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Leyland

Olympian Bus

Leyland Olympian Bus
Workshop Repair Manual

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This is a very comprehensive Factory Workshop Manual suitable for the home mechanic or professional technician.

It is easy to understand with step by step instructions and lots of drawings/photos for you to undertake any task on your Leyland Olympian.

The following Leyland models are covered by this manual:

Leyland Olympian ON 6LXB 1R
Leyland Olympian ON 6LXB 2R
Leyland Olympian ON TL11 2L

Below is a comprehensive list showing what this manual covers:

Miscellaneous Information

Model Range
Approximate Vehicle Weights
Approximate Vehicle Dimensions
General Data

Maintenance

Lubrication Diagram
Maintenance Schedule
Maintenance and Lubrication Procedures
- Batteries
- Gearbox and Charged Coupling Oil Level Check and Change
- Gearbox Voith D851 Oil Level Check, Change, Load Transmitter
- Front Hub Greasing
- Rear Hub Greasing
- Rear Axle Topping up/ Draining/Filling
- Induction Air Filter Element renewal
- Air Suspension Air Filter
- Air Suspension Leveling Valve Hydraulic Fluid level
- Air Suspension Isolator Valve Filter Cleaning
- Automatic Lubrication Reservoir Filling
- Fuel Sedimenter Draining/Cleaning
- Hydraulic System Fluid Change
- Hydraulic Reservoir Filter
- Hydraulic System Priming
- Alternator Drive Belt Adjustment
- Compressor Drive Belt Adjustment
- Starter Motor Lubrication
- C.A.V. Alternator Lubrication
- Wheel Removal and Fitting
- Condenser Drain Valve Cleaning
Valve Clearances (TL 11/15/2)
Injectors (TL 11/15/2)
Fuel Filter Element (TL 11/15/2)
Fuel System Bleeding (TL 1115/2)
Engine Oil Changing (TL 11/15/2)
Engine Oil Filter Element (TL 11/15/2)
Cooling System Draining, Topping up, Filling

Lubricants and fluids

Engine Lubricants
Leyland Specifications
Fuel Oil
Anti-Freeze Fluids and Inhibitors
Air Suspension Leveling Valve

Special tools

Torque Tightening Figures

Engine (TL 11/15/2)

Data
Removal
Refit
Fault Finding

Cooling System

Data
Torque Tightening Figures
Removal and refitment
- Shutter Assembly
- Water Pump
- Radiator
- Header tank
- Cylinder Head Water Outlet Pipe
- Thermostats
- Oil Cooler
Testing
- Thermostats
Overhaul
- Water Pump
- Oil Cooler

Engine Compartment Ventilation Fan Hydraulic System

Data
Description
Removal and Refitment
Fault Diagnosis
Overhaul
- Hydraulic Pump

Engine Cooling Fan Hydraulic System

Data
Description
Overhaul
- Switching valve
- Thermostatic Valve
Testing
- Switching Valve
- Thermostatic Valve

Cylinder Head

Data
Removal and Refitment
- Rocker Shaft Assembly
- Cylinder Head
- Valve Springs
Adjustment
- Valve Clearances
Overhaul
- Cylinder Head
- Valve Seat Insert

Crankcase Assembly

Data
Removal and Refitment
- Tappets and Cam Followers
- Crankshaft Damper
- Crankshaft Pulley and Front Oil Seal
- Timing Gear Case
- Timing Gear Backplate
- Camshaft
- Oil Sump
- Oil Pump
- Oil Filter
- Connecting Rod Big-End Bearings
- Main Bearings and Thrust Washers
- Connecting rod and Piston
- Cylinder Liner
- Crankshaft Rear Oil Seal
- Crankshaft
Overhaul
- Crankshaft Regrind
- Connecting Rod and Piston
- Oil pump

Fuel System

Data
Removal and Refitment
- Injection Pump
- Fuel Lift Pump
- Injector
- Fuel System (Bleeding)
- Throttle Control Valve
Adjustment
- Throttle Linkage
- Stop Linkage
Overhaul
- Fuel Injection Pump

Gearbox

Removal and Refitment
Leyland Fully Charged Hydraucyclic
Voith 851

Propeller Shaft

Removal and Refitment

Propeller Shaft with Yoke Coupling

Removal and Refitment
Fault Diagnosis
Overhaul

Gearbox - Leyland Hydraucyclic, Fully Charged

Data
Description
Brake Band Adjustment
Fault Diagnosis
Overhaul

Electro - Hydraulic Valve Block

Description
Testing
Removal and Refitment

Retarder Valve block - With Two Stage Air Cylinder

Data
Description
Testing
Adjustment
Removal and Refitment

Note: Refer to Voith Literature for Overhaul of Voith D851 Fully Automatic Gearbox

Front Axle

Removal and Refitment
Leyland Axle Beam
Leyland front Axle

Front Axle - Leyland Beam type

General Information
- Data
- Camber and Caster Angles
Overhaul
- Front Hubs
- Stub Axle
- Renewing Stub Axle Bushes
- Renewing Wheel Stubs
Power Assisted Steering Gear
- Removal and Refitment
- ZF 8043 955 132 Steering Box
- Steering Column Housing
- Steering Column Shaft and Universal Joints
- Dismantling Steering Column Housing
- Setting the Steering Limiter valves

Power Assisted Steering Gear - ZF 8043

General Information
- Data
- Description
- Operation
- Periodic Inspections and Fault Finding
- Fault Diagnosis
Overhaul
- Dismantling Steering Box to Major Components
- Checking and Adjusting the Hydraulic Centre

Power Steering Pump and Flow Control System

Removal and Refitment
- Power Steering pump
- Flow Control Valve Assembly
- Reservoir
- Testing the Steering System Components
Power Steering Pump - Plessey
- General Information
  - Data
  - Description
  - Operation
- Overhaul
Test Connection
- General Information
  - Data
  - Description
  - Operation
- Overhaul
- Testing
Flow Control Valve assembly
- General Information
  - Data
  - Description
  - Operation
- Overhaul
- Testing
Steering Linkage
- Removal and Refitment
  - Relay Arm Assembly
  - Draglinks and Track-rods
Steering Linkage
- General Information
  - Data
- Overhaul
  - Relay Arm and Mounting Bracket Assembly
  - Draglinks and Track-rods
  - Setting the Steering Linkage
  - Draglink and Track-rod Adjustment
  - Wheel Stop Setting

Rear Axle

Removal and Refitment
- Leyland with Drop Centre Casing
General Information
- Data
Removal and Refitment
- Axle Shafts
Overhaul
- Hubs
- Rear Axle Unit

Brakes

General information
- Data
- Description
- Diagrammatic Layout of Brake system
- Location of Brake System Components
- Braking System Fault Diagnosis
Brake Assemblies
- Description
- Removal and Refitment of Brake shoes
- Removal and Refitment of Brake Camshafts
Slack Adjuster (S.A.B. Automatic type)
- Description
- Removal and Refitment
- Overhaul
Hand Control valve
- Description
- Removal and Refitment
- Testing and rebuilding valve
Air Compressor
- Description
- Fault Diagnosis
- Removal and Refitment
- Overhaul
Unloader valve
- Description and Operation
- Removal and refitment
- Overhaul
- Testing
- Adjustment
Foot brake Valve
- Description
- Operation
- Removal and Refitment
- Testing
- Overhaul
- Adjustment
- Bench Testing
Single Diaphragm Brake Chambers
- Removal and Refitment
- Testing
- Overhaul
Spring Brake Actuators (Clayton Type 30)
- Removal and Refitment
- Overhaul
- Testing
Spring Brake Actuator (Westinghouse Type 30)
- Removal and Refitment
- Overhaul
- Testing
Relay Valve
- Description and Operation
- Overhaul

Electrical

Electrical System General Information
- Description
- Routine maintenance
- Jump Starting
- Driver Controls
- Warning/ Information Lights
- Front Junction Box
- Rear Junction Box (Upper)
- Batteries
- Isolation Switch
- Steering Column Combination Switch
- Push Button Switches
- Start/Run Switch
- Exterior Lighting Switches
- Coolant Temperature Switch
- Oil Pressure Switch
- Lock-Out Over-ride Switch
- Brake Light Switch
- Accelerator Interlock Valve
- Warning Buzzer
- Micro Switches
- Wiring Diagrams
Lead Acid Batteries
- Filling of Batteries
- Mixing Electrolyte
- Battery Charging
- Testing
Alkaline Batteries
- Routine Precautions
- Operation
- Care of Batteries in Service
- Changing Electrolyte
- Repairs
- Filling and Charging
Butec Charging System (A100 Alternator)
- Data
- Description
- Precautions
- Removal and Refitment
- Maintenance
- Lubrication
- Overhaul
  - Dismantling
  - Inspection and testing
  - Reassembly
  - Bench Testing
- Voltage Regulator Type R102
  - Data
  - Description
  - adjustment
  - Removal and Refitment
  - Fault Detection
CAV Charging System (AC203 Alternator)
- Data
- Description
- Removal and Refitment
- Service Precautions
- Maintenance
- Lubrication
- Overhaul
  - Dismantling
  - Inspection
  - Bearing Renewal
  - Slip-Ring Renewal
  - Reassembly
  - Testing
- Voltage Regulator
  - Removal and Refitment
- Charging System Fault Detection
- Fault Diagnosis
Butec Starter Motor Type MS1A
- Data
- Description
- Operation
- Maintenance
- Fault Tracing
- Overhaul
  - Removing the Solenoid Switch
  - Dismantling the Switch
  - Dismantling the Starter Motor
  - Cleaning and Inspecting
  - Reassembling the Starter Motor
  - Abutment Test

Suspension and Chassis Equipment

Air Suspension System
- Data
- Torque Tightening Figures
- Description
- Operating Test
- Adjustment of vehicle Ride Height
- Removal and Refitment of:
  - Spring Location Link
  - Air Springs
  - Levelling valve
  - Isolator Valve
Shock absorbers
- Data
- Description
- Removal and Refitment
Automatic Lubrication System
- Data
- Description
- Maintenance
- Overhaul
- Fault Finding Chart
- Testing

Body

Glazing
- Description
- Removal and Refitment of Windows
Doors
- Description
- Operation
- Removal and refitment of:
  - Entrance/ Exit Door
  - Drive Shaft Assembly
  - Door Pillar Tube Assembly
  - Door Actuator
  - Double Pilot Air Bleed Valve
  - Air Filter - Regulator Valve
  - Driving Position Door Operating Button Assembly
  - Internal Emergency Door Operating Button Assembly
  - External Emergency Door Operating Button Assembly
- Overhaul - Entrance/Exit Door and Equipment
  - Door Actuator
  - Fault Diagnosis
- Removal and Refitment - Emergency Doors and Engine Access Doors
  - Emergency Door - Lower Section
  - Emergency Door Lower Section - Locks, Handles and Linkages
  - Rear Access Doors - Engine Compartment
Windscreen Wipers and Washers
- Description
- Removal and Refitment of:
  - Wiper Blades
  - Wiper Arms
  - Wiper Motor Assembly
  - Swivel Shaft and Tension Plate Assembly