R3 - Group 200

See IE: Specifications

General

The specification given below is primarily a specification of differences for gas engine G9A.
Gr 24 also includes the tank system.

Engine performance

Engine designation G9A 260 G9A 300

Net power at 1900-2000 rpm 191kW 221kW

Net power according to ISO 1585. The smoke requirements in ECE (260hp) (300hp)
reg. 24, Federal Register and Swedish regulations are complied with.
Engine designation G9A 260 G9A 300

Max torque, 1400 rpm 1200 Nm

Max torque, 1400 rpm 1400 Nm

Compression ratio 10,25:1

Compression pressure at starter motor speed, measured with a warm about 1.2 MPa
engine at full throttle

Note: Use up all gas in the engine line and remove all sparkplugs
before measuring compression with gauge 9999691 and adapter
88810018

Low idle 600 rpm (10 rps)

Maximum revs 2220 rpm (37 rps)

Charge pressure at stalling rpm, tolerance 15 KPa and 100 rpm Gearbox ZF HP

260hp 215 kPa at 1650 rpm

300hp 240 kPa at 1750 rpm

Charge pressure at stalling rpm, tolerance 15 KPa and 100 rpm Gearbox Voith

260hp 205 kPa at 1520 rpm

300hp 240 kPa at 1580 rpm

Measurements

Number of cylinders 6

Cylinder bore 120 mm

Stroke 138 mm

Swept volume 9.4 dm³

Firing sequence 1-5-3-6-2-4

 Direction of rotation Clockwise

Compression ratio 10,25:1

Weight of engine with flywheel, flywheel casing without starter motor (dry) approx. 980 kg

Maximum length 1263 mm

Maximum width 745 mm

Maximum height 1113 mm

Engine

Engine block

Specifications

Length 967 mm

Height, upper block face - crankshaft centre 391 mm

Height, lower block face - crankshaft centre 379 mm

Crankcase pressure

normal value when idling, warmed up engine <1.0 kPa

Cylinder head

Type 6 cylinder

Length 996 mm

Width 410 mm

Height 135 mm

Max unevenness (base plane) 0,1 mm

Cylinder head bolt

Quantity/cylinder head 26

Thread size M16

Length 200 mm

Cylinder liner

Type Wet, exchangeable

Total height 250 mm

Height of sealing surface above block face 0.15 - 0.20 mm

Number of sealing rings per cylinder liner 3

Piston

Type aluminium

Number of ring grooves 3

Front marking Arrow facing forwards

Gudgeon pin diameter 54 mm

Piston rings
Compression rings Specifications Wearing tolerance

Quantity 2 -

Piston ring clearance in grooves:

upper compression ring (t=3.50), colour Red 0.08 - 0.13 mm -

lower compression ring (t=3.00), colour Pink 0.08 - 0.14 mm -

Piston ring gap measured in ring opening:

upper compression ring 0.40 - 0.60 mm -

lower compression ring 0.50 – 0.70 mm -

Oil scraper ring

Quantity 1

Width including spring 3.58 mm -

Piston ring clearance in grooves 0.05 - 0.10 mm -

Piston ring gap measured in ring opening 0.35 - 0.75 mm -

Valve mechanism

Valves
 Specifications

Valve head, diameter:

Inlet 35 mm

Exhaust 34 mm

Valve stem, diameter:

Inlet/Exhaust 8 mm

Valve seat angle (A):

Inlet/Exhaust 29.5°

Seat angle in cylinder head (B):

Inlet/Exhaust 30°

Measurement between valve head and cylinder block face:

Inlet 1.34 ± 0.25 mm

Exhaust 0.64 ± 0.25 mm

Note: The valves must also be replaced when replacing the valve seats.
Valve clearances, cold engine, setting values:

Inlet 0.2 mm

Exhaust 0.8 mm

Valve clearance cold engine, checking value:

Inlet 0.15 - 0.25 mm

Exhaust 0.75 - 0.85 mm

Valve seats

Specifications

Outer diameter (A)

Standard:

Inlet 42.08 mm

Exhaust 40.07 mm

Height (B):

Inlet 7.4±0.1 mm.

Exhaust 6.4±0.1 mm.

Valve seat inlet, location in cylinder head

When replacing the inlet valve seat it is of great importance that the swirl location is correct. The
angles for the locations are given in the illustration on the left:
Short Port 20±5°, and Long Port 32±5°.

Valve seat position

Diameter (C) standard:

Inlet 42.0 mm

Exhaust 40.0 mm

Diameter (C) oversize:

Inlet 42.2 mm

Exhaust 40.2 mm
Seat bottom radius (R):

Inlet/Exhaust max 0.8 mm

Valve guides

Valve guides of type bottle shape Specifications Wear tolerance

Length:

Inlet/Exhaust 83.5 mm -

Inside diameter:

Upper end, against rocker arm max 8.015 mm -

Lower end, against valve max 8.035 mm -

Height above sealing surface of cylinder head:

Inlet 151.5 ± 0.75 mm -

Exhaust 151.5 ± 0.75 mm -

Clearance valve stem-guide:1

Inlet/Exhaust max 0.2 mm

1
The measurements are calculated for the measurement method described in the service literature,
see Group 214.

Rocker arms

Bearing play max 0.1 mm

Valve springs
Inlet/Exhaust

Outer valve spring:

Length, without load 73 - 74 mm

With 590 N load 58 mm

With 1150 N load 45 mm

Coilbound length max 40 mm

Inner valve spring:

Length, without load 70 - 71 mm

With 243 N load 54 mm

With 447 N load 41 mm

Coilbound length max 37 mm

Engine timing

Timing gear
 Specifications

Number of teeth:

1 Drive gear, crankshaft 54

2 Idler gear, outer bull gear 72

Idler gear, inner bull gear 56

3 Idler gear, adjustable 73

4 Drive gear, camshaft 84

5 Idler gear, servo pump 37

6 Drive gear, steering servo and fuel feed pump 31

7 Drive gear, hydraulic pump, cooling fan 42

8 Drive gear, lubrication oil pump 23

9 Engine-driven power take-off (extra equipment) 50

10 Compressor drive gear 40

Backlash 0.05 - 0.17 mm

Shaft journal for idler gear, diameter 100 mm

Bushing for idler gear, diameter 100 mm

Run-out clearance for idler gear max 0.05 mm

Camshaft

Camshaft G9A, marked V3, 20818317

Control of camshaft settings, cold engine and valve clearance

for cylinder 1 inlet valve = 0.
The inlet valve for cylinder 1 at flywheel position 6° ATDC
should be open 1.3±0.3 mm.
When checking, the timing gears must be rotated in the
correct direction (clockwise seen from the front) in order to
take up all backlash.

Wearing
Specifications tolerance

Drives gear -

Number of bearings 7 -

Diameter, bearing journals, standard 69.97 - 70.00 -

mm

Note: Check values only, not for machining.

Diameter, bearing journals, undersize:

0,25 69.72 - 69.78 -

mm

0,50 69.47 - 69.53 -

mm

0,75 69.22 - 69.28 -

mm

Max end float 0.24 mm

Max permitted ovality (with new bearing) 0.05 mm

Bearing, permitted run-out wear 0.05 mm

Valve lift:

inlet 12.6 mm -

exhaust 12.1 mm -

Lift camshaft, inlet 7.25 mm

Lift camshaft, exhaust 8.74 mm

Permissible wear, entire cam profile max 0.1 mm -

Camshaft bearings

Camshaft bearing thickness, standard 1.92 mm -

Oversize:

0.25 2.04 mm -

0.50 2.17 mm -

0.75 2.29 mm -
Crank mechanism

Crankshaft

Specifications

Length 1066 mm

Crankshaft axial clearance1 0.15 mm

Ovality of main bearing journals and big-end bearing journals max 0.01 mm

Taper of main bearing journals and big-end bearing journals max 0.02

Runout of middle bearing 0.15 mm

1
The dimensions refer to oiled parts.

Main bearing journals

Note: Check values only, not for machining.

108.0 mm
Diameter (Ø) standard

Undersize:

0.25 mm 107.85 - 107.87 mm

0.50 mm 107.73 - 107.75 mm

0.75 mm 107.60 - 107.62 mm

1.00 mm 107.48 - 107.50 mm

1.25 mm 107.35 - 107.37 mm

Surface finish, main bearing journal Ra 0.25

Surface finish, radius Ra 0.4

Width, axial bearing journal (A) standard 42 mm

Oversize:

0.2 mm (axial bearing 0.1) 42.17 - 42.22 mm

0.4 mm (axial bearing 0.2) 42.37 - 42.42 mm

0.6 mm (axial bearing 0.3) 42.57 - 42.62 mm

Recess radius (R) 4,5 mm

Thrust washers (axial bearing)

Specifications

Width (B) standard 3.2 mm

Oversize:

0.1 mm 3.2 - 3.3 mm

0.2 mm 3.3 - 3.4 mm

0.3 mm 3.4 - 3.5 mm

Main bearing shells

Outer diameter (C) 113 mm

Thickness (D) standard 2.5 mm

Oversize:

0.25 mm 2.6 - 2.7 mm

0.50 mm 2.7 - 2.8 mm

0.75 mm 2.8 - 2.9 mm

1.00 mm 2.9 - 3.0 mm

1.25 mm 3.1 - 3.2 mm

Run-out, main bearing max 0.11 mm

Main bearing journal

Note: Check values only, not for machining.

88 mm
Diameter (Ø)

Undersize:

0.25 mm 87.85 - 87.87 mm

0.50 mm 87.73 - 87.75 mm

0.75 mm 87.60 - 87.62 mm

1.00 mm 87.48 - 87.50 mm

1.25 mm 87.35 - 87.37 mm

Surface finish, big end bearing journal Ra 0.25

Surface finish, radius Ra 0.4

Width (A) 54 mm

Recess radius (R) 4,5 mm

Big-end bearing shells

Specifications

Outer diameter (B) 93 mm

Thickness (C) standard 2.4 mm

Oversize:

0.25 mm 2.5 - 2.6 mm

0.50 mm 2.6 - 2.7 mm

0.75 mm 2.7 - 2.8 mm

1.00 mm 2.8 - 2.9 mm

1.25 mm 3.0 - 3.1 mm

Diameter, bearing shell bearing seat (D) 92.85 mm

Connecting rod

Length centre - centre (E) 225 mm

Connecting rod bushing internal diameter (G) 54 mm

Axial clearance, connecting rod - crankshaft1: max 0.35 mm

Big-end bearing, radial play1: max 0.10 mm

Straightness, max deviation per 100 mm of measured length 0.06 mm

Twist, max deviation per 100 mm of measured length 0.15 mm

1
The dimensions refer to oiled parts.

Marking:

FRONT on the shaft is turned forward.

Connecting rod and cap are marked as a pair with a three-digit serial number (see
illustration).
Flywheel, fitted

Specifications

Axial run-out measured radius 150 mm max 0.20 mm

Number of teeth on starter gear ring 153

Sensor teeth on flywheel 54

Grinding allowance, flywheel

Flywheel casing, fitted

Axial mismatch for mating surface against clutch housing max 0.1 mm

Radial mismatch for guide against clutch housing max 0.05 mm

Lubrication and oil system

Oil

Lubricating oil demands

Viscosity all alternatives SAE 15W-40

Quality requirement, ACEA E7

specification in
accordance with

Approved synthetic lubricating oils:

Volvo part no. 1161964, Mobil Pegasus 1

Approved mineral or semi-synthetic oils:

BP Vanellus AF5 Castrol RX

Super Gas

Cepsa Ecogas Chevron

Texaco
Geotex VR

ELF Lubrigas 7m FINA Ng Motor

Oil

HRD Maxima Gaz 7 Mobil Delvac

Super GEO

Q8 Mahler T Shell Rimula

NX

Slovnaft Madit Gas Super Statoil

PowerWay GE

Teboil Special GML TOTAL Rubia

Gas

URANIA Turbo Gas

Exchange volume, see service bulletin group

175.

Oil pressure

Operating speed (over 1100 rpm) 300 - 550 kPa

Slow idling min 270 kPa

Oil temperature

Cold engine, engine stopped ambient temperature

Warm engine, engine running (coolant temperature 75-95° C) 90 - 115° C

Lubricating oil pump

Type Gear pump

Number of teeth, drive gear 23

Oil filter

Quantity

Full flow filter 2

Bypass filter 1

Oil valves
1 Safety valve, lubricating oil pump

Marking Purple

2 Bypass valve, bypass filter

Spring, free length 69 mm

With load of 13-15 N (1.3-1.5 kgf) 40 mm

3 Control valve, oil cooler

Marking 124

4 Reduction valve, oil pressure

Marking Blue

5 Bypass valve, full-flow filter

Spring, free length 69 mm

With load of 13-15 N (1.3-1.5 kgf) 40 mm

6 Opening valve, piston cooling

Spring, free length 122 mm

With 95 N (9.5 kgf) load 63 mm

7 Control valve, piston cooling

Spring, free length 122 mm

With 60 N (6.0 kgf) load 84 mm

Fuel system

Gas system, gr 24

Gas system

Fuel, compressed Quality according to:

natural gas CNG ISO/TC193
or bio-gas DVGW Merkblatt
intended for G260/1
vehicle operation SAE J 1616, dry gas only
ISO/DIS 11439, chap 4.5,
dry gas only

Dew point max 32 mg/m3, dew

demand, highest point -9° C at 200 bar
permitted water Oxygen max 1% volume
content and dew Hydrogen Sulphide max
point 23 mg/m3
General Soluble Sulphides max
requirements 23 mg/m3

Gas tanks, type/ Type 4,

location composite/glassfibre
with plastic interior.
Transverse roof
mounting

Volume 5-pack: 1070 litre, 6-

alternatives, 214L pack: 1285 litre, 7-pack:
/ container 1490 litre, 8-pack: 1705
Gas system

litres

Weight, tank 5-pack: approx. 480 kg,

package 6-pack: approx. 550 kg,
7-pack: approx. 680 kg,
8-pack: approx. 750 kg

Tank pressure max 200 bar

with full tank at 15° C

Valve tank Emer Mark106

container

Valve, tightening 130±5 Nm, thread 1” 1/8

torque ” 12FX1-UNF-2A
in cylinder
adapter

Solenoid valve, 35±3 Nm

tightening
torque, core

Solenoid valve, 44 Ω
resistance of coil

Pipe rupture fuse, 3.6 bar

pressure
difference

Temperature 110°±10° C
fuse, melting
temperature

Tightening 30±3 Nm
torques

Fine filter CAP- Fine filtering

616190 exchangeable filter
element
Gas system

Degree of 99.97%, particles 0.3-0.6

filtering micron

Filter cup, 34 Nm,

tightening drain plug 15 Nm
torque

Pressure GFI CA-P78–400

regulator, type

Volvo part no. 20789165

Ingoing tank 248 bar

pressure max

Safety valve, Opening pressure 15±1

outgoing bar
pressure

Working pressure 10.0±0.6 bar

to engine

Solenoid valve, 27±2.2 Ohm at 25° C

resistance (pin E-pin G)

Tank pressure 0-290 bar

sensor,
measurement
range

Output voltage 0.2±0.1 V

at 0 bar (E)

Full tank 3.4±0.1 V

indication (F) at
207 bar

Combi-sensor 0-13 bar / -40 to +150°

working C
pressure/temp
Gas system

(in inlet jet)

Output voltage 0.5 V / 0 bar, 4.5 V / 13

pin 2 / at bar
pressure

Resistance Ohm 4929Ω/0°, 2987Ω/10°,

(pin 3) / at temp° 1868Ω/20°, 1205Ω/30°
C

Injection valve CAP SP 014 S4, PWM 24

298163, type V (4 pcs)

Resistance in coil 30 Ω

Amperage 0.8-1.2 A

Tightening of gas lines and couplings

Hose engine line to Tighten by hand and

cooling loop ECU angle tightening at
180°

Hose engine line to 35 Nm

nipple, pressure
regulator

Hose engine line to 35 Nm

nipple, inlet nozzle

Nipple on the inlet 60 Nm

nozzle

Ferruled coupling, 3/4 turn new

diameter 3 mm assembly
1/4 turn extra
tightening
Ferruled coupling, 1 1/4 turn new
diameter 8, 12, 16 assembly
mm 1/4 turn extra
tightening

Bending radius R Ø3: R12 mm, L14 mm

min Ø8: R24 mm, L23
min. straight length mm
from cut L Ø16: R48 mm, L32
mm

Inlet and exhaust system

Inlet and exhaust system, gr 25

Inlet and exhaust system

Turbocharger 20872409 HX35G

Radial tolerance 0.33-0.50 mm

compressor turbine max

Axial tolerance 0.04-0.09 mm

compressor turbine max

Setting value pressure 0.5-1.04 mm

actuator wastegate opening at a
Inlet and exhaust system

charge
pressure of 1.17
bar
(117 kPa)

Check value 0.33-1.27 mm

opening at 1.17
bar (117 kPa)

Control valve charge Resistance in

pressure, 20819553, type the coil 90±4.5
PWM Ohm

Combi-sensor, charge Volvo

pressure/temp 20524936.

Control value 20°C: / approx

temperature 2620 Ω
40°C / approx
1200 Ω

Control value charge air 1.05 - 1.30 V

pressure (absolute) at 100 kPa

Throttle disc, diameter 58 mm

Throttle, power heating up to 540 W

Throttle control, 20±0,5 mm,

electrically heated, control between lock
rod, default setting nuts
(see illustration below) (80 mm
between ball
joints)

Retaining yoke for return 0 mm, lock nut

spring, length (spring pre- - outer edge
tension) yoke
(see illustration
Inlet and exhaust system

below)

Idle valve, resistance 10-14 Ohm (3-2

coils Open, 1-2
Close)

Duty cycle at idle, warm see Vcads Pro

engine test 24103-3

Air flow sensor, 20774533, flow ≈ 4 - 250

measurement range g/s
gives ≈ 1.3 V –
max 4.75 V

Control valve EGR, 46 Ohm ±7%

resistance coil at 20°C

Restricting washer for the G9A260: 64

EGR function mm
(in the outlet air filter), G9A300: 69
diameter mm

Pulse reflector washer 20852965

EGR, between the turbo
compressor - manifold

Lambda sond 8631643, LSU 4.2 / ASIC

type CJ110 Wide
Band

Measurement range λ 0.80 - λ 1.70

lambda value with
tolerance max 0.05

Resistance across heater approx. 5 Ohm

(pin 3-4, connector block at 20 °C
9036)

Lambda sond, tightening 40-60 Nm

Inlet and exhaust system

torque

Catalytic converter, type Three way

Effective temperature 200°-1000° C

range

Metallic substrate, density 800 cpsi

Wash coat, 1: 5.7 at 150

platinum/palladium, g/ft3
replacement

Exhaust back pressure, 30 kPa at 1900

catalyst and silencer rpm

Throttle control, electrically heated throttle housing, default setting

Air flow meter, voltage (V) / flow (g/s)

Cooling system

Thermostat

Quantity 1

Opening temperature:

Automatic gearbox with retarder 76° C

Coolant

Type Volvo Original

Contains Glycol and anti-corrosion additives

Colour Green

Mixed with Water

Corrosion protection

Use only when anti-freeze is not necessary.

Type Volvo Original

Mixed with Water

Note: Anti-corrosion additive must not be mixed with coolant or anti-corrosion additives of another
type.

Engine control system

Engine electronic control unit

Number of pins 2 x 36

Sensors

Charge pressure sensor

Control value (Bosch 0281 002 576) 1.05 - 1.30 V at 100 kPa

Charge air temperature sensor

Pressure drop indicator

Active V=0.48 × Ubat

Inactive V=0.12 × Ubat

Coolant temperature sensor

Inlet temperature sensor

Engine oil temperature sensor

Camshaft sensor

Distance to camshaft 0.3 - 1.0 mm

Flywheel sensor
Distance to flywheel 0.7 - 2.1 mm

Gr 28 Ignition system

Ignition system

Ignition system, Inductive with

type complete ignition unit
per cylinder

Ignition advance Load-dependant,

variable between +5°
up to +32° btdc

Control value idle +5° to +10° btdc

(600 rpm)

Distance inductive 0.6±0.4 mm

sensor - toothed
wheel

Signal voltage 10-160 V

inductive sensor,
flywheel

Signal voltage 8-120 V

inductive sensor,
camshaft

Resistance 775 -945 Ohm

inductive sensor

Ignition coil with part no. complete

drive stage BIP 390 20555285

Ignition voltage 24-33 kV

Amperage, spark 60-80 mA

Dwell 0.5-1.0 ms dependant

Ignition system

on charge pressure

Sparkplug 0.28±0.05 mm
20700469,
electrode gap

Sparkplug, 35 Nm
tightening torque