White I - 88 Fiat 0816 Flat Salcomix BASF Green Java Green - 97 VW 984 5050 Flat Salcomix BASF Yellow Citrino Yellow - 88 Ford 7434 1040 Flat Salcomix BASF Blue Miró...

  • Page 64: External Conservation

    Safety Measures on Washing the Vehicle once in three months. If during the washing you see that the water does not form drops on the painting, the vehicle may be waxed after the drying. If the vehicle is washed with agressive agents, such as fuel, oil, etc, avoid contact of these agents with the control module, sensors and the electronic It is recommended to use a neutral biodegradable detergent, very foaming, motor actuators.

  • Page 65: Internal Conservation

    Every and any repair, eventually necessary, of the painting or of the vehicle benzene or kerosene, followed by water and neutral soap. bus body itself, may be per formed in any Volare Representative that has special equipment and trained personnel from the factory.
  • Page 66 POLYESTER TISSUES WASHING PROCEDURES DESCRIPTION CLEANING PRODUCT HOW TO USE PRODUTCT Benzene Rub until the stain disappears Solvent Detergent 1/20 Wash the residues with a sponge Emulsifier Grease Ammonia 1/3 Apply slightly Neutralizer Vinegar 1/3 Apply slightly Odour eliminator Benzene Rub until the stain disappears Solvent Detergent 1/20...

  • Page 67: Towing Hook

    TOWING HOOK 2- Never exceed 40 km/h during towing procedure. 3- If possible, keep the engine running during this procedure to ensure the correct When the vehicle is down or damaged and you need to tow it, do as follows: lubrication of the gearbox and keep the hydraulic steering running and the brake stystem pressurizaiton.

  • Page 68: General Instructions

    will ensure the stability and safety of your vehicle; GENERAL INSTRUCTION • Never drive with an excessive number of passangers/luggage exceeding the GENERAL SAFETY REGULATIONS maximum capacity of the vehicle; Driving a vehicle is a big responsibility, since any minor lack of attention or lack •...

  • Page 69: Conama Important Precautions

    • Premature deterioration of the exhaust system; Free Acceleration Fumes Index • Sufficient increase of the fume emission; The Volare vehicle conforms to the CONAMA Resolutions effective at the moment of its production. • Enhanced carbonizaiton of the combustion chambers and injectors;...

  • Page 70: Free Accelaration Fumes Index

    3- Estatic Noise Level emited by the Volare f) Check calibration of the wheels. MARCOPOLO S/A – Volare Division guarantees that all the models stated in this g) Check level of the fuel: this procedure must be performed at the end of every...

  • Page 71: Important Recommendations For Driver

    IMPORTANT: check the tightening and state of the electrical connections 3- Perform gear changing most softly and sincronizingly possible, providing comfort and security for the passengers. of the engine sensors. 4- Always use the clutch pedal to change gears. Incorrect use of the coupling i) Check if all the the vehicle’s instruments and controls are functioning well;...
  • Page 72 14- If the effor t, necessary for steering, changes during the vehicle’s 20- On long descents do not use continuously the brake.. Use the engine brake motion, consult a Volare Representative to perform inspection of the steering as long as possible, reducing the gears.

  • Page 73: Economical Driving

    ECONOMICAL DRIVING 1- Maintain the vehicle operating without activation of the pedals. 2- Ensure the vehicle controllability in an estimating manner, keeping it in the Fuel consumption is connected with a number of factors which make it economical rotation regime. impossible to establish consuming parameters for a vehicle.

  • Page 74: Engine Starting And Stoppage

    e) Do not overload the vehicle and/or its engine. The maximum load may be c) Switch off all the electrical accessories of the vehicle that do not need to be imposed on the engine, however, do not let it continue long. Overload may be switched on;...
  • Page 75 If does not stop glowing, it means that the 2- Do not rest your foot on the clutch pedal. Such procedure causes wear of system has detected a failure, find out the failure and contact the nearest Volare the bearing the clutch collar.

  • Page 76: Engine Stoppage

    ENGINE STOPPAGE 5- Cover in hermetically the engine air inlet and outlet; a) After the vehicle stoppage, reduce the engine rotations using the lower gear; 6- Pulverize wax-based conservation products on the chassis, engine, if necessary, on pulverize wax on the painting of external surfaces; b) Let it operating during 1 minute before switching it off.

  • Page 77: Weights And Capacities

    and lubrications generally should be performed most frequently possible than electronic module; prescribed in the preventive maintenance chart. • Do not add the master key in the electric circuit supplying the electric module; • Always when oil level check and drainage plugs are removed, is is recommended to use adequated keys in order to avoid damage of the plugs, •...

  • Page 78: Precautions Concerning The Alternator Operation

    Marcopolo S/A – Volare Division is not liable for the accidents resulted from carelessness or improper handling of the batteries. • Battery, connected with inversion of poles, provokes immediate destruction of the alternator diods.
  • Page 79 Prevention and Cares with Electronic Components Perform the operations in the indicated order: To avoid damages to the electronic components in the electric system, do not ATTENTION: Always protect your eyes and do not rest on the batteries. disconnect the battery with the operating engine. Do not use rings, watch, bracelets, etc.

  • Page 80: Engine

    • To ensure a good operation of the electronic module connectors, it is necessary to lock them perfectly. The Volare is equipped with an electronic diagnosis system that makes it possible to inform eventual problems in the engine by ELECTRONIC MODULE means of glowing lamps on the panel.
  • Page 81 Switched ON Level 1 motor controlability Volare Representative at the first opportunity C o n t i n u e y o u r t r a v e l , Reaction: immidiate motor degradation however, consult the neares...

  • Page 82: Vehicle's Reaction

    Volare b) Insert back the gage rod until the stop piece. Remove it again and check the Representantes.

  • Page 83: Feed System

    IMPORTANT: a) At normal engine operating temperature and with the leveled vehicle, remove A- Primary element (5) must not be cleaned. Replace it everytime when the drain cap (3) and let the oil run completely down; the warning light on the panel (1) starts glowing. b) Install again the drain cap;...
  • Page 84 a) Remove the cover and the primary element according to the abovementioned description, in item a) and b) of Procedure for replacing the primary filter element; b) Pull out the element (6); C) TEST OF THE RESTRICITON SENSOR 2- New primary filter element installation procedure: The restriction sensor (7) indicates, by means of warning light, (1) on the panel, an excessive restriction of the air passing through the filter.

  • Page 85: Fuel System

    Periodically check if the gap of the discharge valve is not obstructed. If your vehicle is equipped with two fuel filters: one located on the right side of the engine and the other on the front part of the Volare. FUEL SYSTEM FUEL SUPPLY SYSTEM...

  • Page 86: Fuel Filter Drainage

    on the next page; Change of the Fuel Filter Elements Filter 1 Filter 2 g) Activate the engine and check for possible leakage. Head 1 FUEL FILTER DRAINAGE Input Filter Element A The water separating filter is located in the front part of your vehicle. Element B Daily Base A...

  • Page 87: Low Pressure Fuel System Bleeding

    1- Release the switching-arm (A) of the bleeding pump turning it counterclockwise; • Try to find out the causes or require assistence of a Volare Representative. 2- Loosen the bleeding bolt (B); • It does not need to drain the filter (2). Change it according to the Preventive Maintenance Chart.

  • Page 88: Fuel Tank

    High-Pressure Pump Its function in the system is to provide fuel in the exact quantity under high pressure The cap to get access to the fuel tank float is for the distributing tubes (common rail). located in the passenger compartment. The high-pressure pump is a high-pressure component.

  • Page 89: Cooling System

    d) Fill in and check for possible leakage. COOLING SYSTEM IMPORTANT: Entrust this procedure to the trained personnel. RADIATOR NOTE: Try to fill up the vehicle at the end of every working shift. This Cleaning of the Radiator procedure will protect from the water condensation on the upper tank walls. It is very important to keep the water radiator and intercooler (1) grilles always Crankcase Ventilation Tube clean.
  • Page 90 Supply hole (upper cap) When the engine is cold, the level should not be lower than the minimum mark – MIN. When the engine is hot, the level should not exceed the maximum mark – MAX. and added with anticorrosion agent. This Cooling Liquid Level Check Procedure is as follows: protects from formation of incrustations that, as the time goes on, form a layer...

  • Page 91: Thermostatic Valve

    In case of superheating, do not disactivate the engine immediately: let it operating water + additive agent from the cooling system and add the following mixture: 50% of water + 50% of additive agent Havoline XLC. idle until the temperature drops up to the normal levels. After it, switch off the engine and check the cause(s) of the superheating.
  • Page 92 Every time when necessary to remove the clutch fluid, deposit it into a clean If after the air elimination is detected that the operation is not still firm, cosult a recipient, without water and free of both mineral and vegetal impurities, in order Volare Representative.

  • Page 93: Transmission - Gearbox

    • Activating a gear, do not exert force in any other direction except for the normal course; Some internal adjustments and change of the master cylinder and/or auxiliary • Changing gears, release totally the accelerator pedal. Double activation of the cylinder cover.

  • Page 94: Gearbox - Automatic

    of heating and cooling that occur in the transmission in service. Procedures for Gear Changing in the Automatic Gearbox Press the lever button to set it in any position. Never proceed with changing Oil Drainage gears without pressing it. It is very important to drain the transmission when the oil is hot. To this end, R - To change gears from 1, 2, D, OD to the R gear, or vice versa, completely remove the magnetic plug (2) under the frame.
  • Page 95 • Make sure that the engine is operating at a low-gear rotation; Symbol Description Function or path types Reverse gear Move the vehicle back. • Make sure that the handbrake is not activated; Neutral or dead To start the engine and for the operations point during the vehicle’s stops.
  • Page 96 c) Switch off all the vehicle’s electric accessories that are not required to be brake; switched on. d) Activate the parking brake; d) Activate the starting switch, setting it in position 3 – starting. e) Switch off the engine; VEHICLE STARTING AND PARKING. Starting the Vehicle WARNING LIGHTS AND CONTROL KEYS OF ALLISON AUTOMATIC TRANSMISSION...
  • Page 97 Switching ON/OFF the Vehicle Safety Measures to be taken When the light (1) starts glowing, it indicates operation errors: operate the gearbox Select gear N before switching ON/OFF the engine. Depending on cold intensity, it as it was described above. may be necessary to add an oil of less viscosity (see the operating manual Allison that accompanies the vehicle for more details).

  • Page 98: Crankcase

    (1) located on the left side of the frame. Oil and filter change should be carried out at the Volare Representative or at the Allison. After the first 8 000 km and before every 160 000 km or 48 months, depending on Oil Change in the Differential Gear what occurs first.

  • Page 99: Pneumatic Suspension

    40 km/h, from 5 of the internal guard. This procedure should be carried out at a Volare to 10 minutes, or 2 to 3 km to ensure that all the ports are properly filled Representative.

  • Page 100: Hydraulic Steering System

    When necessary, contact a Volare Representative. Oil Change in the Hydraulic Steering System HYDRAULIC STEERING SYSTEM • To perform oil change in the steering hydraulic system, contact a Volare The steering sytem comprises one steering sector with incorporated cylinder, one Representative.
  • Page 101 IMPORTANT: This procedure should be performed at a Volare c) Release the fixing nuts of the wheel and lift it by means of the jack until it is Representative Office. free under the ground; d) Remove the nuts and the wheel carefully, preventing the screw thread from damage;...
  • Page 102 • Remove foreign bodies eventually stuck in the wheels; Do not perform modifications on the ends of the valve rods of the pneumatic suspension level. When necessary, contact a Volare Representative. • Examine periodically the state of the rim, valves and cap;...

  • Page 103: Tyres

    deformations or other damages. Check the pressure only with cold tyres, because in hot tyres, the pressure increases naturally. All the crankcase cross-arms On the rear axle (both sides) Changing Tyres TYRES For longer tyres durabiity, it is necessary to perform the change every 5 000 km.

  • Page 104: Spare Wheel

    • Manouvering the vehicle, avoid making it stopped; • Perform balancing with warm tyres; SPARE WHEEL The position of the spare wheel varies in accordance with a Volare model. Models Volare W8 and W9 On the right side of the vehicle, near the side hatch.

  • Page 105: Brake System

    Besides inspections within the planned periods, it is also important to driver correctly. The Volare is equipped with a air pneumatic system, moved by air, with drum brake on the four wheels. The Volare features the Freio Motor, a complementary system connected with the exhaust system of the vehicle that reforces security of braking on descent.
  • Page 106 it is not necessary to perform a periodic brake adjustment. Service Brake • Check the state of the brake shoe lining, changing them, if necessary. When When auxiliary compressed air connections are needed (inflator, brake engine, replacing the shoe lining, perform it axle by axle, in order to avoid disbalancing horn, cleaning gun and others), connect only to the joint number 24 on the in the brake system;...
  • Page 107 c) Disactivate the parking brake; the skids surface, should be immediately replaced. d) Inspect the brake lining throuth the inspection openings situated on the brake NOTES: support plates; The parking brake should be released only when the system pressure comes e) Turn the adjusting pin until the shoe lining blocks the drum;...
  • Page 108 Brake Diagram 1- Pedal valve 2- Dual manometer 3- Parking brake valve 4- Interrupter 5- 4-way valve 6- Dry air reservoir 7- Rear chamber - Spring brake 8- Front chamber 9- Front chamber 10- Air compressor 11- Pressure regulator 12- Drain valve 13- Humid air reservoir 14- 2-way valve 15- Rapid discharge valve...

  • Page 109: Specifications

    EE = Interaxle * For A6 model, when required by the client at the act of purchase, there are available 2.920 mm, 3.600 mm and 3.750 mm interaxle versions. 2- WEIGHTS AND CAPACITIES MODEL VOLARE W8 e W9 Front Axle 2.200 kg...
  • Page 110 3 – ELECTRIC SYSTEM MODEL VOLARE W8 and W9 24 V System 24 V Baterry - Voltage 02 x 70 Ah Battery - Corrent 4- ENGINE MODEL VOLARE W8 and W9 Model ACTEON 4.12 TCE Brand Number of cylinders 4 in line Capacity 4.800 cm³...
  • Page 111 5- FEED SYSTEM MODEL VOLARE W8 and W9 Capacity 150 litres Fuel tank Position Left frame-rail Element Type Paper Element Air Filter Filtering Area 52.000 cm² 6- COOLING SYSTEM MODELVOLARE W8 and W9 Water Radiator Heat Dissipation Area 3.127 cm²...
  • Page 112 8 a - MANUAL TRANSMISSION - GEARBOX MODEL VOLARE W8 and W9 Brand EATON Model FSO 4405 C Gear Number 05 forward and 01 reverse First Gear 5,762:1 Second Gear 2,640:1 Third Gear 1,528:1 Reduction Ratio Fourth Gear 1,000:1 Fifth Gear...
  • Page 113 Fifth Gear 0,71:1 Reverse Gear 4,49:1 Convertor Castrol Transynd Capacity 14 litres Cooling System Total Capacity 17 litres 9 - CRANKCASE MODEL VOLARE W8 and W9 Type Crosspieces Universal Joints Series 1480 10- TRACTION AXLE MODEL VOLARE W8 and W9 Brand...
  • Page 114 10- TRACTION AXLE, CONTINUED MODEL VOLARE W8 and W9 Coupling Ratio 4,10:1 Opc: 4,56:1 Opc: 4,78:1 Crown Gear Number of teeth Pinion Gear Type of Axle Totally Fluctuating Terminal ( YOKE) Series 1480 SAE 85W 140 API GL 5 EP...
  • Page 115 13- REAR SUSPENSION MODEL VOLARE W8 and W9 Type Interconnected simi-eliptic spring and telescopic shock absorber Shock Absorbers Double-action First Stage Number of plates/width 80 mm Second Stage Springs Right 118 mm Assembly Height Left 118 mm 14- WHEELS MODEL VOLARE...
  • Page 116 16- CHASSIS MODEL VOLARE W8 and W9 DESCRIPTION Standart Executive Dimensions Type 7655 x 865 mm 6195 x 865 mm 17- STEERING SYSTEM MODELO VOLARE W8 and W9 Model ZF SERVOCOM 8090 Number of turns ATF Tipo A Capacity 1,7 litres...
  • Page 117 20 – ENGINE BRAKE DESCRIPTION Mode of functioning Electropneumatic Actuation Exhaust Pipe 20 a - INSTRUMENTS (WHEN BUS IS EQUIPPED WITH A MANUAL GEARBOX) MODEL VOLARE W8 and W9 Reference VDO MTCO 1390 Type Electronic Tachograph Register Capacity Weekly – Opt. Daily...

  • Page 118: Lubrication Chart - Chart 1

    LUBRICATION CHART - CHART 1 DESCRIPTION LUBRICANT (type) NOMENCLATURE Engine SAE 15W 40 API CH-4/CI-4 Traction Axle SAE 85W 140 API GL5 EP Hydraulic Steering System ATF TIPO A Gearbox FSO 4405 C SAE 80/90 API GL 3/4 Automatic Gearbox - Series 2100 Castrol Transynd Fluid for Hydraulic Brake and Clutch Fluid...

  • Page 119: Lubricates Chart - Chart

    LUBRICANT CHART - CHART 2 RE-TIGHTENING CHART – CHART 3 LUBRICANT (type) NOMENCLATURE TORQUES Thread Torque (kgfm) SAE 90W 140 API GL5 EP Grease Calcium or lithium-based greas Powder Graphite For systems requiring dry lubrication Recomended brands: 10,0 TEXACO: MORFACK MP2 (lithium-based) Re-tighten the fixing screws and nuts of your bus body supports and components IPIRANGA: ISA-FAX (calcium based) according to the periods specified in this Manual.

  • Page 120: Audio And Video Electric Diagram

    AUDIO AND VIDEO ELECTRIC DIAGRAM BASIC CAPTIONS CONNECTOR CENTRAL ELECTRIC MOTHER CARD GROUND STRUCTURE GROUND RELAY R3 RELAY R3 SELECTOR MODULE SELECTOR MODULE RELAY R3 SELECTOR MODULE SELECTOR MODULE RELAY R3...

  • Page 121: Audio And Video Electric Diagram

    AUDIO AND VIDEO ELECTRIC DIAGRAM BASIC CAPTIONS CONNECTOR CENTRAL ELECTRIC MOTHER CARD GROUND STRUCTURE GROUND ANTENNA...

  • Page 122: Door Pneumatic Command

    PNEUMATIC COMMAND OF THE DOOR Door emergency activation valve Door activation valve button (left side of the panel) Sedan door activation piston Door activation external valve Air output adjustment in the piston...
  • Page 123 AIR TUBES COLOR Item Color Function Blue Open Green Close Reservoir Pressure Panel open and close valve Front grille open and close valve Emission valve Door piston...
  • Page 124 DESCRIPTION Owner’s Manual Code: 10055903 PREPARATION Volare Technical Assistance EDITION September/2008 Group:02 PUBLISHING TRANSLATION Viacheslav Yakovlev...

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