Leyland Olympian Bus Factory Workshop and Spare Parts Manual | PDF Download | carmanualsdirect

Leyland Olympian Workshop and Spare Parts Manual | PDF Download

Description

Leyland Olympian Factory Workshop and Spare Parts Manual | PDF Download

For owners and mechanics dedicated to maintaining the classic Leyland Olympian bus, a comprehensive workshop manual is an invaluable resource. The Factory Leyland Olympian Workshop Repair and Spare Parts Manual, available in PDF format, provides detailed instructions and information covering every aspect of the Olympian Bus. Spanning over 1000 pages, this manual is an essential tool for ensuring the longevity and optimal performance of these iconic vehicles.

This detailed manual caters specifically to the following Leyland Olympian models:

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

Comprehensive Coverage

The workshop manual encompasses a wide range of topics, from basic maintenance to complex overhauls. It begins with general data, including approximate vehicle weights and dimensions, before delving into specific systems and components. Key areas covered include:

Maintenance: Scheduled maintenance procedures, battery care, and fluid changes are outlined to keep the bus in top condition.
Air Suspension: Detailed information on the air suspension system, including troubleshooting and adjustments.
Hydraulic System: Covers the hydraulic system, including fluid changes, filter maintenance, and priming procedures.
Cooling System: Addresses all aspects of the cooling system, from the radiator and water pump to thermostats and oil coolers. Torque tightening figures are also provided.

Engine Overhaul Instructions

A significant portion of the manual is dedicated to the engines, providing complete overhaul instructions for both the Leyland TL11/15/2 Engine and the Gardner 6LXB Engine. This includes:

Cylinder Head: Detailed instructions for removal, refitting, and valve spring maintenance.
Crankcase Assembly: Covers tappets, camshafts, oil pumps, connecting rods, pistons, cylinder liners, and crankshaft maintenance.
Fuel System: Addresses fuel injection pumps, fuel lift pumps, bleeding procedures, and throttle control.

Transmission and Driveline

The manual also provides in-depth information on the transmission and driveline, including:

Propeller Shaft: Instructions for maintaining and repairing the propeller shaft with its yoke coupling.
Gearbox: Comprehensive overhaul procedures for the Leyland HydrauCyclic fully charged gearbox, including the electro-hydraulic valve block and retarder valve block.

Axles and Steering

Detailed guidance is offered for maintaining and repairing both the front and rear axles:

Front Axle: Covers Leyland axle beams, front hubs, stub axles, and power-assisted steering gear.
Rear Axle: Includes removal and refitting instructions for Leyland axles with drop center casings, as well as axle shaft and hub maintenance.
Steering System: Comprehensive section on the power steering system, including the pump, flow control, and steering linkage.

Brakes

The braking system is thoroughly covered, including:

Diagrammatic layout of the brake system and component locations.
Braking system fault diagnosis.
Maintenance and repair of brake assemblies, slack adjusters, control valves, air compressors, and brake chambers.

Electrical System

The manual provides a complete overview of the Leyland Olympian's electrical system, including:

General information, routine maintenance, and jump-starting procedures.
Detailed diagrams and descriptions of driver controls, warning lights, and junction boxes.
Information on batteries, switches, wiring diagrams, and charging systems (including Butec and CAV systems).
Overhaul instructions for the Butec Starter Motor.

Suspension and Chassis

The suspension and chassis section covers:

Air suspension system data, description, operating tests, and ride height adjustments.
Removal and refitting instructions for spring location links, air springs, leveling valves, and shock absorbers.
Automatic lubrication system details and fault finding.

Body

The final section addresses body components, including:

Glazing, doors, door actuators, and emergency door mechanisms.
Windscreen wipers and washers.

Conclusion

The Factory Leyland Olympian Workshop Repair Manual is an indispensable resource for anyone involved in the maintenance and repair of these buses. Its comprehensive coverage, detailed instructions, and clear diagrams make it an essential tool for mechanics and owners alike. With this manual, keeping your Leyland Olympian running smoothly for years to come is within reach.

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Below is a very comprehensive list of contents of the workshop manual:

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) and Gardner 6LXB
- Data
- Removal
- Refit
- Fault Finding
Cooling System
- Data
- Torque Tightening Figures
- Removal and re-fitment
  - 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 Re-fitment
- 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 Re-fitment
  - Rocker Shaft Assembly
  - Cylinder Head
  - Valve Springs
- Adjustment
  - Valve Clearances
- Overhaul
  - Cylinder Head
  - Valve Seat Insert
Crankcase Assembly
- Data
- Removal and Re-fitment
  - Tappets and Cam Followers
  - Crankshaft Damper
  - Crankshaft Pulley and Front Oil Seal
  - Timing Gear Case
  - Timing Gear Back plate
  - 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 Re-fitment
  - Injection Pump
  - Fuel Lift Pump
  - Injector
  - Fuel System (Bleeding)
  - Throttle Control Valve
- Adjustment
  - Throttle Linkage
  - Stop Linkage
- Overhaul
  - Fuel Injection Pump
Gearbox
- Removal and Re- fitment
- Leyland Fully Charged Hydraucyclic
- Voith 851
Propeller Shaft
- Removal and Refitment
Propeller Shaft with Yoke Coupling
- Removal and Re -fitment
- Fault Diagnosis
- Overhaul
Gearbox - Leyland Hydraucyclic, Fully Charged
- Data
- Description
- Brake Band Adjustment
- Fault Diagnosis
- Overhaul
Electro - Hydraulic Valve Block
- Description
- Testing
- Removal and Re-fitment
Retarder Valve block - With Two Stage Air Cylinder
- Data
- Description
- Testing
- Adjustment
- Removal and Re -fitment

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

Front Axle
- Removal and Re -fitment
- 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 Re-fitment
  - 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 Re-fitment
  - 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 Re-fitment
    - Relay Arm Assembly
    - Drag links 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 Re-fitment
  - Leyland with Drop Centre Casing
- General Information
  - Data
- Removal and Re-fitment
  - 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

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Language: English

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