Body builder instructions

Volvo Truck Corporation

D
Göteborg, Sweden

Date Group Release Page

Supersedes VBI Release 03 from 1.07.
Changes are marked with a bar (|) in the margin. 2.07 95 04 1(42)

Hydraulic system and Power take-off

FM, FH, NH, VERSION2

Contents
“General” page 2
“Power take-off” page 3
“Clutch dependent power take-off” page 4
“Clutch independent power take-off” page 4
“Power take-off, performance” page 6
“Gearbox mounted power take-off” page 6
“Speed ratios for gearbox mounted power take-offs” page 7
“Flywheel mounted power take-off” page 8
“Engine mounted power take-off” page 9
“Hydraulic pumps” page 10
“Pump connections” page 10
“Pump types” page 11
“Installation” page 12
“4x4, 6x6 All wheel drive” page 12
“Engine PTO in combination with I-Shift and Geartronic” page 12
“Double front axle system, 8x2, 8x4” page 13
“Accessibility of PTOF and PTPT ” page 18
“Delivery conditions for factory installed PTO” page 18
“Delivery conditions for factory installed hydraulic pumps” page 18
“Connections to engine mounted hydraulic pump” page 20
“Installation requirements for hydraulic pump at final assembly” page 21
“Permissible pump bending torque” page 22
“Propeller shaft installation” page 23
“Position in the truck” page 24
“Dimensioning of hydraulic system and hydraulic pumps” page 32
“Pipes, lines and hoses” page 32
“Hydraulic oil tank” page 36
“Starting up” page 37
“Calculation of hydraulic pump size” page 38

20179629
ENG25485.ihval English
Printed in Sweden
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 2(42)

General
Auxiliary equipment require power take-offs, either when
the truck is stationary or when it is in motion. Various
power take-off alternatives can be chosen, depending
on the bodywork.

The work is generally carried out by equipment which

is powered by a hydraulic motor. The hydraulic motor,
together with a pump and associated equipment, form the
basis of the hydraulic system. The pump, which provides
the hydraulic pressure and flow to the motor, is the heart
of the hydraulic system.

All power take-offs covered by this chapter are available

D
factory installed. Some variants can also be ordered from
Volvo Parts AB.

T9006703
For further information about:

• Power take-offs and Hydraulic pumps, please refer

to “Product and variant information” and the
booklet “Power Take-Offs and Hydraulic Pumps”.

• Essential dimensions with the power take-off fitted

to the vehicle, please refer to “Supplementary
Drawings”

• Wiring diagram for connecting a power take-off to

Geartronic and Powertronic gearboxes, please refer
to Body builder instruction “Vehicle electronics”.

• Power take-off working conditions and parameter

settings, please refer to Body builder instruction
“Vehicle electronics”.

It is important to dimension an optimum hydraulic system, Note: The body builder should enclose an information
and to specify the correct pump size to provide sufficient binder, delivered with the truck, including hydraulic
oil flow and prevent overloading of the power take-off. For system data (system dimensioning description and
recommended instructions, please refer to: “Dimensioning dimensioning criteria).
of hydraulic system and hydraulic pumps” page 32. Service, function and safety descriptions should also
be enclosed.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 3(42)

Power take-off
There is a number of different power take-off variants
available, with single or double outlets. The power take-off
is supplied with either a flange connection and/or a direct
connection to the hydraulic pump (opening with a splined
DIN connection).

Power take-offs are classified into two family variants:

Clutch dependent and Clutch independent

Abbreviations
D
PTR = Single power take-off gearbox, rear mounted (Power take-off Transmission Rear). All are
rear-facing.
PTRD = Double power take-off gearbox, rear mounted (Power take-off, Transmission, Rear mounted,
Double).
PTOF = Flywheel mounted power take-off (Power Take-off Flywheel). (FM9, FM12 and FM13). This
variant is available with rear-facing flange or opening for hydraulic pump located at twelve o’ clock.
PTPT = PowerTronic power take-off (PowerTronic Power Take-off). Torque converter mounted. Available
with rear-facing flange or opening for hydraulic pump, both located at one o’clock (seen from
rear of gearbox).
PTES = Engine mounted power take-off (Power Take-off Engine Side). The pump is connected directly to
a timing gear. The variant is always delivered complete with its hydraulic unions prepared.
PTER = Engine mounted power take-off located at the rear end of the engine (Power Take-off Engine
Rear.)
EPTT = Maximum permitted torque on engine power take off (Engine Power Take off Torque)
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 4(42)

Clutch dependent power take-off

Clutch dependent power take-offs are designed to work
when the truck is parked. Common applications are
tipping trucks, mobile cranes, tank trucks etc. They are
mounted on the gearbox and stop working when the
clutch pedal is depressed.

Note: The clutch pedal must be depressed to engage or

disengage the power take-off.

•
•
•
PTR-XX

PTRD-XX

PTR-X
D T4006562

PTR-FH

Clutch independent power take-off

A clutch independent power take-off is mainly used when
work is to be done when driving. Refrigerators, hook lifts,
concrete mixer, snow ploughs/sand spreaders etc. They
are designed to be installed either on the engine or the
flywheel.

Flywheel PTO
A flywheel mounted power take-off is either driven from
the flywheel or as a sandwich unit, installed between
the engine and the gearbox. It is driven via a hydraulic
multi-plate clutch.

• PTOF-XXX

• PTPT-X

T4021278

PTPT (V1805PT, V2006PT, 2506PT)

T4006510

PTOF

T4012377

PTPT (V1605PT, V1705PT, V1706PT, V1906PT,

V2206PT)
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 5(42)

D
Engine PTO
An engine mounted power take-off is mounted on the rear
of the timing cover.

D12
On the D12, the engine PTO comes together with a
hydraulic pump:

• PTES-XXX

D9, D13, D16

On the D9, D13 and D16 engines the power take-off is
ordered separately, either as:

• PTER-DIN (DIN5462/ISO7653 connection)

• PTER1300 (flange SAE1300) (not D13)

• PTER1400 (flange SAE1400)

The hydraulic pump (variants HPE-XXX) is ordered

separately on these engines together with PTO variant
PTER-DIN:

• PTER-DIN + HPE-XXX
(Engine power take off together with engine mounted
hydraulic pump)

Note: Former variant names are changed.

PTER-FXX/-VXX are replaced by PTER-DIN +
HPE-FXX/-VXX.

T4019448

PTER-DIN + HPE-FXX
T9008395

PTER-DIN
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 6(42)

Power take-off, performance

Gearbox mounted power take-off
B = Backward
YB = Outer shaft, backward
YF = Outer shaft, forward
IB = Inner shaft, backward

Power
take-off

PTR - FL
Type

Flange
Connection
Dimension

SAE1300
Direction of
rotation 1 2 3

1
D Power take-
off, direction
Max torque
(Nm)

400
Max power
(kW)

PTR - FH
DIN5462 / ISO
PTR - D Direct 2 B 600 65
7653
PTR - DM DIN 5462 / ISO
Direct 1 400
PTR - DH 7653

PTRD - F Flange SAE1400 2

YB

Direct 6 3 YF
DIN 5462 / ISO
PTRD - D
Direct 6 7653 YB 4 5
2 550 90
6
Direct DIN 5462 / ISO 3 YF
7653
PTRD - D1
Flange SAE1400 2
YB

6 4 5
Direct DIN7653 3 YF See table 100
below
YB
PTRD - D2 SAE1300 2

Flange
SAE1400 1
IB

1
Counter clockwise when facing back of engine
2
Clockwise when facing back of engine
3
Counter clockwise when facing front of engine
4
A gearbox oil cooler is required if power taken exceeds 75 kW for more than 15 minutes.
5
The total power inner and outer shaft must not exceed 100 kW.
6
Max suitable pump.Forward facing outlet: V/VO 1708, 2009, 2214, 2514, 2814, 2412IS without retarder F1-61; with retarder F1-101. V/VO
2412AT, 2512AT, 2812AT, 3112AT F1-101. No VP1 variable pump is possible.

Maximum PTO torque PTRD-D2 Maximum PTO torque PTRD-D2

Inner shaft Outer shaft (sum of front Inner shaft Outer shaft (sum of front
and rear PTO) and rear PTO)
1000 150 500 380
900 195 400 425
800 240 300 470
700 285 200 520
600 330 130 550
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 7(42)

Speed ratios for gearbox mounted power take-offs

Speed ratio: 1:X.x (1: = engine, X.x = power take-off)
L = Low gear
H = High gear

Power
take-off

PTR-FL
PTR-FH
Power
take-off
weight
(kg)

16.0
15.0
V1708/
V2009

1:0.73
1:1.23
L
V2214/
V2514/
V2814
H
D
1:0.91
1:1.54
V02214/
V02514

L H
1:1.14
1:1.91
L
1:0.73
1:1.23
V2412IS

H
1:0.93
1:1.57
L
VO2814

1:0.92
1:1.56
H
1:1.16
1:1.96
PTR-D 6.5 1:0.70 1:0.88 1:1.10 1:0.70 1:0.90 1:0.89 1:1.12
PTR-DM 13.0 1:1.06 1:1.32 1:1.65 1:1.06 1:1.35 1:1.34 1:1.68
PTR-DH 13.0 1:1.23 1:1.54 1:1.91 1:1.23 1:1.57 1:1.56 1:1.96
PTRD-F 19.0
PTRD-D 20.0
PTRD-D1 26.0 1:1.30 1:1.62 1:2.02 1:1.30 1:1.65 1:1.64 1:2.06

PTRD-D2
Outer
PTRD-D2 32.0
Inner, 1:0.60 1:0.75 1:0.94 1:0.60 1:0.77 1:0.76 1:0.95
flange

Power take-off Power take- V2412AT /

VO2512AT/
off weight V2512AT/
VO3112AT
(kg) V2812AT
L H L H
PTR-FL 16.0 1:0.73 1:0.93 1:0.93 1:1.18
PTR-FH 15.0 1:1.23 1:1.57 1:1.57 1:2.00
PTR-D 6.5 1:0.70 1:0.90 1:0.90 1:1.15
PTR-DM 13.0 1:1.06 1:1.35 1:1.35 1:1.72
PTR-DH 13.0 1:1.23 1:1.57 1:1.57 1:2.00
PTRD-F 19.0 1:1.30 1:1.65 1:1.65 1:2.10
PTRD-D 20.0 1:1.30 1:1.65 1:1.65 1:2.10
PTRD-D1 26.0 1:1.30 1:1.65 1:1.65 1:2.10
PTRD-D2 Outer 1:1.30 1:1.65 1:1.65 1:2.10
PTRD-D2 Inner, 32.0
1:0.60 1:0.77 1:0.77 1:0.98
flange
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 8(42)

Flywheel mounted power take-off

Speed ratio: 1:1 (1: = engine, X.x = power take-off)

PTOFLY

1
Power
take-off

PTOF-DIF
PTOF-DIH
Connection
Type

Flange
Direct
Dimension

SAE1400
DIN5462 / ISO7653
Counter clockwise when facing back of engine
D
Direction of
rotation 1

1
Max
torque
(Nm)

800
<15
min-
utes

110
Max power (kW)
>15
min-
utes

60
With oil
cooler

110

V1605PT, V1705PT, V1706PT, V1906PT, V2206PT (Powertronic)

Power Connection Max power (kW)
take-off Max
Type Dimension Direction of <15 >15
torque With oil
rotation 1 min- min-
(Nm) cooler
utes utes
PTPT-F Flange SAE1400
1 650 - 100 -
PTPT-D Direct DIN5462 /ISO7653
1
Counter clockwise when facing back of engine

V2506PT, V2006PT, V1805PT (Powertronic)

Power Connection Direction of Max torque (Nm) Max power (kW)
take-off rotation 1
Type Dimen- 600–1000 rpm >1000 Air crash tender >2 min-
sion rpm only utes
>1500 <2
rpm minutes
<2
minutes
Flange SAE1400 600 rpm 650
PTPT-F 700 rpm 700
1 800 rpm 750 850 1050 200 130
Direct DIN5464 900 rpm 800
PTPT-D 1000 rpm 850
/ISO7653
1
Counter clockwise when facing back of engine
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 9(42)

Engine mounted power take-off

Speed ratio: 1:X.x (1: = engine, X.x = power take-off)

Engine

D9

D12
Speed ratio

1:1.08

1:0.97
Direction of
rotation 1

D Max permissible torque (Nm) 2

< 5 km/h 1000

> 5 km/h 650
< 5 km/h and including load from
other PTO’s: 600 Nm, otherwise
430 Nm (regardless of speed and
load from other PTO’s)
Power take-off

PTER-xxx

PTES-XXX

D13A 1:1.26 PTER-XXX +

650
EPTT650
1

PTER-XXX +
1000
EPTT1000
D16C PTER-XXX +
1:1.15 650
-W0616 EPTT650
PTER-XXX +
D16C 650
EPTT650
W0617- 1:1.26
+ D16E PTER-XXX +
1000
EPTT1000
1
Counter clockwise when facing back of engine
2
The engagement of the hydraulic pump must not give any pressure peaks exceeding the rated pressure.

Note: Low stiffness of the prop shaft and big inertia on

the pump will give low resonance frequency, which can be
triggered by the frequency in the engine.
The engagement time has to be so long that no pressure
peaks will occur, and the best way to verify this is to
measure the pressure close to the pump.

Resonance frequency
The minimum torsional resonance frequency is 300 Hz for
the system propeller shaft to PTO pump. Failure to this
demand can cause severe damages to the engine.

Resonance frequency (f) for a propeller shaft driven PTO Example:

is calculated as:

1
rk k = 2,8 x 105 Nm/rad
J = 0,05 kgm2
f=
2 22 J
s
f = resonance frequency (Hz) 1 2:8 2 10 5
k = stiffness of prop shaft and coupling(s) (Nm/rad) f=
2 2 
2 0:05
= 377 Hz
J = hydraulic pump and coupling mass moment of
inertia (kgm2)
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 10(42)

Hydraulic pumps
Abbreviations

•
•
HPE
HPG

Pump connections
=
=

Plugged-in pumps
Flange mounted
D
Hydraulic pump mounted to an engine power take off (Hydraulic Pump Engine mounted).
Hydraulic pump mounted to a gearbox power take off (Hydraulic Pump Gearbox mounted).

There are two types of connections for hydraulic pumps:

Plugged-in pumps
Plugged-in pumps are connected directly to the power
take-off via a splined shaft. Connection is done according
to DIN5462/ISO 7653 standard.

The VP1- and F1 Plus pumps are available for plugged-in

mounting.

T4006560

“Plugged-in”

Flange mounted pumps

The hydraulic pumps can also be connected to the power
take-off via a propeller shaft. Connection is done to a
flange according to SAE 1300 or SAE 1400 standard.

The VP1- and F1 Plus pumps are possible to connect

to a propeller shaft.

T9006112

Flange mounted
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 11(42)

Pump types
The following pump types are available from Volvo:

• Pumps with fixed displacement

• Pumps with variable displacement
Fixed displacement pump
This type of hydraulic pump is adapted for a single circuit
system with fixed volume.

The fixed displacement pump consists internally of one or

two single circuit(s), from the suction port to the pressure
port(s).
D
Examples:

• HPE / HPG-F41 (Parker F1-41)

• HPE / HPG-F51 (Parker F1-51)
• HPE / HPG-F61 (Parker F1-61)
• HPE / HPG-F81 (Parker F1-81)
• HPE / HPG-F101 (Parker F1-101)
• HPE-T53 (Parker F2-53/53)
• HPE-T70 (Parker F2-70/35)

Variable displacement pump

This type of hydraulic pump is also adapted for a single
circuit system, from the suction port to the pressure
port, but with variable displacement. When installed in a
load sensing system, the variable displacement pump
(VP1) supplies the correct amount of flow required by the
various work functions currently engaged. This means
that the energy consumption and heat generated are
minimized and much reduced in comparison with a fixed
displacement pump used in the same system.

Examples:

• HPE-V45 (Parker VP1-45)

• HPE-V75 (Parker VP1-75)
• HPE / HPG-V120 (Parker VP1-120)
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 12(42)

Installation
CAUTION
Hoses and pipes should not be routed too near the
warm points in the truck. Avoid crossed pipes which
could cause chafing. (Risk for fire if a leakage should
occur and the transfer of heat to the hydraulic oil).
D
4x4, 6x6 All wheel drive
All gearbox mounted PTO’s are possible to use for
all wheel drive vehicles, except for PTR-FL, PTR-FH,
PTRD-F, PTRD-D1 and PTRD-D2. (There are no space
for propeller shaft from PTO due to transfer box.)

The two power take-offs for automatic (Powertronic)

gearbox (PTPT-F and PTPT-D) are available as options.

Engine mounted hydraulic pump with

VT2006PT/VT2506PT is not available from fac-
tory (lack of space).

The direct driven power take-offs (PTOF-DIF and

PTOF-DIH), which are installed between the engine and
a manual gearbox, could not be installed because the
distance between the transfer box and the rear of the
gearbox is too short.

Engine PTO in combination with I-Shift and Geartronic

V2214, V2514, V2412IS
The power take-off could only be engaged when the
truck is standing still or driven on one selected gear.
The reason for this is that the power for changing
gears not could be controlled otherwise. This type of
installations are similar to the gearbox mounted PTO’s
in this matter.

V2412AT, V2512AT, VO2512AT, V2812AT, VO3112AT

On the new I-shift the power take-off could be engaged
during driving, but to large loads can cause gear shift
problems. To avoid this, engine PTO loads while driving
should be limited to:

Engine Maximum torque (Nm)

D9 200
D13 300
D16 300

Note: An example of an application that is not allowed is

Refuse trucks, if compacting during gear shift and using
higher torque than maximum limitation (see table above).
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 13(42)

Double front axle system, 8x2, 8x4

Choice of power take-off / hydraulic pump
Some combinations of engine/gearbox/power take-off and
engine/gearbox/power take-off with rear-mounted pumps
can not be used on 8x2 and 8x4 chassis. This is because
of the risk of damage to gearbox, power take-off, pump
and hydraulic connections due to the second steering
axle. Recommended combinations are found in the table
below.
Note: Power take-off PTRD-D has a forward-facing
opening for a pump which can be installed in line with
the gearbox.
D
This opening is not affected by the second steering axle,
but check that a power take-off is permissible.

Combinations possible to build with FAS1795

FAS = Front axle spread
BI = Backward installation
FI = Forward installation
X = Chosen variant
N.A. = Not applicable – (conflict with front axle)

PTR-D, PTR-DM, PTR-DH, PTRD-F

Engine Gearbox PTR-D PTR-DM PTRD-F
PTR-DH

BI BI BI
D9 V2009 HPG-F101 HPG-F101 Flange
V2214 HPG–F61 HPG–F61 Flange
VO2214 HPG-F61 HPG-F61 Flange
V2412 HPG-F101 HPG-V120 Flange
V2412AT HPG-F101 HPG–V120 Flange
V2512AT HPG-F101 HPG-V120 Flange
D12 V2009 HPG-F101 HPG-F101 Flange
V2214 N.A. N.A. Flange
VO2214 N.A. N.A. Flange
V2412 HPG-F101 HPG-V120 Flange
D13 V2009 HPG-F101 HPG-V120 Flange
V2214 HPG-F101 HPG-F101 Flange
VO2214 HPG-F101 HPG-F101 Flange
V2514 HPG-F101 HPG-F101 Flange
VO2514 HPG-F101 HPG-F101 Flange
V2412AT HPG-F101 HPG-V120 Flange
V2512AT HPG-F101 HPG-V120 Flange
VO2512AT HPG-F101 HPG-V120 Flange
D16 V2814 N.A. N.A. N.A.
VO2814 N.A. N.A. N.A.
V2812AT HPG-F101 HPG-F101 N.A.
VO3112AT HPG-F101 HPG-F101 N.A.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 14(42)

D
FAS = Front axle spread
BI = Backward installation
FI = Forward installation
X = Chosen variant
N.A. = Not applicable – (conflict with front axle)

PTRD-D, PTRD-D1, PTRD-D2

Note: Variants PTRD-D1/-D2 together with double front
axle are not available as standard from factory.

Engine Gearbox Power take off

PTRD-D PTRD-D1/-D2
BI FI BI FI
1 1
D9 V2009 HPG-F101 HPG-F101 Flange HPG-F101
1 1
V2214 HPG-F101 HPG-F101 Flange HPG-F101
1 1
VO2214 HPG-F101 HPG-F101 Flange HPG-F101
V2412 HPG-F101 2 HPG-F101 1
Flange HPG-F101 1

2
V2412AT HPG-F101 HPG-F101 Flange HPG-F101
2
V2512AT HPG-F101 HPG-F101 Flange HPG-F101
1 1
D12 V2009 HPG-F101 HPG-F101 Flange HPG-F101
1 1
V2214 HPG-F101 HPG-F101 Flange HPG-F101
1 1
VO2214 HPG-F101 HPG-F101 Flange HPG-F101
2
V2412 HPG-F101 HPG-F101 Flange HPG-F101
1 1
D13 V2009 HPG-F101 HPG-F101 Flange HPG-F101
1 1
V2214 HPG-F101 HPG-F101 Flange HPG-F101
1 1
VO2214 HPG-F101 HPG-F101 Flange HPG-F101
1 1
V2514 HPG-F101 HPG-F101 Flange HPG-F101
1 1
VO2514 HPG-F101 HPG-F101 Flange HPG-F101
2
V2412AT HPG-F101 HPG-F101 Flange HPG-F101
2
V2512AT HPG-F101 HPG-F101 Flange HPG-F101
2
VO2512AT HPG-F101 HPG-F101 Flange HPG-F101
1 1
D16 V2814 HPG-F61 HPG-F101 N.A. HPG-F101
1 1
VO2814 HPG-F61 HPG-F101 N.A. HPG-F101
V2812AT HPG-F101 HPG-F101 N.A. HPG-F101
VO3112AT HPG-F101 HPG-F101 N.A. HPG-F101
1
See note below
2
HPG-V12, does fit but is not available from factory as standard variant.

Note: Maximum size of the hydraulic pump is:

HPG-F61 gearbox without retarder
HPG–F101 gearboxes with retarder

CAUTION
The only allowed pump mounting direction is shown in
the illustration.

T9008157
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 15(42)

Combinations possible to build with FAS1995

FAS = Front axle spread
BI = Backward installation
FI = Forward installation
N.A. = Not applicable – (conflict with first spring bracket
second front axle)

PTR-D, PTR-DM, PTR-DH, PTRD-F

Engine Gearbox
PTR-D
D PTR-DM
PTR-DH
PTRD-F

BI BI BI FI
1
V2009 HPG-F101 HPG-F101 Flange N.A.
1
V2214 HPG-F101 HPG-F101 Flange N.A.
1
V02214 HPG-F101 HPG-F101 Flange N.A.
D9
V2412IS HPG-F101 HPG-V120 Flange N.A.
V2412AT HPG-F101 HPG-V120 Flange N.A.
V2512AT HPG-F101 HPG-V120 Flange N.A.
V2009 HPG-F101 HPG-V120 Flange N.A.
V2214 HPG-F101 HPG-F101 Flange N.A.
D12
VO2214 HPG-F101 HPG-F101 Flange N.A.
V2412IS HPG-F101 HPG-V120 Flange N.A.
V2009 HPG-F101 HPG-V120 Flange N.A.
1
V2214 HPG-F101 HPG-F101 Flange N.A.
1
VO2214 HPG-F101 HPG-F101 Flange N.A.
1
V2514 HPG-F101 HPG-F101 Flange N.A.
D13 1
VO2514 HPG-F101 HPG-F101 Flange N.A.
V2412AT HPG-F101 HPG-V120 Flange N.A.
V2512AT HPG-F101 HPG-V120 Flange N.A.
VO2512AT HPG-F101 HPG-V120 Flange N.A.
V2814 HPG-F101 HPG-F101 Flange N.A.
VO2814 HPG-F101 HPG-F101 Flange N.A.
D16
V2812AT HPG-F101 HPG-F101 Flange N.A.
VO3112AT HPG-F101 HPG-F101 Flange N.A.
1
HPG-V120 does fit but is not available from factory as standard variant, the same goes for the variable pumps VP1–45 and VP1–75. Note!
Be aware of the direction of rotation.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 16(42)

D
PTRD-D, PTRD-D1, PTRD-D2
Note: Variants PTRD-D1/-D2 together with double front
axle are not available as standard from factory.

PTRD-D1
PTRD-D
Engine Gearbox PTRD-D2
BI FI BI FI
1
V2009 HPG-F101 N.A. Flange N.A.
1
V2214 HPG-F101 N.A. Flange N.A.
1
V02214 HPG-F101 N.A. Flange N.A.
D9 1
V2412OS HPG-F101 N.A. Flange N.A.
1
V2412AT HPG-F101 N.A. Flange N.A.
1
V2512AT HPG-F101 N.A. Flange N.A.
1
V2009B HPG-F101 N.A. Flange N.A.
1
V2214B HPG-F101 N.A. Flange N.A.
D12 1
VO2214B HPG-F101 N.A. Flange N.A.
1
V2412B HPG-F101 N.A. Flange N.A.
1
V2009B HPG-F101 N.A. Flange N.A.
1
V2214B HPG-F101 N.A. Flange N.A.
1
VO2214B HPG-F101 N.A. Flange N.A.
1
V2514B HPG-F101 N.A. Flange N.A.
D13 1
VO2514B HPG-F101 N.A. Flange N.A.
1
V2412AT HPG-F101 N.A. Flange N.A.
1
V2512AT HPG-F101 N.A. Flange N.A.
1
VO2512AT HPG-F101 N.A. Flange N.A.
V2814B HPG-F101 HPG-F101 2 Flange HPG-F101 2

2 2
VO2814B HPG-F101 HPG-F101 Flange HPG-F101
D16
V2812AT HPG-F101 N.A. Flange N.A.
VO3112AT HPG-F101 N.A. Flange N.A.
1
HPG-V120 does fit but is not available from factory as standard variant, the same goes for the variable pumps VP1–45 and VP1–75. Note!
Be aware of the direction of rotation.
2
See note below

Note: Maximum size of the hydraulic pump is:

HPG-F61 gearbox without retarder
HPG–F101 gearboxes with retarder
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 17(42)

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Distance to second front axle
The table below shows the distance between the front
edge of the second front axle and the mounting surface
for the power take-off on the gearbox.

The length L of each power take-off must be deducted

from the distances in the table to give the distance
between the power take-off and the second front axle.

FAS1795 (Front axle spread 1795 mm)

Engine Gearbox
V2009 V2412IS V2214/VO2214/ V2412A V2812AT
V2514/VO2514/ V2512A VO3112AT
V2814/VO2814 VO2512AT
D9 413 mm 488 mm 338 mm 511 mm 493 mm
D12 388 mm 463 mm 313 mm 486 mm 468 mm
D13 388 mm 463 mm 313 mm 486 mm 468 mm
D16 283 mm 358 mm 208 mm 381 mm 363 mm

FAS1995 (Front axle spread 1995 mm)

Engine Gearbox
V2009 V2412IS V2214/VO2214/ V2412A V2812AT
V2514/VO2514/ V2512A VO3112AT
V2814/VO2814 VO2512AT
D9 613 mm 688 mm 538 mm 711 mm 693 mm
D12 588 mm 663 mm 513 mm 686 mm 668 mm
D13 588 mm 663 mm 513 mm 686 mm 668 mm
D16 483 mm 558 mm 408 mm 581 mm 563 mm

The length of each power take-off is:

Power L (mm)
take-off

PTR-D 98

PTR-DM 120

PTR-DH 120

PTRD-D 120
PTRD-D1 226

PTRD-D2 226
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 18(42)

Accessibility of PTOF and PTPT

If a top-mounted power take-off is installed on the gearbox
and there is a fixed body building, we recommend that
a service hatch should be made in the floor as in Body
builder instructions “Attachments”.

Delivery conditions for factory installed PTO

A kit for mounting a pump on variant PTR-D, containing
sleeve, washer, retainer ring and screw is available on
cab door on left side. Kit and pump is mounted according
to the adjacent illustration.
D
T9008796

Delivery conditions for factory installed hydraulic pumps

CAUTION
Hydraulic pumps must never be in use without oil flow
in the hydraulic system.

For trucks with gearbox mounted PTO:

To prevent the possibility to engage the hydraulic pump
before definitive assembly, the following is done from
factory:

• The PTO magnetic valve outlet is blocked up by a

hexagon socket plug.
One or two valves is plugged, depending on type of
PTO.

• The valve nipple, which the body builder should

connect, is placed in a plastic bag and strapped on the
end of the pneumatic hose at magnetic valve

For pumps mounted on PTO PTR-D, and rearmounted

in outerport on PTR-D, the direction of rotation must be
changed to clockwise direction.

T9008795
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 19(42)

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For trucks with engine mounted PTO:
The hydraulic pump is always engaged; therefore
sufficient lubrication is needed continuously for the pump.

• To establish lubrication during transport from factory to

final assembly at body builder, a temporary hydraulic
transport kit is added at the factory.

• The components in the kit (tank, hoses and unions)

should be replaced; they are not dimensioned for the
working pressure in the definitive hydraulic system.

Note: The replacement must be performed in particularly

clean conditions. Dirt and other contamination which
finds its way into the hydraulic system could easily
cause severe damage.

The dimensioned drawings “Position in the truck” page 24

show where the unions for connection to the permanent
equipment is located.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 20(42)

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Temporary hydraulic transport kit

There are two different temporary kits, and the size of

the oil reservoir differs:

1. Temporary hydraulic transport kit (for fixed

displacement pumps)

Engine Amount of oil if refill is needed:

D12 1.5 ± 0.1 litre
D9/D13/D16 0.3 ± 0.05 litre
(HPE-FXX)
T9008337
D9/D13/D16 0.25 + 0.05 litre
(HPE-TXX)
2. Temporary hydraulic transport kit (for variable
displacement or customer adaptation installed hydraulic
pump)

Engine Amount of oil if refill is needed:

D9/D12 Minimum level on reservoir should be
D13/D16 achieved after that the engine is started.
Approx. 10 litre

T9008338

Connections to engine mounted hydraulic pump

A Factory delivered Factory installed connection from
the hydraulic pump. Dimension 25S (M36 x 2).

B Body builder Body builder’s connection. Hose

connection with 24 cone.

C Suction side Smallest external connection diameter

see table below:

Hydraulic pump Diameter X (mm)

PTES-FXX 50
PTES-VXX
HPE-V45
HPE-V75
HPE-FXX 63
HPE-TXX
HPG-FXX
T9008408
HPE-V120 75
X = smallest external connection diameter.
HPG-V120
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 21(42)

Installation requirements for hydraulic pump at final assembly

CAUTION
Hydraulic pumps must never be in use without oil flow
in the hydraulic system.

Fixed displacement pump, HPE-FXX (F1 single flow)

• Remove the temporary oil reservoir kit, tank, fittings
and hoses are not designed for use in high pressure
installations
D
• See to that enough oil flow (minimum 5l/min) is running
in the final hydraulic system back to the hydraulic tank
when the hydraulic pump is running unloaded. If not,
a drain line must be installed from bypass valve to
hydraulic tank entering below oil surface (to avoid
“foaming” the oil).

Fixed displacement pump, HPE-TXX (F2 twin flow)

• Remove the temporary oil reservoir kit, tank, fittings
and hoses are not designed for use in high pressure
installations.

• The drain hose from bypass valve, supplied loose

from factory, must be connected to hydraulic tank
entering below oil surface (to avoid “foaming” the oil).
Dimension of hose fitting is M12x1,5 DIN 20078N.
It is allowable to shorten the drain hose, but a new
fitting must be attached in a proper way.

Variable displacement pump, HPE-VXX (VP1)

• Remove the temporary oil reservoir kit, tank, fittings
and hoses are not designed for use in high pressure
installations.

• The bypass valve attached to the tank together

with the hose between pump and by pass
valve shall be kept and a drain hose should be
connected between port “T” and hydraulic tank.
It is allowable to shorten the drain hose between
pump and bypass valve but a new fitting (M12x1,5 DIN
20078N) must be attached to fit onto fitting in bypass
valve.

• The load signal on its way to port “LS” at the load

sensing regulator on the hydraulic pump shall be
connected in port “X” on the bypass valve as well.

• A drain line must be installed between port “T” on the

hydraulic pump and the hydraulic tank since the load
sensing regulator is not internally drained.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 22(42)

Permissible pump bending torque

The hydraulic pump mounted to a power take-off causes
bending torque at the power take-off.

A gearbox mounted power take-off as well as an engine

mounted power take-off has the following maximum
permissible torque:

PTR/PTRD/PTOF/PTPT/PTER
PTO

PTR/PTRD
Maximum bending
torque (Nm)
40
D
PTOF-DIH 40
PTPT-D 40
PTER 40

Note: If dual mounted pumps are used, the total torque

must not exceed 40 Nm.

Calculation of pump bending torque

Torque is calculated with the formula below:

Mb = m 2 g 2 A
Mb Bending moment at pump connection to power
take-off (Nm).
m Pump weight (kg).

g Normal acceleration = 9.81 N/kg.

A Distance between pump centre of gravity and

anchorage on power take-off (m).

Note: This calculation method is used irrespective of

PTO/pump location.

T9007591
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 23(42)

Propeller shaft installation

If a power take-off with coupling flange is to be used, the
pump is installed by means of a bracket, either on an
existing crossmember or on the sub-frame. An alternative
method is to install an extra crossmember and install the
pump on it. In this case, it is important to design the
crossmember so that it can withstand the forces involved
when the chassis twists and bends. The best way to
achieve this is to design the crossmember as a normal,
intermediate crossmember.

The same requirements apply to power take-off propeller

shafts as for drive line propeller shafts.
D T9006112

For best service life, the true joint angle should be kept
between 0.5 – 8 degrees.

It is important that angles β1 and β2 are equal.

T9006113

Dimensions of power take-off flanges

T9008512 W4002387

SAE1400 SAE1300
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 24(42)

Position in the truck

Note: All dimensions specified in mm.

Flywheel mounted power take-off

PTOF-DIF (flange)
The following abbreviations are used in the table and
illustrations below:
D
For information about Gearbox mounted, rear power
take-off and Powertronic power take-off please refer
to “Supplementary Drawings”.

X = Front reference hole in chassis

A = Messurement to centre of rear most edge of flange.

B – G = Represent other different measurements (see

illustrations below).

Engine A B C D E F G
D9A 164 164 FRAMEHIG
746 425 46 1988 –239
181 181 FRAMELOW
D9B 164 115 FRAMEHIG
746 425 46 1988 –228
181 132 FRAMELOW
D12 166 230 FRAMEHIG
770 425 46 1938 229
183 247 FRAMELOW
D13 163 113 FRAMEHIG
771 425 44 1988 –228
180 130 FRAMELOW

Note: On trucks with a flywheel mounted power take-off,

the gearbox crossmember has a different position to what
is shown on the chassis drawing.

T9008155

T9007095
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 25(42)

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PTOF-DIH (hydraulic)
The following abbreviations are used in the table and
illustrations below:
X = Front reference hole in chassis

A = Measurement to centre of connecting point.

B – G = Represent other different measurements (see

illustrations below).

Engine A B C D E F G
D9A 164 164 FRAMEHIG
717 425 47 1988 –239
181 181 FRAMELOW
D9B 164 115 FRAMEHIG
717 425 47 1988 –228
181 132 FRAMELOW
D12 166 231 FRAMEHIG
738 425 49 1938 229
183 183 FRAMELOW
D13 163 113 FRAMEHIG
738 425 46 1988 –228
180 130 FRAMELOW

Note: On trucks with a flywheel mounted power take-off,

the gearbox crossmember has a different position to what
is shown on the chassis drawing.

T9008154

T9007097
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 26(42)

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Engine mounted power take-off
The following abbreviation is used in the illustrations
below:
FA = Front Axle FAA10/FAA20 (FAA11 gives a
substraction of 100 mm (-100)

T9008395

Engine D9
Measurement (mm) Measurement (mm)
Nipple suction side Nipple pressure side
A B C D E F
PTER-DIN + 754 384 23 670 391 78 FRAMEHIG
HPE-F41/-F51/-F61
40 95 FRAMELOW
(PTER-F41/-F51/-F61)
PTER-DIN + 804 395 31 723 404 80 FRAMEHIG
HPE-F81/-F10
48 97 FRAMELOW
(PTER-F81/-F10)
PTER-DIN + 821 309 210 744 / 780 1 197 / 169 1 176 / 161 1 FRAMEHIG
HPE-T53/-T70 1
227 193 / 178 FRAMELOW
PTER-DIN + 716 321 43 696 417 105 FRAMEHIG
HPE-V45/-V75
60 122 FRAMELOW
(PTER-V45/-V75)
Centre of connection
PTER-DIN 438 236 8 FRAMEHIG
25 FRAMELOW
Centre of flange
PTER1300 30 FRAMEHIG
PTER1400 484 241
47 FRAMELOW
1
Inner port/Outer port
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 27(42)

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Engine D13
Measurement (mm) Measurement (mm)
Nipple suction side Nipple pressure side
A B C D E F
PTER-DIN + 754 382 11 670 399 64 FRAMEHIG
HPE-F41/-F51/-F61
28 81 FRAMELOW
PTER-DIN + 804 394 16 722 413 62 FRAMEHIG
HPE-F81/-F10
33 79 FRAMELOW
1 1 1
PTER-DIN + 840 383 13 752 / 773 420 / 399 67 / 97 FRAMEHIG
HPE-T53/-T70 1
30 84 / 114 FRAMELOW
PTER-DIN + 717 323 44 695 430 84 FRAMEHIG
HPE-V45/-V75
60 101 FRAMELOW

PTER-DIN + 820 427 29 735 269 99 FRAMEHIG

HPE-V120 46 116 FRAMELOW
Centre of connection
PTER-DIN 440 237 44 FRAMEHIG
61 FRAMELOW
Centre of flange

PTER1400 41 FRAMEHIG
486 237
58 FRAMELOW
1
Inner port/Outer port

Engine D16C (—W0616)

Measurement (mm) Measurement (mm)
Nipple suction side Nipple pressure side
A B C D E F
PTER-DIN + 862 406 42 777 425 93 FRAMEHIG
HPE-F41/-F51/-F61
59 110 FRAMELOW
(PTER-F41/-F51/-
F61)
PTER-DIN + 911 418 46 829 439 91 FRAMEHIG
HPE-F81/-F10
63 108 FRAMELOW
(PTER-F81/-F10)
PTER-DIN + 824 349 94 797 455 112 FRAMEHIG
HPE-V45/-V75
111 129 FRAMELOW
(PTER-V45/-V75)
Centre of connection
PTER-DIN 548 263 82 FRAMEHIG
99 FRAMELOW
Centre of flange
PTER1300 105 FRAMEHIG
PTER1400 589 263
122 FRAMELOW
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 28(42)

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Engine D16C (W0617–) + D16E
Measurement (mm) Measurement (mm)
Nipple suction side Nipple pressure side
A B C D E F
PTER-DIN + 862 413 45 777 430 98 FRAMEHIG
HPE-F41/-F51/-F61
62 115 FRAMELOW
(PTER-F41/-F51/-
F61)
PTER-DIN + 911 425 50 829 444 98 FRAMEHIG
HPE-F81/-F10
67 115 FRAMELOW
(PTER-F81/-F10)
PTER-DIN + 994 453 23 886 / 907 1 474 / 453 1 80 / 110 1 FRAMEHIG
HPE-T53/-T70
40 97 / 127 1 FRAMELOW
PTER-DIN + 802 461 118 802 461 118 FRAMEHIG
HPE-V45/-V75
135 135 FRAMELOW
(PTER-V45/-V75)
Centre of connection
PTER-DIN 548 263 82 FRAMEHIG
99 FRAMELOW
Centre of flange
PTER1300 105 FRAMEHIG
PTER1400 589 263
122 FRAMELOW
1
Inner port/Outer port
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 29(42)

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HPE-F41, –F51, –F61, –F81, –F10, –T53, –T70 (fixed pump)
(PTER-F41, –F51, –F61, –F81, –F10)

T9008176

HPE-V45, –V75, –V120 (variable pump)

(PTER-V45, –V75)

T9008113
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 30(42)

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PTER-1300, –1400 (engine rear)

T9008392

PTER-DIN (engine rear)

T9008393
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 31(42)

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Engine D12
PTES-V45, -V75 (variable pump)

T9008095

PTES-F41, -F51, -F61, –F81, -F10 (fixed pump)

T9008096
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 32(42)

Dimensioning of hydraulic system and hydraulic pumps

It is important to dimension an optimum hydraulic system,

and to specify the correct pump size to provide sufficient
oil flow and prevent overloading of the power take-off.
D
Note: The body builder should enclose an information
binder, delivered with the truck, including hydraulic
system data (system dimensioning description and
dimensioning criteria).
Service, function and safety descriptions should also
be enclosed.

Pipes, lines and hoses

Connected to the hydraulic pump are a high-pressure
hose, suction and drain lines.

When dimensioning the hydraulic system, it is important

that:
• Hoses and lines must be connected to the pump with
unions. Sealing rings must be used between pump
and union.

• Teflon tape or similar must not be used since pieces

can break off and get into the hydraulic system and
eventually cause damage.

• If steel piping is used, it must be installed so that

movements and vibrations do not cause leakage.
Normally hoses should be used nearest the pump.

• Oxide scale must be removed from pipes which have

been heat-bent or welded. Flush or blow the pipes
clean before installing them.

CAUTION
Hoses and pipes should not be routed too near the
warm points in the truck. There are two reasons for
this, namely risk for fire if a leakage should occur, and
the transfer of heat to the hydraulic oil.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 33(42)

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High-pressure hose
These hoses must have a minimum of four steel wire
coil inserts in order to withstand the high pressure in the
hydraulic system.

When mounting an high-pressure hose:

• Make sure the hoses are not twisted when connected
up.

• Make sure the hoses are long enough.

• Strive to get as few bends as possible on a hose.

• Avoid kinks by using correct unions. Only pressed

unions may be used when replacing hose unions.

Note: Check for oil leakage and for high noise levels in
the system when the truck is in motion.

Suction line
The suction line is made of piping or armoured hose which
retains its shape even when there is vacuum in the line.

To avoid cavitation:
• The suction line should be as short as possible and
should not exceed 4 metres. In the event longer lines
are required, larger line dimensions must be used.

• The suction line should connect to the bottom of the

tank and must be correctly tightened to prevent air
getting into the oil.

• The suction line must have a wide diameter and must

be free from kinks and constrictions.

Note: Avoid suction lines of high-pressure hooks and

hooks made locally from pipe pieces welded together.
They could cause unnecessary suction resistance.

Suitable suction line sizes at different flow quantities and

with a flow speed of less than 0,8 m/s:

Inner diameter Ø (mm) Flow up to litre/minute

50 0–120
64 101–150
75 > 150
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 34(42)

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Drain line and bypass valve
If the hydraulic pump is installed to a constantly running
PTO, it is provided with a bypass valve.

The bypass valve reduces the oil flow through the pump
to obtain low heat generation and to avoid cavitation.

Fixed displacement pump

HPE-FXX (F1 single flow)
In order to prevent heat build-up in the pump during
transportation, it is important that at least 5 litre/minute
comes out of the filter at “q” (refer to the schematic below).
This applies to an “open centre” system when the valve is
in the bypass mode (non-activated solenoid).

Note: It the flow at “q” is less than 5 litre/minute (caused

e.g. by a high pressure drop in the main system) when
the valve is in the bypass mode or if the hydraulic system
is of the “closed centre” type, then an external drain
line must be installed from the bypass valve drain port
directly to the hydraulic tank.

HPE-TXX (F2 twin flow)

In order to secure a cooling flow through the system, a
separate drain line is already connected to the bypass
valve from factory and the other end of the hose is
temporary plugged. At final assembly the hose should be
connected to the hydraulic tank, entering below oil level
(preferable to the filter housing on the oil tank).

Bypass valve
For the fixed displacement hydraulic pumps the bypass
valve is attached directly on top of the end cap of the
hydraulic pump. It is electrical operated and the valve
function must only be activated or released at no-load
(below 20 bar) system pressure.

For F2- twin flow hydraulic pump it can be used when,

temporarily, one of the two circuits is not required; the
power loss is thus reduced as the non-required flow is not
forced through lines and “open centre” valves
1 Pilot operated check valve
2 Solenoid valve
3 Directional control valve (“open centre”)
T9008080
4 Hydraulic pump
HPE-FXX
5 Valve block
6 Drain port
7 (External line)
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 35(42)

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Variable displacement pump
HPE-VXX (VP1)
At final assembly, since the control valve on the hydraulic
pump is not internally drained, there must be an external
drain line installed between port “T” and the hydraulic
tank.

Bypass valve
For variable displacement pump the bypass is, from
factory, attached to the temporary oil reservoir and
connected to the hydraulic pump via a hose to the port for
gauge outlet, (on VP1-45 and VP1-75 port beside suction
port and on the VP1-120 port “M”on the control valve).

The valve, which requires no additional control valve,

allows the pump to operate on- or off-load up to its
maximum self–priming speed.

When a load sensing valve function is engaged, the

bypass flow is cut off (as port ’X’ is being pressurized).
1 Hydraulic pump
2 Nipple with orifice
3 Bypass valve
4 Load sensing valve
5 Load sensing (LS) signal

T9008497

HPE–V120
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 36(42)

Hydraulic oil tank

The tank must be large enough to avoid cavitation and
overheating. A suitable volume is 1,5 times the nominal
pump flow per minute.

The tank includes:

1 Air filter, fitted (as required) in a tube and provided with
a non-return valve
2 Level gauge
3 Suction connector equipped with full-flow tap
4 Angled, perforated plate on which air bubbles
accumulate and rise to the surface
5 Return oil filter
D
When installing a hydraulic tank: T9008314

• The volume of the hydraulic tank must be dimensioned

1,5 times the nominal pump flow during normal working
conditions.

• Make sure that the placing of the hydraulic tank does

not limit the performance of the hydraulic pump.
For example: The suction fitting must not be placed
below the inlet of the return pipe.

• It is important that the deaeration surface is big

enough. Prevent external dust and dirt from entering
the hydraulic system. The inside of the tank must be
well cleaned. To prevent dust getting into the system,
the air filter should have the same filtration degree as
the return oil filter.

• Oil is topped-up through the return oil filter, preferably

via a rapid joint on the return line where the oil can
be pumped in.

• Check oil level and ensure that it is oil of recommended

type and viscosity.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 37(42)

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Return oil filter
A return oil filter should be installed in the tank or in the
return line. The filter should be dimensioned for a capacity
which is approx. twice that of the pump flow.

Recommended filtration level:

• 25 µm (absolute) in clean environment or at low
pressures (0–200 bar).
• 10 µm (absolute) in contaminated environment or at
high pressures (200–300 bar).

Check return pipe and filter condition and check for oil
leakage.

Note: The filter must be replaced at least once a year.

Hydraulic oil
Hydraulic fluids type HLP (DIN51524), ATF (automatic
transmission fluid) and engine oil type API/CD can be CAUTION
used.
Do not mix oils of different quality.
Recommended viscosity:
• 20-30 mm²/s (cSt).

Starting up
Make sure the entire hydraulic system is clean before
filling it with a recommended fluid. In particular the pump, CAUTION
which must be purged to remove any entrapped air in the
pump housing (use the uppermost purge port). Make sure the suction connector always is below the
minimum level of the hydraulic oil.
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 38(42)

Calculation of hydraulic pump size

The following information is required to dimension the
hydraulic system:

•
•
•
•
•
Oil flow Q (l/min), to the equipment

Oil pressure p (bar), to do the work intended

Permissible torque or power taken from the engine

Permissible pump speed

PTO Gear ratio

D
Control the pump environment with the Parker
calculation program.
Go to Introduction on the VBI homepage, choose
Software requirement and click on Parker.

Engine speed
Engine speed limit for engine mounted hydraulic pumps
Vehicles specified with engine mounted hydraulic pumps
will always have a maximum engine speed (rpm) pre set
from factory.

Depending of pump size and if the vehicle is equipped

with BBM (Body Builder Module) or not, the setting is
between 1700–2500 rpm.
This has been done by using data parameters in the
vehicle control unit, and when the hydraulic pump is in
service, the maximum engine speed cannot be overridden
by pressing the throttle.

If the hydraulic system is designed in such way that the

self-suction speed of the hydraulic pump is reduced, then
the limited value should be modified using VCADS Pro or
Body Builder Pro software.

Engine speed control

Check that the permissible speed, specified by the pump
manufacturer on the pump, is not exceeded.

Pump speed per minute n is governed by engine speed

ne and power take-off gear ratio Z:

n = ne 2 Z
n = Pump speed (rpm)
ne = Engine speed (rpm)
Z = Power take-off gear ratio
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 39(42)

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Pump speed
The maximum (self-suction) speeds given in the catalogue
apply at 1.0 bar (abs.) intake pressure.

To achieve correct pump speed the following is required:

• Oil level approx. 0.5 m above pump inlet

• Correctly dimensioned suction pipe

• Original suction nipple

• Correctly designed hydraulic fluid reservoir

The flow speed in the suction pipes should be less than

1 m/s. Poor suction conditions lead to cavitation, high
noise levels, shorter operational lifetime and, in the worst
case, pump failure.

Pump capacity
The pump capacity or size D (cm³/rotation) should be able Control the pump environment with the Parker
to give sufficient oil flow Q (l/min) for the equipment. The calculation program.
choice of size depends on the oil flow required, engine Go to Introduction on the VBI homepage, choose
speed and power take-off gearing. A small pump can give Software requirement and click on Parker.
a large oil flow if the power take-off gear ratio is large, or if
the engine speed is high.

Pump size is calculated as:

D 2 n 2 v Q 2 1000
Q= <=> D =
1000 n 2 v

n = Pump speed (ne x Z)

D = Pump size (cm³/rotation)
ne = Engine speed
Q = Oil flow (l/min)
Z = Power take-off gear ratio
ηv = volymetric efficiency
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 40(42)

D
Torque control
A certain torque, Mku is required from the power take-off
at the pump shaft to drive the pump. This torque must
not exceed the permissible torque for the power take-off.
Expressed in Nm, this torque is:

D2p
Mku = < Mku; till:
63 2 hm

Mku = Torque at power take-off (Nm)

D = Pump size (cm³/rotation)

p = Hydraulic working pressure (bar)

Mku, till. = Permissible torque for the power take-off

(Nm)

ηhm = Mechanical efficiency

< = Less than

Torque control, engine

Torque control of the engine Mmot must not exceed the
permissible torque for the engine (please refer to Body
builder instructions “Power take-off, performance”) at a
given engine speed.
Engine torque is equal to power take-off torque x gear
ratio.

Mmot =Mku 2 Z<Mmot; till:

Mmot = Engine torque (Nm)

Z = Power take-off gear ratio
Mku = Torque at power take-off (Nm)
Mmot, till. = Permissible engine torque (Nm)
< = Less than

Power requirements
The power N needed to drive the pump is proportional to
the flow and working pressure and inversely proportional
to the efficiency of the pump η.

Check that pump power curve, to see that it has the

capacity needed to provide the calculated power N.

Q2p
N=
600 2  t

N = Power (kW)
Q = Flow through pump (l/min)
p = Working pressure (bar)
ηt = Overall pump efficiency(app. 0.95)

 t=v 2  hm:
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 41(42)

Flow:
Pressure:
Engine rpm:
PTO ratio:

Determine the pump speed

60-80 l/min
230 bar
800 rpm
1:1.53
D
Example 1 (Tipper), Selecting pump size clutch dependent PTO
Operating conditions

n = ne x Z=800 x 1.53 = 1200 rpm

Choosing the pump size

D 2 n 2 v Q 2 1000 70 2 1000
Q= . D= . =60 cm3 =rotation
1000 n 2 v 1200 2 0; 98
Select F1-61 and check torque and power.

Torque requirement of the pump

D2p
Mku = = 59; 5 2 230 =222 Nm
63 2 hm 63 2 0; 98

Power requirement of the pump

Q2p
N= = 70 2 230 = 28 kW
600 2 t 600 2 0; 95
Volvo Truck Corporation Date Group Release Page
Body builder instructions 2.07 95 04 42(42)

D
Example 2 (General crane), Selecting pump size clutch independent PTO
Operating conditions
Flow: 80 l/min
Pressure: 250 bar
Engine rpm: 800 - 900 rpm
PTO ratio: 1:0.97

Determine the pump speed

n = ne x Z = 800 x 0,97 = 800 rpm

Choosing the pump size

D 2 n 2 v Q 2 1000 80 2 1000
Q= . D= . =102 cm3 =rotation
1000 n 2 v 800 2 0; 98
Select F1-101 and check torque and power.

Torque requirement of the pump

D2p ; 9 2 250
M=
63 2 hm
= 102
63 2 0; 98
= 417 Nm

Power requirement of the pump

Q2p
N= = 102 2 250 = 45 kW
600 2 t 600 2 0; 95