DRIVERS MANUAL

SB(R) 230 PF EURO 3

SB(R) 4000+ PF/XF EURO 3

0607 DW 05071704
This drivers manual consists of sections
which describe the driving and care of your
vehicle.
Each main section starts with a table of
contents.
This drivers manual shall be governed by
and applied in accordance with the laws of
the Netherlands
Any dispute here under shall be referred to
the decision of the District Court of
‘s-Gravenhage in the Netherlands.

© 2006 07 VDL Bus International bv,

Eindhoven, The Netherlands.

In the interest of continuing product

development VDL Bus International bv
reserves the right to change specifications
or products at any time without prior notice.

No part of this publication may be

reproduced and/or published by printing, by
photocopying, on microfilm or in any way
whatsoever without the prior consent in
writing of VDL Bus International bv.
1. Preface 1

2. Warnings and safety precautions 2

3. IIdentification 3

4. Instruments and actuators 4

5. Main display 5

6. Driving 6

7. Inspections and maintenance 7

8. Emergency repairs 8

9. Technical data 9

CONTENT

3
4

4
1. Preface 1

PREFACE 1
 INTRODUCTION
1
This instruction manual contains all the nec-
essary information concerning the use of
the vehicle that has been entrusted into your
care. Read this instruction manual carefully
before driving the vehicle for the first time.
Good knowledge of the operating instruc-
tions increases your driving pleasure and
generally has a positive influence on the life
span of the vehicle.
Every effort has been made to make the
layout of this instruction manual as practical
and convenient as possible. It contains a
description of the vehicle’s identification
information, how to operate the vehicle and
the most efficient method of driving the
vehicle. Attention is also given to the daily,
weekly and periodic maintenance, as well
as how to carry out small repairs yourself.
It is, however, reassuring to know that
DAF/VDL Bus has an extensive service
organization in Europe. DAF International
Truck Service (I.T.S.) is a good example of
this. For a driver who has broken down
abroad, the I.T.S. in Eindhoven, the
Netherlands, is available 24 hours a day to
offer assistance and to limit the time that the
2 PREFACE
vehicle is out of operation to a minimum.
The I.T.S. can be contacted by phoning
+31 (0)40 2143000.
Comment:
This instruction manual is based on the
chassis and equipment as it left the VDL
Bus factory. Please write down the chas-
sis number or license plate number:
Depending on the desired bodywork and
equipment, the bodywork builder often
makes alterations to electrical system of
the vehicle.
Furthermore, every vehicle is adjusted in
accordance with the legal regulations of
the country concerned and the expected
operating conditions. It is, therefore,
possible that the text and diagrams
contained in this instruction manual do
not reflect exactly the situation in your
vehicle. This, however, does not effect
the operation and maintenance.
If this instruction manual is delivered for
a vehicle that has already been in use,
for example, after loosing the original
copy, please take into account the fact
that the information contained in this
instruction manual may differ from the
initial specification of the vehicle.
IMPORTANT
Make sure this instruction manual is always
kept in the vehicle. Read this instruction
manual carefully before driving the vehicle
for the first time. Full advantage of all the
possibilities that this VDL Bus vehicle has to
offer can only be taken after reading this
instruction manual.
WARNING SIGNS
Warning signs have been included in this
instruction manual in order to make the use
of the vehicle as safe as possible.
Each warning is preceded by a warning sign.
2. Warnings and safety precautions 2

WARNINGS AND SAFETY PRECAUTIONS 3

 Page
2 The warning sign .................................... 5
Warning and safety regulation ................ 5
Important technical items ....................... 7

4 WARNING AND SAFETY PRECAUTIONS

THE WARNING SIGN
When the warning symbol above is display-
ed in this document, the information given is
extremely important for safety and health.
Not taking this information into account may
cause serious injury or even death.
The safety regulations given
below must be strictly
observed in order to prevent
damage to the vehicle and to
prevent endangering your own
health and safety, as well as the
health and safety of others.
WARNINGS AND SAFETY REGULATIONS
Comply with all warnings and safety regu-
lations given in this instruction manual.
Always read and observe the instructions
and warnings given on labels and stickers
fitted to the vehicle’s components.
These have b een fitted for your own health
and safety, so do not ignore them!
ENGINE
Do not run the engine in a closed and
unventilated space. Make sure exhaust
fumes are properly extracted.
COMPONENTS
Remain a safe distance from rotating and/or
moving components.
COOLING SYSTEM FILLING CAP
Do not remove the cooling system’s filler cap
whilst the engine is at the operating
temperature. Relieve pressure first whilst
slowly removing filler cap.
SAFETY TRIANGLE
Make sure you always have a safety triangle
(this is compulsory in some countries) and
possibly some other safety markings. 2
If you break down whilst driving, always wear
clothing which acts to give a warning when
you leave the vehicle.
FIRE EXTINGUISHER
Make sure you always have a fire extin-
guisher (this is compulsory in some coun-
tries) at hand. Make sure you can find it blind-
fold. The fire extinguisher must be properly
attached, be within the reach of the driver
and easily accessible for any relief workers.
Have the condition of the fire extinguisher
checked annually. Have the fire extinguisher
refilled as quickly as possible after it has
been used.
AFTER A FIRE
When burning, some plastic sealants can
produce an aggressive acid when mixed with
water. Therefore, do not touch any water
used to extinguish a fire without using
protection.
WARNINGS AND SAFETY PRECAUTIONS 5
 FIRST AID KIT
Make sure you always have an adequate
first aid kit with you (obligatory in some
2 countries). Replace items which were used
with new ones as soon as possible. Ensure
the content not to exceed the expiring date.
WINTER CONDITIONS
Whenever you expect winter conditions (par-
ticularly in mountainous regions), make sure
you have winter tyres fitted and have snow
chains available. (Also see “Maintenance
work before and after the winter season”.)
Do not use snow chains on the
front steered wheels to avoid
the chains to damage the
bodywork. Use winter tyres.
WEIGHTS
Make sure the following weights are not
exceeded.
- Max. weight per axle
- Max. vehicle weight (GVW)
- Max. train weight (GCW)
- Max. trailer weight
Also see the identification plate
6 WARNING AND SAFETY PRECAUTIONS
According to European regulation 96/53/EG,
the GVW of vehicles with 2-axles must not
exceed 18 tons and with 3-axles must not
exceed 26 tons within the EU.
OILS AND LUBRICANTS
Some oils and lubricants which are used
could be harmful to your health if you come
into contact with them.
This also applies to the coolant, screen
wash, coolant in the air conditioning system,
battery acid and diesel oil. Therefore, avoid
bodily contact as much as possible.
To prevent fire, ensure that the engine and
the surrounding area are free from flammable
liquids.
Be careful when changing hot oil. This can
cause serious injury.
MAINTENANCE
Always use blocks or rams when carrying
out maintenance work under a raised
vehicle.
- Always wear gloves and well-fitting
clothing. If necessary, apply protective
cream to your skin.
- Avoid inhaling dust from the brakes.
These components must only be
touched in a well ventilated room which
has good dust extraction.
MAINTENANCE OF THE AIR
CONDITIONING SYSTEM
The air conditioning system contains
coolant which is under high pressure. You
must not disassemble any components of
the air conditioning system. Maintenance
work on the air conditioning system may only
be carried out by qualified personnel.
If the air conditioning system no longer
functions, it must be repaired as quickly as
possible by a VDL Bus workshop in order to
avoid large-scale damage to the system.
Regularly turn on the air conditioning
system (once a month), even if it is not re-
quired.
IMPORTANT TECHNICAL ITEMS
Strictly observe the instructions below in
order to prevent damage to the vehicle.
ORIGINAL PARTS
Do not modify your vehicle with non-original
DAF/VDL Bus parts. Bear in mind that any
modification to your VDL Bus vehicle with
non-original parts may adversely affect its
performance, safety, durability and the
guarantee. Modification may also conflict
with legal requirements.
RUNNING-IN
It is better not to place the vehicle under a
heavy load during the running-in period.
Therefore drive carefully and avoid heavy
acceleration for the first 1,500 km. This also
applies when a revised engine, gearbox or
differential has been fitted.
The following technical items of spe-
cial importance apply to both the
running-in period and to the period
thereafter.
After a cold start, drive in a low gear and at
a moderate engine speed until the engine is
at operating temperature and the
temperature gauge indicator is in the middle
of the range.
Regularly look at the instrument panel
whilst driving and take precautionary
measures when observing irregularities.
Never allow the engine to idle unneces-
sarily. This is harmful to the engine and
causes unnecessary pollution of the environ-
ment.
Please note that the power steering function
is disabled when turning off the engine
whilst driving. A stronger force will then be
needed to steer the vehicle.
2
Allow the engine to idle for at least 5 minutes
after a long journey or after being placed
under heavy load before turning off the con-
tact switch. It is important to idle the engine
to prevent the coolant temperature from
being too high and to allow the turbo
compressor to cool down.
The cooling of the engine is thermostatically
controlled. Therefore it is prohibited to cover
the radiator in winter. Also clean the wire
screen in front of the radiator/intercooler
regularly.
It is not recommended to remove the
thermostat if the coolant temperature
becomes (too) high, since the engine
temperature will not decrease as a result of
doing this.
The turbocharger is a precision component.
Therefore, any abnormal noise caused by
the turbocompressor must be reported
immediately.
WARNINGS AND SAFETY PRECAUTIONS 7
 AIR LEAKS
There can be an air leak if the pressure in
the air reservoirs drops quickly when the
2 engine is not running. Since the safety of the
service brake system is reduced as a result
of this, the leak must be repaired as quickly
as possible.
Note:
Pressure drops when the engine is not
running might be caused by automatic
corrections of the air suspension level.
INSTALLATION VOLTAGE
The vehicle has a 24 Volt electrical unit.
When replacing or adding electrical or elec-
tronic components, always check whether
these are suitable for this voltage.
8 WARNING AND SAFETY PRECAUTIONS
BATTERIES
Never remove the battery
clamps whilst the engine is
running!
When charging the batteries, make sure
there is good ventilation and avoid sparks
or an open fire. Use a normal battery charger.
Only use a quick-charger (with voltage
protection!) if absolutely necessary; the
battery cables must in this case always be
removed.
Always remove the battery’s earth connec-
tion when working on the electrical unit.
Never place tools on a battery. This may
cause a short-circuit and, in extreme cases,
may cause the battery to explode.
CHARGING BATTERIES
Allow frozen batteries to
defrost before charging them.
Remove all the filler caps
before charging.
First connect the positive clamp (+) of the
battery charger to the positive pole (+) of the
battery and then the negative clamp (-) to
the negative pole (-). Turn the battery charger
off after the battery has been charged and
remove the negative clamp before removing
the positive clamp.
The battery cables may remain fitted under
normal charging conditions. Voltage peaks
higher than 32 Volts must be avoided at all
times. When quick-charging the batteries,
both battery cables must be disconnected,
because otherwise the electronics may be
damaged.
STARTING THE VEHICLE USING OTHER
AUXILIARY STARTING DEVICES
It is permitted to start the vehicle by means
of separate booster batteries (approx. 24
Volts) or by means of another vehicle with a
running engine (approx. 28 Volts). The
battery cables must not be removed when
starting the vehicle in this way. Connect the
jump leads first to the positive clamp (+) and
then to the negative clamp (-).
To disconnect, first release the negative
clamp (-) and then the positive clamp (+).
If the batteries are completely empty and
the motor is running, it is important that the
jump leads are not disconnected
immediately. To prevent damage to the
electrical system (peak voltage!) the engine
must run for at least 5 minutes before the
jump leads are disconnected.
Carry out the following if the engine is running
and the batteries have been charged for at
least 5 minutes.
- Turn on as many power consumers as
possible (for example: head lights, fog
lights, heating fans, etc.).
- Disconnect the auxiliary cables.
- Turn all the power consumers back off.
Never start the engine using a quick
charging device!
It is however, permitted to start the engine
using an auxiliary starting device or an
emergency starting device if a voltage
limiting device (max. value 32 Volts) is used.
Failure to observe the
instructions above may
damage the electronic
components.
WELDING
For welding on the vehicle and/or
superstructure, see the "Workshop manual"
and "Bodybuilders Guidelines".
Failure to observe the
instructions above may
damage the electronic
components.
ENVIRONMENTAL WARNINGS
Pollution is a serious threat to the environ-
ment. You are recommended to observe the
following rules in order to limit pollution to a
minimum:
- Do not pour used oil, hydraulic oil or
coolant into drains, sewers or onto the
round. This is also illegal. These liquids
should be sent to the appropriate
authorities for recycling or destruction.
- Ensure that the vehicle is regularly
serviced. Correct vehicle maintenance
contributes to maximum fuel savings and
reduces polluting exhaust gases and
avoids liquid leakage.
MOBILE TELEPHONE AND
TRANSMITTING EQUIPMENT
The following must be taken into account
when using commercial mobile telephones 2
and transmitting equipment:
- Mobile Telephones and transmitting
equipment must not be used in the bus
without a separate external aerial!
- Furthermore, the optimal range of the
device will only be obtained through the
use of an external aerial.
Using a Mobile Telephone or
transmitting equipment without
a separate external aerial can
create a strong electro-
magnetic field (resonance
effect) in the bus. If this occurs,
faults may occur in the vehicle
electrics.
Comment:
Always follow the instructions of the
mobile telephone and/or the transmitting
device.
WARNINGS AND SAFETY PRECAUTIONS 9
2

10 WARNING AND SAFETY PRECAUTIONS

3. Identification 33

IDENTIFICATION 11
 Page
VIN code on rear module ..................... 13
Module number on front module .......... 13
DAF XE engine number ....................... 13
3 DAF PE engine number ....................... 14
Identification plate location ................... 14
Identification card ................................. 14
Vehicle identification plate .................... 15
Vehicle identification number ............... 16

12 IDENTIFICATION
 XMG
23456

BOSCH
3

03060B

IDENTIFICATION

VIN CODE ON REAR MODULE MODULE NUMBER ON FRONT MODULE DAF XE ENGINE NUMBER:

The VIN code (Vehicle Identification Number) On the front module, the last six figures of The engine number is stamped on the
is stamped on the inside of the right-hand the VIN code are stamped on the bracket engine block at the right-hand side of the bus,
longitudinal beam. The VIN code is the flange of the steering box. above the starter motor near the UPEC.
vehicle’s legal identification number.

IDENTIFICATION 13
3

ENG
N
IE

03059B

DAF PE ENGINE NUMBER IDENTIFICATION PLATE IDENTIFICATION CARD

The engine number is stamped on the
cylinder block at the left-hand side of the bus,
nearby the compressor
The engine identification plate is fitted to the
inlet manifold.
Besides the specification number of the
engine, the plate also gives the engine type
and the engine number, as well as some of
the specifications.
Every vehicle has an identification card. This
card is used to determine which type of
components the vehicle is constructed from.
If, at a later date, changes are made to the
vehicle, then these must be noted on the
identification card.
These changes must also be reported to
VDL Bus International bv.
The identification card is important if help is
needed from I.T.S., as well as for finding the
correct component numbers for repairs.

14 IDENTIFICATION

VEHICLE IDENTIFICATION PLATE
The vehicle identification plate is usually fit-
ted in the entrance bay by the bodywork
builder. A picture of the identification plate is
given on the right. A declaration of the vehi-
cle identification number is also given, as has
been compulsory in EU member states since
1982.
Remark:
Numbers 1, 7, 8 and 11 are not normally
applicable to buses. These positions will,
therefore, not be filled in.
3
*1.Legally permissible maximum train 9. Technically permissible axle load (from
weight (GCW) front to rear)
*2.Legally permissible maximum vehicle *10. Legally permissible axle load (from front
weight (GVW) to rear)
3. National approval number *11. Legally permissible maximum fifth wheel
4. Vehicle identification number pressure
5. EU approval number (N.A.)
6. Technically permissible maximum
Vehicle weight (GVW) * In the country of registration
7. Technically permissible maximum train
weight (GCW)
8. Technically permissible fifth wheel
pressure
IDENTIFICATION 15
 VEHICLE IDENTIFICATION NUMBER

X M G D E 40 X S 0H123456
Geographical position
Chassis serial number
3 of manufactory
The Netherlands

VDL Bus International bv

Vehicle type Engine air intake

40 SB(R) 4000 S Turbo + intercooler

Engine position

D SB bus (rear engine)

Drive line

E 4x2 Engine stroke volume

R 6 x 2 single assembly on the
trailing axle P 9.2 litre (vertical)
X 12.60 litre (vertical)

16 IDENTIFICATION
4. Instruments and actuators 4

INSTRUMENTS AND ACTUATORS 17

 Page
Instrument panel .................................. 19
Instrument panel lay-out ....................... 20
Switches, gauges and controls on
instrument panel ................................... 22
Actuators .............................................. 27
4 Steering column switches .................... 28
Left hand combination switch ............... 28
Right hand combination switch ............ 29
Adjustable steering column .................. 29
Tachograph .......................................... 30

18 INSTRUMENTS AND ACTUATORS

INSTRUMENT PANEL

Activation of the instrument panel: De-activation of the instrument panel:

When the instrument panel is activated by
turning on main switch (20) a selftest is
made. The operation of the next items can
be evaluated:
- The warning lights (10) will lit.
- A buzzer will sound for a short period.
- The needles of the speedometer,
rev counter, fuel gauge and coolant
temperature gauge will turn once to their
maximum position and return to their zero
position.
- The main display will appear as a black
screen and turn into grey when
functionality of the display is correct. The
air pressure gauges will appear.
Only after the steering lock/contact/start
switch is turned to the A-position the main
switch on the instrument panel can be turned
off.
After turning off the main switch the main
display will gradually light down into the stand 4
by mode and after some time will be turned
off completely into the sleep mode (black
display).

When the steering lock/contact/start switch

is turned to the A-position some symbols will
appear on the main display. See also the
chapters "MAIN DISPLAY" en "DRIVING".

INSTRUMENTS AND ACTUATORS 19

 INSTRUMENT PANEL LAY-OUT

20 INSTRUMENTS AND ACTUATORS

N.B. The design of the instrument panel can vary for each vehicle.

1. Menu-switch
2. Rear fog lights switch
3. Main light switch
4. Hazard warning lights switch
5. Front fog lights switch
6. Light dimmer switch instrument panel
7. Speedometer 4
8. Odometer and trip meter
8a. Trip meter reset button
9. Fuel gauge
9a. Indicator fuel low
10. Warning indicators
11. Main display
12. Coolant temperature gauge
12a. Indicator coolant temperature to high
13. Rev counter
14. Retarder foot control pre-selection switch
15. Air suspension kneeling/ferry lift switch
16. Trailing axle steering lock switch (SBR)
17. Differential lock switch (optional)
18. Tractive assistance switch (SBR)
19. Air suspension driving level switch
20. Main switch
21. R36 central safety switch (optional)

The term "optional" relates to items which are

available as an option

INSTRUMENTS AND ACTUATORS 21

 SWITCHES, GAUGES AND CONTROLS
ON THE INSTRUMENT PANEL
1. MENU-SWITCH
The three screens on the main
display (11) can be selected by using
menu-switch 1 on the instrument
panel. The main switch (20) and the
4 ignition switch must be activated first.
2. REAR FOG LIGHTS SWITCH
This rocker switch is used to turn on
the rear log lights when the dipped
beam or main beam is already
turned on, or when the front fog lights
are already turned on.
The switch must be used again to
turn the lights back on, if necessary,
after the contact switch has been
turned off.
The inspection light in the switch and
the inspection light (B6) are lit when
the fog lights are turned on.
Note:
The legal requirements for the
use of fog lights vary in each
country.
22 INSTRUMENTS AND ACTUATORS
3. MAIN LIGHT SWITCH
The main light switch has three
positions:
- 0 position: pressed at the bottom:
lights are turned off.
- I position: Width indicator lights
and side-marker lights are turned
on.
- II position: pressed at the top:
Dipped beam/main beam, width
indicator lights and side-marker
lights are turned on.
If the lights are turned on, the
warning light in the switch will be lit.
4. HAZARD WARNING LIGHTS
SWITCH
All the indicators work simulta-
neously when the rocker switch is
turned to the on position. The haz-
ard warning lights are turned off
when the tumbler switch is returned
to the off position. The inspection
light (A6) and the light in the tumbler
switch indicate that the hazard warn-
ing lights are on. The inspection light
(A6) flashes quickly if one of the
lights is broken. This function also
works if the main switch is turned off.
5. FRONT FOG LIGHTS SWITCH
This rocker switch can be used to
turn on the front fog lights when the
main light switch is in position I or II.
If the fog lights are turned on, the
warning light in the switch will be lit.
Note:
The legal requirements for the
use of fog lights vary in each
country.
6. LIGHT DIMMER SWITCH
If the main light switch is in position I
or II, the instrument lights, as well as
the inspection lights in the various
switches, will be lit. The intensity of
the instrument panel lights can be
adjusted in six stages using the
dimmer switch. After the lowest
intensity is reached the light intensity
is reselected. The intensity last is
memorised when the ignition is
switched off.

7. SPEEDOMETER
Depending on the type of speedometer, the
speedometer has a scale mark in km/h or a
scale mark in km/h and MPH.
8. ODOMETER/ TRIP METER
Following the activation of the ignition switch,
the odometer, trip meter and clock appear in
the speedometer display.
The reset-button 8a for the trip meter can be
found under the speedometer display.
By pressing the reset button for longer than
4 seconds, the trip meter can be reset.
The clock in the display is synchronised with
the tachograph clock. Adjusting the clock can
only be done via the tachograph.
4
9. FUEL GAUGE
The fuel gauge only works when the main
switch is activated.
After switching on the contact-switch the fuel
gauge indicator will point out the actual fuel
level with a certain delay.
The orange warning indicator on the right
hand side of the fuel gauge lights up as soon
as the reserve level in the fuel tank is
reached. Fill up the vehicle as soon as
possible.
INSTRUMENTS AND ACTUATORS 23
4

10. WARNING LIGHTS 11. MAIN DISPLAY (LCD screen) 12. COOLANT TEMP GAUGE

The indications given are described in the
chapter “MAIN DISPLAY”.
The following three screens can be shown
in the main display:
- Information screen
- Warning screen
- Error screen
The various screens can be
selected by using menu-switch
1 on the instrument panel.
The symbols used are described in the
chapter “MAIN DISPLAY”.
The engine must not be fully loaded when
the temperature gauge is in the orange
region. The engine is at operating
temperature when the temperature gauge
indicator is in the middle of the range.
The following points must be checked if the
temperature of the coolant rapidly increases
and/or the gauge reaches the red region
(warning light left of the gauge will lit):
- The coolant level (caution danger of
scalding; see topping up coolant in
chapter "MAINTENANCE").
- The oil level of the hydraulic fan drive.
- The Poly V-belt and the water hoses.

24 INSTRUMENTS AND ACTUATORS

 14. RETARDER FOOT CONTROL
PRE-SELECTION SWITCH
The retarder foot control function can
be turned OFF by pressing the
rocker switch on the symbol.
The information symbol I-E1 on the
main display appears and the
indication light in the switch is lit
when the retarder function is turned
OFF.
For instructions to use see chapter
"DRIVING".
Pressing the rocker switch on the
bottom the retarder foot control
13. REV COUNTER function will be available again.
Only re-engage the retarder
Shaded green: Permitted for light foot control function at very
load low speed because this can
Green: Economical result in very violent reactions
Orange: Less economical in the drive line.
Red: Not permitted
15. AIR SUSPENSION KNEELING
/FERRY LIFT SWITCH
The momentary switch can be used
to alter the vehicle height (ground
clearance) in special
circumstances. The switch activates
the pneumatic suspension system.
Since the height settings and the
conditions under which they can be
used are configured in the software
and the parameters, they may differ
for each vehicle.
A) Two positions lower (press the
switch for a short period of time for
each position). It is only possible to
activate the kneeling function and
the super kneeling function at a very
low speed. For certain software 4
programming, it is also necessary to
apply the halt brake or the parking
brake.
B) Two positions higher (press the
switch for a short period of time for
each position). It is only possible to
activate the bus lane function and
the ferry lift function at a very slow
speed. The vehicle will automatically
return to the normal driving height
above a certain speed.
The height adjustment may
only be used temporarily. Drive
only at a walking pace. Be
careful to ensure that when
adjusting the vehicle height
that persons or objects do not
become trapped between the
vehicle and the road or the roof
of a construction.
Information symbol I-E4
INSTRUMENTS AND ACTUATORS 25
 appears on the main display
when the vehicle is either in the
raised or lowered position.
See also "MAIN DISPLAY AND
INFORMATION SYMBOLS".
16. TRAILING AXLE STRAIGHT
AHEAD LOCK SWITCH
4 Using this rocker switch with the
symbol lock is closed the
trailing axle is set and locked in a
straight ahead position.
This kocker switch only to be
applied whilst driving on loose
ground or on a slippery road
surface or strong variable
drive- and exits. The straight
ahead lock may be turned on
whilst the vehicle is stationary
or moving slowly. De-activate
the lock as soon as possible.
See also "DRIVING".
17. DIFFERENTIAL LOCK
SWITCH
Optionally a differential lock can be
applied. The differential lock can be
turned on and off using this rocker
switch. The inspection light in the
rocker switch indicates that the
26 INSTRUMENTS AND ACTUATORS
differential lock is turned on. The
information symbol I-C6 appears on
the main display when the differential
lock is on.
The differential lock may only
be used when driving on loose
ground or on a slippery road
surface, but never on a surface
which provides good traction.
The differential lock should be
turned on whilst the vehicle is
stationary or moving very
slowly and when the clutch
pedal is depressed.
The differential lock may never
be turned on whilst the wheels
are spinning.
In case of a automatic gearbox
the vehicle should come to a
standstill and in neutral (N).
18. TRACTIVE ASSISTANCE
SWITCH
Vehicles with a trailing axle are
equipped with a momentary switch
for tractive assistance. Activate the
system by pressing the momentary
switch on the symbol and again de-
activated by pressing the switch at
the bottom. When the air is released
from the air bellows on the trailing
axle, the driven axle experience
temporarily more grip.
The momentary switch may be
actuated at speeds lower than 5 km/
h and is automatically de-activated
above 30 km/h. The tractive
assistance is active for 90 seconds
after it is selected. The system can
only be re-activated after 50 seconds
have elapsed. See also “DRIVING”.
19. AIR SUSPENSION
DRIVING LEVEL SWITCH
The vehicle can be brought back to
the normal driving level by pressing
the momentary switch once. The
switch can be used when the vehicle
is stationary or moving very slowly.
Be careful to ensure that when
adjusting the vehicle height
that persons or objects do not
become trapped between the
vehicle and the road or the roof
of a construction.
20. MAIN SWITCH ACTUATORS
If the main switch is turned off, the
electrical unit does not provide a 1. Left-hand combination switch 5. Brake pedal
current except for the hazard 2. Engine brake switch 6. Accelerator pedal
warning lights and the tachometer. 3. Pneumatic steering wheel adjustment switch 7. Right-hand combination switch
The main switch can not be turned 4. Clutch pedal
off as long as the steering lock/con-
tact/start switch is activated.
4
21. R36 SWITCH
(CENTRAL SAFETY SWITCH)
When the central safety switch is
operated:
- the engine is automatically
switched off,
- the hazard warning lights start to
flash,
- the electrical system is
de-energised with the exception
of the tachograph and the hazard
lights.
Switches back the R36-switch to
reset the system. Follow the start
procedure to re-start the engine.

INSTRUMENTS AND ACTUATORS 27

 STEERING COLUMN SWITCHES LEFT-HAND COMBINATION SWITCH
Direction indicators
There are two switches on the steering The indicators will only work with the ignition
column. The functions of the left hand switch switched on.To operate the direction
are as follows: 3 indicators briefly when changing lanes, the
- Lighting (headlight flash/dipped beam/ switch should be pulled back slightly against
main beam) the perceptible spring pressure. It will spring
- Direction indicators 0 back when it is released.
R
4 - Horn I
- Windscreen wipers (interval/speed/ Horn
wash) H
Press button (K) (Horn can only operate with
the ignition switched on).
The function of the right-hand switch are as K J
L
03690 B
follows: Interval for intermittent wipe
- Engine speed control The standard interval is 2 or 10 seconds
- Cruise-control depending on the value programmed in the
- Variable vehicle speed limiter H Centre position (dipped beam, with lights electronic unit.
- Retarder on) The windscreen wipers only work if the
I Headlight flash ignition switch on.
J Main beam Always switch off the windscreen wipers
L Direction indicators, left - in winter conditions - before putting the
R Direction indicators, right ignition key in the rest position in order
K Horn to prevent damage to windscreen wipers
3 Windscreen wiper switch which are frozen solid.
O Wipers off
--- Intermittent wipe Windscreen washers
I Wipers on, low speed The windscreen washers are activated by
II Wipers on, high speed pressing the spring-operated switch (3). The
windscreen wipers are activated after 2
seconds and will make 2 wiper strokes.

28 INSTRUMENTS AND ACTUATORS

RIGHT-HAND COMBINATION SWITCH ADJUSTABLE STEERING COLUMN

1 2 3

SET

OFF
R
0 OFF
4
LIM
- Cruise-control
SET
S The cruise control can only be engaged
R
RE
if the vehicle speed is higher than
03691 B
30 km/h.
- Variable vehicle speed limiter
The variable vehicle speed limiter (also
know as foot-on cruise control) allows the
Various control functions can be switched on vehicle speed to be limited to a speed The position of the steering column and the
and off using control functions 1, 2 and 3 on set by the driver whilst accelerator pedal height of the steering wheel are
the combination switch: is operated. pneumatically adjustable. The switch on the
- Retarder floor of the bus must be pressed in order to
- Engine speed control The steering column switch can be used adjust the steering column. Both settings
The engine speed control allows the to select a specific braking torque. (position and height) can be adjusted at the
engine speed to be directly increased to same time. The steering column is locked
a pre-programmed value in the electronic Note: again by releasing the button on the floor of
unit. The engine speed can be increased For more information on these control the bus.
or decreased to a required value. functions see the chapter "DRIVING" .
Adjusting only possible when
the parking brake is applied
and in some specifications if
the door is open.

INSTRUMENTS AND ACTUATORS 29

 TACHOGRAPH

An MTCO (disc) tachograph or an DTCO

(digital) tachograph is mounted depending
on the vehicle specification.

For more information we refer to the

operating instruction of the tachograph
4 supplier.

30 INSTRUMENTS AND ACTUATORS

5. Main display 5

MAIN DISPLAY GENERAL 31

 Page KEY TO ABBREVIATIONS:
Driver information ................................. 33
Warning lights overview ....................... 33 ABS Anti-lock Braking System
Warning lights description .................... 34 ASR Anti Spin Regulation
Main display general ............................ 36 ECAS Electronically Controlled Air
Information screen ............................... 37 Suspension
Warning screen .................................... 41 ECU Electronic Control Unit
Error Screen ......................................... 44 (compares VFC, ICM en IOU's)
5 EDC Electric Distribution Centre
ESC Engine Speed Control
ICM Instrument panel Control Module
IOU Input Output Unit
RET Retarder
UPEC Unit Pump Electronically
Controlled
VFC Vehicle Function Controller

32 MAIN DISPLAY GENERAL

DRIVER INFORMATION WARNING LIGHTS OVERVIEW

The instrument panel and main display will

show the driver all information regarding
function and operation of the vehicle. The
information appears by up-lighted warning
lights and via symbols on the main display.

The main display is a liquid crystal display

screen (LCD). Under cold circumstances 5
(overnight below 4 degrees Celsius), the
main display might appear to display in
reverse mode. This behaviour is considered
normal and will gradually disappear when
warming-up the vehicle interior. The
warming-up time will depend on the A1 Charging current/ battery low voltage B1 Tachograph
overnight storage temperature. A2 Air pressure too low B2 ABS fault
A3 Central warning AMBER B5 Dipped beam
In the first part of this chapter the warning A4 Central warning RED B6 Rear fog lights
lights will be explained. In the second part A5 Main beam
the symbols on the main display. A6 Indicators/ hazard

After turning on the main switch 20 on the

instrument panel all warning lights will lit for
a short time to check their function.

MAIN DISPLAY WARNING LIGHTS 33

 WARNING LIGHTS DESCRIPTION
CHARGING CURRENT
WARNING LIGHT (A1)
The warning light goes out when the
engine is running.
If starting the engine does not
turn over and warning light A1
lights up simultaneously with
amber light A3 or red light A4,
5 then charge up the empty
batteries or replace them.
When driving the vehicle (or
with engine running) the
warning light A1 illuminates
simultaneously with the red
warning light, this indicates
that there is no charging
current. Stop the vehicle as
soon as possible and turn off
the engine. Since the batteries
are constantly being dis-
charged, all non-essential
electrical power consumers
should be turned off. Check
whether the V-belts are faulty
or slipping. If not this could
indicate a defect in the alterna-
tor or wiring. If the warning
34 MAIN DISPLAY WARNING LIGHTS
buzzer is also audible, then the
battery level is so low that
functionality may be lost. Have
the fault repaired as quickly as
possible at a VDL Bus work-
shop.
AIR PRESSURE LIGHT (A2)
AIR PRESSURE TOO LOW
This warning light is lit if the air
pressure in one of the service brake
circuits is too low. The parking brake
lever in locked position can only be
disengaged when the warning
indicator A2 is off.
After a cold start, increasing the idle
speed can speed up the air pressure
build up.
When this warning light
appears whilst driving, stop
immediately at a save place.
The parking brake may be used
as an emergency brake if there
is a problem with the service
brake. N.B. Whilst using the
parking brake the ABS will not
work!
AMBER COLOURED (A3)
WARNING LIGHT
The AMBER central warning light is
lit if a minor fault occurs in a vehicle
system. The main display shows
automatically during a period of 5
seconds which system has caused
the fault (for example coolant level
low).
You may continue driving but
action must be taken at first
opportunity to remedy the
fault!
Read also the description of
the relevant warning lights and
the symbols that appears on
the screen of the main display.
RED COLOURED (A4)
WARNING LIGHT
The red central warning light is lit if a
serious fault occurs in a vehicle
system. The main display shows
which system has caused the fault.
A buzzer will also sound in case off:
temperature in the engine compart-
ment is too high or with running
engine if battery voltage is low either
or the oil pressure is too low either
or coolant level is low either or the
pressure in the pneumatic system is
under 6 bar.
If a red warning LIGHT appears,
stop immediately at a save
place and turn off the engine!
Read also the description of
the relevant warning lights and
symbols that appears on the
screen of the main display.
Have the error repaired as
quickly as possible by a VDL
Bus workshop.
MAIN BEAM
INSPECTION LIGHT (A5)
This inspection light is lit if the main
beam is turned on or a flash signal
is given.
INDICATORS / HAZARD
INSPECTION LIGHT (A6)
This light flashes together with the
vehicle’s indicators and the hazard
warning lights. If this light flashes
more quickly, the light bulb is faulty
or old. Remedy; replace the bulb.
TACHOGRAPH (B1)
This inspection light is lit if a failure
occurs in the tachograph, a related
component or in the communication
in between.
See also "TACHOGRAPH".
DIPPED BEAM
INSPECTION LIGHT (B5))
The inspection light is lit when the
dipped beam is turned on.
REAR FOG LIGHT
INSPECTION LIGHT (B6)
This inspection light is lit when the
rear fog light is turned on.
WARNING LIGHT ABS (B2)
This light is lit if there is a fault in the
ABS system.
This light is lit in combination 5
with warning indicator A3 if
there is a fault with the ABS.
Stop immediately at a safe
place!
In this case, check the fuses in
the ABS electronic box. If the
fault is not corrected by
inserting a new fuse, the vehi-
cle may only be driven to the
nearest VDL Bus workshop.
Have the fault repaired
immediately! The ABS system
will no longer function, al-
though the service brake will
still continue to function
correctly.
MAIN DISPLAY WARNING LIGHTS 35
 MAIN DISPLAY GENERAL

When the main switch 20 of the vehicle is The warning-screen appears in the event The error-screen appears in the event of a
switched on the LCD main display will be of a system error (the amber warning light critical error in the vehicle (the warning
activated. After a black start up screen the A3 also appears). indicator A4 also appears).
menu switch 1 can display the following After 5 seconds the warning-screen will This error-screen will be active until the error
screens: disappear and will be replaced by the is solved.
- Information-screen information screen. By activating the menu In case of de-actuating the screen by menu
- Warning-screen switch 1 the warning-screen can be switch 1 the error screen will return after 5
- Error-screen reactivated. seconds.
5

The symbol <i> on the left-hand side of the
main display indicates the activated
information screen.
By depressing the menu-switch 1 on the
instrument panel, the information-,
warning- and error-screen can
be displayed.
The air pressure gauges on the right-hand
side of the main display are always visible
regardless of which screen is selected in the
main display.
The position of the symbols can very in the
different screens. The function of each
symbol is described further on in this chapter.
Simultaneous screens are possible. The
activated screens will be displayed on the
button bar on the main display. The symbol
of which screen is displayed is located on
the left-hand side of the main display.

36 MAIN DISPLAY GENERAL

DESCRIPTION OF THE SYMBOLS ON
THE INFORMATION-SCREEN.
INFORMATION SYMBOL (I-C1)
AIR CONDITIONING
This symbol appears when the
airconditioning is turned on.

INFORMATION SYMBOL (I-C2)

ASR (ANTI SPIN REGULATION)
Optionally a ASR system can be
I-E1 Retarder foot control disengaged applied. This symbol appears when 5
I-E2 Retarder in operation the ASR system is activated. ASR is
I-E3 Trailing axle NOT locked a fully automatic system which is
I-E4 Air suspension level integrated with the ABS system and
The 3 different levels are the engine management system.
I =Information-screen described in the following text The ASR prevents the wheels from
I-C1 Aircondition on (body builder) I-E5 Traction control activated spinning when pulling away and
I-C2 ASR I-E6 Glow automatic engaged driving on slippery roads (especially
I-C3 Bus stop (body builder) during acceleration in curves). If the
I-C4 Bus stop wheelchair (body builder) I-G6 Parking brake activated wheels spin, depending on the
I-C5 Not applicable driving circumstances, the driven
I-C6 Differential lock activated The coordinates of the symbols in the ma- wheels are slowed down and/or the
I-C7 Air pressure gauges (actual situation) trix on the screen are defined using letters acceleration is reduced. There are
along the left hand side and numbers along no controls or interrupter for the ASR
I-D1 Door/hatch not locked (body builder) the top. The co-ordinates are shown in system.
I-D2 Emergency door not locked (body b) brackets, e.g. (I-C1).
I-D3 Halt brake (body builder)
I-D4 Parking heater (body builder) The body builder symbols only will be
I-D5 Oil pressure when engine not running displayed if those are activated by the body
I-D6 Ramp activated builder

MAIN DISPLAY INFORMATION SYMBOLS 37

 INFORMATION SYMBOL (I-C3)
BUS STOPPING
Optionally a bus stop button can be
applied. This symbol appears when
de button has been pressed.
INFORMATION SYMBOL (I-C4)
BUS STOPPING
5 Optionally a bus stop button for
disabled can be applied. This symbol
appears when the button has been
pressed.
INFORMATION SYMBOL (I-C6)
DIFFERENTIAL LOCKED
Optionally a differential lock can be
applied. This symbol appears when
the differential lock switch 17 is
activated.
38 MAIN DISPLAY INFORMATION SYMBOLS
The air pressure indication symbol for the
service brake system is always visible and
shows the actual air pressure level.
AIR PRESSURE GAUGES (I-C7)
The gauges are working when the
main-switch is in position “ON”.
Each gauge indicates the air
pressure in the reservoirs of one of
the service brake system circuirs
(circuit 1 and 2). Warning light A2 is
lit if the pressure is below 6 bar and
a buzzer sounds when the engine
is running.
The parking brake can only be
released once circuit 3 is filled. This
might cause a certain delay.
It is not permitted to drive the
vehicle if the air pressure is
below 6 bar.
INFORMATION SYMBOL (I-D1)
DOOR / HATCH NOT LOCKED
Optionally a signal can be applied.
This symbol appears when the door
or the hatch is not locked.
INFORMATION SYMBOL (I-D2)
EMERGENCY DOOR NOT
LOCKED
Optionally a signal can be applied.
This symbol appears when the
emergency door is not locked.
INFORMATION SYMBOL (I-D3)
HALT BRAKE
Optionally a halt brake system can
be applied. This symbol appears
when the halt brake is activated.
INFORMATION SYMBOL (I-D4)
PARKING HEATER
Optionally a parking heater can be
applied. This symbol appears when
the parking heater is activated.
INFORMATION SYMBOL (I-D5)
ENGINE OIL PRESSURE
This symbol appears when the main
switch 20 is activated and the engine
is not running. This symbol must
disappear after starting the engine.
INFORMATION SYMBOL (I-D6)
RAMP ACTIVATED
Optionally a ramp can be applied.
This symbol appears when the
device is activated.
INFORMATION SYMBOL (I-E1)
RETARDER OFF
This symbol appears when the
retarder foot control function is
disengaged using switch 14.
INFORMATION SYMBOL (I-E2)
RETARDER IN OPERATION
This symbol appears when the
retarder is activated by means of the
foot control or the manual control.
See also operating instructions
retarder in chapter "DRIVING".
If this symbol flashes the
requested braking force
cannot be provided. The
retarder may be temporarily
too hot. Adjust the vehicle
speed using the service brake
and changes to the lowest
possible gear (increase the
engine speed).
INFORMATION SYMBOL (I-E3)
TRAILING AXLE NOT LOCKED
Only applicable for vehicles with a
trailing axle. This symbol (unlocked)
appears at driving speeds below 30
km/h when the trailing axle steering
lock switch 16 is NOT activated.
This symbol indicates that the trailing
axle steering ability is enabled.
Also see chapter “DRIVING”.
MAIN DISPLAY INFORMATION SYMBOLS
INFORMATION SYMBOL (I-E4)
VEHICLE NOT AT DRIVING LEVEL
When the ignition switch is turned on,
this symbol is briefly visible. The
symbol I-E4 is visible when the
vehicle is not at the normal driving
height. If necessary, use switch 19
“air suspension driving level switch”
to bring the vehicle to the normal 5
driving height.
INFORMATION SYMBOL (I-E4)
KNEELING LEVEL
When this symbol appears, the
vehicle is not at the driving height but
in the kneeled position.
Use switch 19 to bring the vehicle
to the normal driving height.
Increasing speed of the (slow
moving) vehicle will bring the vehicle
to the normal driving height
automatically.
39
 INFORMATION SYMBOL (I-E4)
SUPER KNEELING LEVEL
When this symbol appears, the
vehicle is not at the driving height but
in the super kneeled position.
Use switch 19 to bring the vehicle
to the normal driving height.
Increasing speed of the (slow
5 moving) vehicle will bring the vehicle
to the normal driving height
automatically.
INFORMATION SYMBOL (I-E4)
BUS LANE LEVEL
When this symbol appears, the
vehicle is not at the driving height but
in the super kneeled position.
Use switch 19 to bring the vehicle
to the normal driving height.
Increasing speed of the (slow
moving) vehicle will bring the vehicle
to the normal driving height
automatically.
40 MAIN DISPLAY INFORMATION SYMBOLS
INFORMATION SYMBOL (I-E4)
FERRY LIFT
When this symbol appears, the
vehicle is not at the driving height but
in the ferry lift position.
Use switch 19 to bring the vehicle
to the normal driving height.
Increasing speed of the (slow
moving) vehicle will bring the vehicle
to the normal driving height
automatically.
INFORMATION SYMBOL (I-E5)
TRAILER AXLE TRACTION
CONTROL ACTIVATED
Only applicable for vehicles with a
trailing axle. This symbol appears
when traction control is activated by
using switch 18. When the air is
released from the air bellows on the
trailing axle, the driven axle
experiences temporarily more grip.
The traction control is operational
during a period of 90 seconds. It will
automatically be de-activated if the
vehicle speed exceeds 30 km/h and
remains off until the switch is
pressed again.
INFORMATION SYMBOL (I-E6)
GLOW
This symbol appears when the
pre-glow time or after-glow time has
been activated by the electronic unit.
When the contact switch is turned
on, the pre-glow time and after-glow
time will be determined by the engine
management’s electronic UPEC
unit.
SYMBOL (I-G6)
PARKING BRAKE ON
This symbol appears when the par-
king brake is activated. The symbol
disappears when the parking brake
is released.
Note:
If parking brake is on this symbol is
always visible regardless of which
screen is selected in the main
display and appears at co-ordinates
I-G6, W-G6 and E-G6 for each
respective screen.
DESCRIPTION OF THE SYMBOLS ON
THE WARNING-SCREEN. W-E1 Engine management fault
W-E2 Not applicable WARNING SYMBOL (W-C1)
W-E3 Ramp activated GEAR BOX
W-E4 Retarder function not correctly This symbol appears when there is
W-E5 Not applicable a gearbox failure.
W-E6 Not applicable
WARNING SYMBOL (W-C2)
W-F1 Not applicable BRAKE LINING
W-F2 Not applicable (driving level) This symbol appears when the brake
W-F3 Trailing axle locking system lining reaches the minimum 5
thickness.
W-G6 Parking brake activated
WARNING SYMBOL (W-C4)
The co-ordinates of the symbols in the ma- COOLANT LEVEL TOO LOW
W = Warning-screen trix on the screen are defined using letters If this symbol appears the coolant
W-C1 Gearbox failure along the left hand side and numbers along level is too low.
W-C2 Brake lining minimum thickness the top. The co-ordinates are shown in For checking and topping up
W-C3 Not applicable brackets, e.g. (W-C1). of the coolant level please
W-C4 Coolant level too low read instructions in the
W-C5 Differential lock error If one of the symbols shown chapter "MAINTENANCE".
W-C6 Door / hatch not locked below appears, then the amber
W-C7 Air pressure gauges (actual situation) coloured warning light A3 will WARNING SYMBOL (W-C5)
be illuminated. DIFFERENTIAL LOCK ERROR
W-D1 Electronic Control Unit error It is permitted to continue This symbol appears should an er-
W-D2 Not applicable driving, but action must be ta- ror occur after the differential lock
W-D3 Function to describe by body builder ken at the earliest opportunity has been selected using switch 17.
W-D4 Halt brake malfunction to resolve the problem! Read
W-D5 Emergency hammer also the remarks beside the
W-D6 Air suspension ECAS fault symbols printed in bold letters.

MAIN DISPLAY WARNING SYMBOLS 41

 WARNING SYMBOL (W-C6)
DOOR / HATCH NOT LOCKED
Optionally a signal can be applied.
This symbol appears when the door
or the hatch is not locked.
WARNING SYMBOL
ERROR IN ECU (W-D1)
5 This symbol appears should an er-
ror occur in one of the electronic
units or in the communication
between.
WARNING SYMBOL (W-D3)
FAILURE
Optionally a failure signal can be
applied. Consult body builder
description.
WARNING SYMBOL (W-D4)
HALT BRAKE
This symbol appears should an er-
ror occur in the halt brake system.
Until the error is fixed apply
the service brake in case the
doors are opened.
42 MAIN DISPLAY WARNING SYMBOLS
WARNING SYMBOL (W-D5)
EMERGENCY HAMMER
Optionally a warning signal can be
applied. This symbol appears when
the hammer is removed.
Make sure a new emergency
hammer is fitted as soon as
possible.
WARNING SYMBOL (W-D6)
ECAS FAULT
This symbol appears when there is
a small fault in the ECAS system and
the system no longer functions
correctly.
WARNING SYMBOL (W-E1)
ENGINE MANAGEMENT
This symbol appears when there is
a small fault in the engine manage-
ment system (UPEC) and the
system no longer functions correctly.
WARNING SYMBOL (W-E3)
RAMP ACTIVATED
Optionally a ramp can be applied.
This symbol appears when the
device is activated.
WARNING SYMBOL (W-E4)
RETARDER NOT WORKING
This symbol appears should an er-
ror occur in the retarder and the
system no longer functions correctly.
WARNING SYMBOL (W-F3)
TRAILING AXLE LOCKING
SYSTEM
Only applicable for vehicles with a
trailing axle. Defect in one of the 2
air supply chains of the locking
system in the event the vehicle
speed is above 30 km/h and the
symbol (unlocked) is still not
extinguished.
The trailer axle locking
system will still be
operational, but repair of the
defect air supply is urgently
needed.
SYMBOL (W-G6)
PARKING BRAKE ACTIVATED
This symbol appears when the par-
king brake is activated. The symbol
disappears when the parking brake
is released.
Note:
If parking brake is on this symbol is
always visible regardless of which 5
screen is selected in the main
display and appears at co-ordinates
I-G6, W-G6 and E-G6 for each
respective screen.
Because there is no actual
fault when symbol W-G6
appears, the amber coloured
warning indicator A3 will not
illuminated

MAIN DISPLAY WARNING SYMBOLS 43

 DESCRIPTION OF THE SYMBOLS ON
THE ERROR-SCREEN.
ERROR SYMBOL (E-C2)
TRAILER AXLE NOT LOCKED
Only applicable for vehicles with a
trailing axle. Serious defect or fault
in the locking system in the event the
vehicle speed is above 30 km/h and
E-E1 Gearbox error the symbol (unlocked) is still not
extinguished. Have the error
5 E-G6 Parking brake activated repaired as quickly as possible by
a VDL Bus workshop.
The co-ordinates of the symbols in the ma-
trix on the screen are defined using letters ERROR SYMBOL (E-C5) ENGINE
along the left hand side and numbers along OIL PRESSURE TOO LOW
E = Error-screen the top. The co-ordinates are shown in This symbol appears when the
E-C1 Not applicable brackets, e.g. (E-C1). engine is running and the oil
E-C2 Trailer axle not locked pressure is too low. Also a buzzer
E-C3 Not applicable If one of the symbols shown will sound.
E-C4 Not applicable below appears, then the red Allow the engine to cool
E-C5 Engine oil level too low coloured warning light A4 will down. Check oil level and
E-C6 Engine management error be illuminated. then top up oil. If the symbol
E-C7 Air pressure gauges (actual situation) Stop immediately at a save remains visible turn of the
place and turn off the engine! engine and have the error
E-D1 ECAS error Read also the remarks beside repaired as quickly as
E-D2 Alternator voltage too high the symbols printed in bold possible by a VDL Bus work-
E-D3 Engine compartment temp. too high letters. shop.
E-D4 Function to describe by body builder
E-D5 Electronic Control Unit error
E-D6 Coolant level too low

44 MAIN DISPLAY ERROR SYMBOLS

ERROR SYMBOL (E-C6)
ENGINE MANAGEMENT ERROR
This symbol appears when there is
a serious fault in the engine mana-
gement system (UPEC) that might
cause the engine to stop. Have the
error repaired as quickly as
possible by a VDL Bus workshop.
ERROR SYMBOL (E-D1)
ECAS ERROR
This symbol appears when there is
a serious fault in the ECAS air
suspension system. Have the error
repaired as quickly as possible by
a VDL Bus workshop.
ERROR SYMBOL (E-D2)
ALTERNATOR VOLTAGE HIGH
This symbol appears when the load
voltage of the alternating current al-
ternator rises above 30 V. The
battery voltage is then too high and
the battery may boil.
Turn on as many electrical
consumers as possible. The
vehicle must not be driven
any further if the symbol
remains visible! Have the fault
repaired immediately by a
VDL Bus workshop.
ERROR SYMBOL (E-D3)
ENGINE COMPARTMENT TEMP
This symbol appears if the
temperature in the engine
compartment exceeds 110° C. Also
a buzzer will sound.
Indication 1: If coolant tempe-
rature indicates a cooling
problem then allow the engine
to idle for a couple of minutes
and turn the engine off.
Indication 2: If no indication
of a cooling problem then
beware of fire. Therefore, be
careful when entering the
engine compartment.
There is a fire risk!
Turn off the current using the
main switch or the R36
switch. If there is a danger,
make sure the passengers
are safe.
Have a fire extinguisher at
hand when entering the
engine compartment. Do not 5
open the hatch when smoke
appears, but try to extinguish
via other entrances. A fire
may flare up when entrance
hatch to the engine
compartment is opened.
ERROR SYMBOL (E-D5)
ERROR IN ECU (E-D1)
This symbol appears should an er-
ror occur in one of the electronic
control units or in the communication
between. Have the error repaired
as quickly as possible by a VDL
Bus workshop.
MAIN DISPLAY ERROR SYMBOLS 45
 ERROR SYMBOL (E-D6)
COOLANT LEVEL TOO LOW
If this symbol appears the coolant
level is too low.
Probably caused by serious
leakage. Allow the engine to
cool down, find and repair the
leakage and then top up
5 coolant level. If the symbol
remains visible have the error
repaired as quickly as
possible by a VDL Bus work-
shop.
ERROR SYMBOL (E-E1)
GEAR BOX
This symbol appears when there is
a gearbox failure. Have the error
repaired as quickly as possible by
a VDL Bus workshop.
46 MAIN DISPLAY ERROR SYMBOLS
SYMBOL (E-G6)
PARKING BRAKE ON
This symbol appears when the
parking brake is activated. The
symbol disappears when the parking
brake is released.
Note:
If parking brake is on this symbol is
always visible regardless of which
screen is selected in the main
display and appears at co-ordinates
I-G6, W-G6 and E-G6 for each
respective screen.
Because there is no actual
fault when symbol E-G6
appears, the red coloured
warning indicator A4 will not
illuminated.
6. Driving 66

DRIVING 47
 Page Page
General information .............................. 49 Speed limiter ........................................ 64
Steering lock/contact-/start switch ........ 49 Cruise-control ....................................... 64
Control panel in engine compartment .. 50 Variable vehicle speed limiter ............... 65
Pre glow system ................................... 50 Engine rev control ................................ 66
Start procedure .................................... 51 Air conditioning rev control ................... 68
Stopping/ switch off engine/ and de- Steering ................................................ 68
activating instrument panel .................. 52 Differential lock ..................................... 68
Parking brake/emergency brake .......... 52 Driving with a trailer axle (3e axle) ......... 69
Manual gearbox ................................... 53 Driving whilst towing a trailer ................ 70
Automatic gearbox ............................... 54
6 Retarder ............................................... 57
Retarder manual engaging .................. 58
Retarder manual deactivating .............. 58
Retarder V = constant control function . 59
Retarder symbols on main display ....... 59
The brakes ........................................... 60
ABS ...................................................... 60
Warning light ABS ................................ 60
ASR ...................................................... 60
Service brake (foot brake) .................... 61
Driving with combined brake ................ 61
Retarder foot control braking force ....... 62
Engine brake (exhaust) ........................ 62
Halt brake ............................................. 63

48 DRIVING
GENERAL INFORMATION STEERING LOCK/
CONTACT/START SWITCH
Before setting out on a journey, always
check: Never remove the key whilst Position M: Contact on.
- the vehicle for possible water or oil leaks driving. This cause the steering All the electricity consumers can be turned
- engine oil level gear to become locked. on.
- the fluid level in the washer fluid
reservoir Position D: Starting
- the air filter indicator The key will return to position M when
- wheel attachment and tyre pressures released.
- tread depth of tyres
- tread of each tyre for even distribution of Comment:
wear pattern The key cannot be removed from the con-
- the correct setting of seat and mirrors tact slot if the battery voltage is too low. 6
- operation of lights and instruments The key can be turned from position St
- the fuel level on instrument panel to position M, but cannot be turned any
further or back.
After each journey check that:
- the main switch is OFF
- The parking brake is ON
- the doors of the vehicle are locked
St. position: Off position
Note: The key may be removed.
If the vehicle is parked on a hill pay The steering wheel will be locked when the
attention to the incline and the surface. If key is removed.
necessary place chocks in front of or
behind the wheels and turn the front Position A: Unlocked position
wheels so that if the vehicle does start The steering wheel is unlocked. The key
moving, it will not roll onto the road. cannot be removed.

DRIVING 49
 CONTROL PANEL IN THE ENGINE
COMPARTMENT
For safety reasons and to help with certain
service work, the engine can be started from
the engine compartment.
6 Apply the vehicle’s parking brake and put the
When the FRONT/REAR switch is set to
REAR, it is not possible to start the vehicle
using the contact/start switch, or vice versa.
N.B. Apply the parking brake first!
The conditions for starting the engine from
the engine compartment are:
- Main switch in the “On” position.
- Contact/start switch in the “On” position,
“M”.
- Gearbox in neutral, “N”.
50 DRIVING
PRE-GLOW SYSTEM
When the contact switch is turned on, the
In order to prevent accidents whilst carrying electronic unit automatically determines the
out work in the engine compartment, inter- required pre-glow time and after-glow time.
rupters can be fitted in the engine control box The necessary pre-glow time and after-glow
which make it impossible to start the engine time depends on the temperature measured
from the driver’s position when the engine by the engine management’s electronic unit.
hatch is open. The interrupters are fitted by The information symbol I-E6 will appear on
the bodywork builder. the main display if the pre-glow time is acti-
vated by the electronic unit.
Starting the engine from the engine
compartment
gearbox into neutral.
First turn on the main switch on the instru-
ment panel and turn the steering lock/con-
tact/start switch in the M-position.
At the rear of the engine compartment: place
the selector switch S1 to position “Rear”.
Start the engine by pressing switch S2 up-
wards.
Pressing switch S2 downwards can turn off
the engine.
S1. Front/rear selector switch
S2. Engine start/stop button
Turn selector switch S1 in position “FRONT”
afterwards.
START PROCEDURE
Use the exhauster or open the
doors of the building if the
engine is started in a closed
space. The exhaust fumes
contain carbon monoxide,
which is an invisible and
odourless poisonous gas. If
inhaled, this gas may cause
unconsciousness or even
death.
1. Apply the vehicle’s parking brake.
2. Put the gearbox in "neutral" (N).
3. Turn on the main switch. The instrument
panel will perform a self-test. During the
test all warning lights and the instrument
panel lights will lit. The needles on all
gauges will turn once to their maximum
position and return to their zero position,
this confirms the correct function of those
gauges. A buzzer in the instrument panel
will sound for a short period.
The main display and the odometer/trip
meter will be illuminated after the self-
test. The information screen and the
pressure gauges will be exposed on the
main display.
4. Rotate the lock/contact/start switch to the
M-position. The diagnosis system will
check all relevant electronic functions off
the vehicle. At the same moment the
charging current light (A1) will lit and on
the main display symbol I-D5 “engine
standstill oil pressure” will be visible.
Symbol I-E6 “glow” will shortly appear
when engine temperature is low. Symbol
“trailer axle not locked” I-E3 will appear
when a trailer axles is applied.
5. Starting: Wait until the information symbol
“glow” I-E6 is no longer visible before
turning the contact switch further to the
D position. If the engine fails to start, the
key must be released after 10 seconds.
Wait a couple of seconds and try again.
When the engine is running,
the engine speed must not be
increased before the oil
pressure symbol I-D5 on the
main display has disappeared.
All warning lights and symbols
on the main display should
disappear after starting the
engine, with exception of the
parking brake symbol and - in
case the vehicle is equipped
with a trailing axle - the trailing
axle not locked symbol on the
main display. In case the instru-
ment panel shows other
warning lights or symbols act
according to the instruction in 6
the chapter “MAIN DISPLAY
AND INDICATORS”.
DRIVING 51
 STOPPING/ SWITCH OFF ENGINE AND
DE-ACTIVATING INSTRUMENT PANEL
Put the gearbox in neutral "N" when de
vehicle is stationary.
Before switching of the engine - after a long
trip or when the engine has been subjected
to high loading - let it idle for ad least 5
minutes. It is important to let the engine run
for a while in order to prevent the coolant
temperature becoming to high and to allow
the turbocharger to cool down.
Switch the engine off by turning the contact
6 key to A-position or St-position.
Only after the steering lock/contact/start
switch is turned to the A-position the main
switch on the instrument panel can be turned
off.
After turning off the main switch the main
display will gradually light down into the stand
by mode and after some time will be turned
off completely into the sleep mode (black
display).
Comment:
The engine can also be stopped using
the “stop” push button on the control
panel in the engine compartment.
52 DRIVING
PARKING BRAKE/ EMERGENCY BRAKE
Parking brake as a emergency brake
Only apply the parking brake
as a emergency brake if the
service brake does not work.
Since the parking brake only
effects the rear wheels, it has
a limited braking capacity. The
wheels may skid, because the
parking brake is not equipped
Always apply the parking brake
with ABS.
after parking the vehicle and
when leaving the drivers seat.
Actuating the parking brake as
Do not release the parking
a emergency brake in a vehicle
brake whilst the steering lock
with a AS Tronic gearbox whilst
is still engaged. The vehicle
driving on a slippery road may
can not be steered if the stee-
result in the engine coming to
ring lock is still engaged.
a standstill. Power assisted
steering is then no longer
Lift the locking ring (2) and push the parking
available!
brake lever (1) forwards, to release the park-
ing brake.
Pull the parking brake lever gradually
To engage the parking brake, the parking
backward to stop the vehicle. Do not move
brake lever must be pulled fully backwards
the parking lever past the locking cam. In
till it clicks. Check whether it will hold by
full backward position the maximum braking
giving the parking brake lever a small push.
force is applied to the rear wheels.
When the parking brake is engaged a
symbol will appear on the main display.

Parking or remaining stationary on a
slippery incline
Never park the vehicle on a
slippery incline.
Do not leave the driver’s seat
when the vehicle is stationary
on a slippery and/or snowy
incline. Remain present in
order to apply the footbrake if
it appears that, as a result of
the slippery surface, the grip
of the wheels to which the
parking brake is applied in
order to keep the vehicle
stationary is less than the
force of gravity.
Include a co-driver for journeys which may
include slippery inclines, so that the driver
can remain in his seat if the vehicle
becomes stationary on a slippery incline.
Keep a mobile telephone and a local
emergency number close at hand in or-
der to call for help, if necessary.
MANUAL GEARBOX
R 1 3 5
N2 4 6
02713B
Optionally a GO-170, GO-190 or GO-210
gearbox can be applied.
Drive away in first gear. Preferably keep your
revs between 600 and 800 min-1. Do not
push the accelerator pedal whilst driving on
a flat road. Don't go beyond 1,000 min-1 in
1st and 2nd gear. Therefore, make sure the
rev counter remains in the green section! The
EURO 3 engines do have almost 100% of
torque from an engine speed slightly higher
than the idling speed; so stay in the green
area! Caused by the high torque of the new
EURO 3 engines the vehicle can pull away
with almost stationary revs when the vehi-
cle is fully loaded! This way you can prevent
fast wear of the clutch.
In order to avoid fast wear of the clutch plate
and the clutch pressure group we strongly
advise you when shunting this vehicle only
to use the lowest gear.
The gear lever has seven positions:
Six forward gears and one reverse gear (R).
The gearbox is synchronised, so do not use
the double de-clutch method.
Comment:
Incorrect changing of the gears may dam-
age the engine or clutch. 6
The gearbox may only be put into reverse
when the vehicle is at a complete standstill.
When changing down gear, always make
sure the speed is not too fast for the gear
being changed into.
Activating en de-activating retarder
Read instruction retarder manual control and
service brake for correct activating en de-
activating of the retarder.
DRIVING 53
 AUTOMATIC GEARBOX
Optionally a ZF AS Tronic or a ZF Ecomat2
gearbox can be applied. Both gearboxes are
described below.
Both gearboxes are equipped with an
integrated retarder. Read instruction in the
chapters "retarder manual control" and
"service brake" for engaging and
disengaging of retarder.
The driver must not leave the
6 vehicle when the engine is
running and the gear is
selected (selector switch set to
D or R)!
The vehicle can be moved by
releasing the brakes and
simply depressing the
accelerator.
In order to prevent the vehicle
from accidentally rolling
forward, the service brake or
parking brake must be
engaged.
The gearbox is set
automatically to N (Neutral)
after switching off the engine.
54 DRIVING
ZF AS TRONIC GEARBOX
The ZF AS Tronic is a fully automatic
changing gearbox with automatic clutch
control, which eliminates the need for a
clutch pedal.
By toggling the clutch lever in the (A/M)
direction the driver selects to drive full
automatic (A) or manual (M). Switching is
always possible even while the vehicle is in
motion. It is not required to change the
position of the accelerator during the shift
process.
Whilst starting the engine the
rotary switch must be in the N
(Neutral) position.
Moving the rotary switch from
R to D and visa versa, may only
be undertaken when the
vehicle is at a standstill.
In the full automatic position, clutch and gear
control are operated electronically and the
engine will operate in the most economical
area.
In case of manual operation, each intended
gear change is checked by the electronics
and if necessary, is ignored to prevent
misuse of the driveline.
The display of the AS Tronic shows to the
driver all important system information, such
as: neutral position, current gear, clutch
overload or any faults in the system.
For more information we refer to the ZF
Operating Instruction.
ZF ECOMAT2 GEARBOX
Optionally a automatic gearbox can be
applied. The ZF automatic gearbox has 6
forward gears and 1 reverse gear. This
gearbox is equipped with a torque converter.
The automatic gearbox is electronically
operated via a set of switches on the
instrument panel.
Depending on the use of the vehicle, the
automatic gearbox can have the following
positions:
- 3 positions - DNR
- 6 positions - 123 DNR
ATTENTION!
When selecting another gear from N
(neutral) the service brake always
must be applied!
The positions:
Position D:
In this position, the gearbox automatically
selects the correct gear (depending on
different parameters such as: driving speed
and the position of the accelerator pedal). In
this position, the vehicle has a tendency to
crawl!
Stand N:
In this position, the gearbox is in neutral. Only
select this position when the vehicle is sta-
tionary and the parking brake is activated!
Position R:
This position selects the reverse gear. Do
not accelerate too hard when reversing.
ATTENTION!
When you wish to drive forwards, first
stop the vehicle and then shift to a
forward position.
Positions 1, 2 and 3
Depending on the positions 1, 2 and 3, these
positions ensure that there is only limited
automatic shifting UP of gears.
Starting
The engine can only be started if the gear
selector is in the N position.
When using the ZF automatic gearbox, pay
attention to the following: When the tempera-
ture is lower than -15° C, start the engine
and run it at 1,000 rpm for approximately 5
minutes with the gear selector in the N posi-
tion before pulling away.
Pulling away
When the vehicle is stationary and when the 6
parking brake and the foot brake are applied
and when the engine is idling, select the
desired position, D (forwards) or R (reverse),
wait 1 to 2 seconds, release the parking
brake and the foot brake. The large torque
will cause the bus to pull away immediately.
When a gear is selected, the corresponding
light will be lit. If this is not lit, then the
gearbox may not be in gear. A flashing light
indicates a fault. Have the fault repaired by
a VDL Bus workshop.
DRIVING 55
 ATTENTION!
If the N position is accidentally
selected whilst driving, the gearbox
must be returned to the D position
whilst lightly engaging the service
brake to prevent damage to the
gearbox. The electronic shifting
mechanism will select the gear which
corresponds to the speed of the
vehicle.
If this happens when cruise control is
6 activated first disengage cruise
control The engine will idle. Whilst
lightly engaging the service brake the
gearbox must be returned to the D
position
Kick-down shifting automatic gearbox
A kick-down switch is integrated in the ac-
celerator pedal. The accelerator pedal must
be fully depressed if the vehicle needs to pull
away more quickly. Than the gearbox will
automatically select the gear which provides
the highest pulling power.
56 DRIVING
Driving in mountainous regions
Climbing with automatic gearbox
If, for example, when driving up an incline in
the D position, the incline is too steep for the
second gear but not steep enough for the
first gear, then accelerating fully will cause
the gearbox to continuously shift UP and
DOWN gears. This is not beneficial to the
life span of the automatic gearbox. Shifting
UP can be prevented by selecting position
1. After position 1 (manually) has been
selected, only the 1st gear is engaged and
the gearbox will be prevented from
automatically shifting UP further. The same
applies in principle for positions 2 and 3.
When driving up the gearbox will never shift
UP higher than the selected position. Kick-
down shifting can also be used when the
control buttons are in these positions.
Driving in mountainous regions
Descending with automatic gearbox
The correct speed should be maintained
when descending. This should, preferably,
be the same speed as when climbing.
Therefore, before starting the descent,
engage the retarder switch on the steering
column. The correct speed of descent must
be maintained by applying the retarder and
service brake.
When the retarder is used, the electronic
gearbox management automatically selects
the correct gear of descent.
The retarder will switch up and down in steps
when applied via the right hand steering
column switch. The retarder will increase or
decrease its preformance smoothly when
applied via the foot pedal. When extra engine
braking power is needed, select speed range
1,2 or 3 as required to limit upshifts.
In extreme cases, the upshift
interlock cuts out to protect the
engine. In this case, the
transmission can shift up into
the highest gear, whatever
speed range is selected. Risk
of accidents!
Watch the rev. counter!

Activating and deactivating of integrated
retarder in ZF Ecomat2
The next warning is applicable whilst driving
with ZF Ecomat2 automatic gearbox on a
critical (slippery by loose gravel, dirt, rain,
snow, freezing rain or similar) road surface.
It is advisable to disengaged
the retarder foot control
function using switch 14 on the
instrument panel. The retarder
integrated in the ZF automatic
gearbox is a primary retarder.
This means that the torqueses
which are slowed down by the
retarder must be multiplied by
the transmission of the gear
the automatic gearbox is in.
For example, when the retarder
is working hard in a certain
gear and the gearbox changes
down to a lower gear, the
braking force of the retarder
may suddenly double.
This may cause a slip. Or, if the
gearbox is in a low gear and
then changes to a higher gear,
the braking force of the
retarder may suddenly be
halved, keep this in mind!
RETARDER
General
The retarder is a wear-resistant, hydraulic
or electrically operating continuous brake.
It is primarily intended for use in prolonged
braking, for example when decelerating from
high speed on a level road or when driving
downhill. This reduces service brake wear.
The retarder can be activated by means off:
- right-hand combination switch on stee-
ring column
- applying the foot brake pedal (first stage
of the pedal will activate the retarder and 6
applying further pressure to the pedal will
progressively activate the service brake)
Note:
The most favourable range in which the
retarder delivers the greatest braking ef-
fect is the range above 1500 engine revs.
A retarder cannot be used as a
parking brake. The retarder
does not exert any braking
power at a standstill or low
vehicle speeds.
DRIVING 57
 Use the retarder for prolonged When retarder is activated the The division of the maximum braking effect
braking, for example when rear braking lights will lit to of the retarder is related to the gearbox type
driving downhill. Use the brake inform the other traffic. One and shows as follows:
pedal for relatively short exception on this rule is whilst
braking operations. This will using the v = constant function. GO manual
prevent overheating of the ZF AS Tronic Ecomat 2
wheel brakes. Rest position 0% 0%
Retarder manual engaging Position A 33% 50%
When ABS is in use, the Position B 66% 75%
retarder will be switched off for Position C 100% 100%
as long as ABS is in operation. V=constant 0-100% n.a.
6 R
OFF
0 OFF
Driving on a critical (slippery by Using the engine brake in combination with
loose gravel, dirt, rain, snow, LIM the manual controlled retarder will further
freezing rain or similar) road SET
S
improve the braking effect. Keep the engine
R
RE
surface it is advisable not to E speed high!
activate the manual retarder 1
control and to disengaged the B Manual deactivating retarder
A
retarder foot control function The retarder is disengaged by moving the
using switch 14 on the instru- 03695 B C switch (1) forward to the rest position (E)
ment panel. again.
See also instruction braking. The retarder is engaged by moving the
combination switch on the steering column
backwards from the rest position (E). The
retarder has three positions (A, B and C).

58 DRIVING
The V = constant control function
The GO manual gearbox with the R115
retarder and the ZF AS Tronic gearbox are
both additional equipped with a constant
speed function. When descending and
activating the V = constant function the
retarder will limit the vehicle speed to the
driver set speed. Assumed that in that
situation the braking effect is adequate for
the job.
Note:
Maximum braking effect is possible with
the V-constant control!
Activating the V-constant control
The V-constant control is activated by
pressing the spring-operated switch (2).
Symbol I-E2 will appear on the main display
when the retarder is activated.
Retarder symbols on main display
SET
R
OFF
D I-E2 and W-E4
0
OFF
LIM Symbol I-E2 appears on the main display
SET
when the retarder is activated by means of
S
R
RE the foot control or the manual control.
E
If symbol I-E2 flashes the
1 2
requested braking force
03694 B
cannot be provided. The
retarder may be temporarily 6
Deactivating V=constant control too hot. Adjust the vehicle
When switch (1) is moved forward (D) from speed using the service brake
the rest position (E) the V-constant control and changes to a lower gear
is disengaged. The switch then returns to the (thus increase engine speed).
rest position.
Symbol W-E4 appears in
combination with the amber
whilst using the v = constant warning light A3 should an er-
function the rear braking lights ror occur in the retarder and
will not lit the system no longer functions
correctly. It is permitted to con-
tinue driving, but action must
be taken at the earliest
opportunity to resolve the
problem!
DRIVING 59
 THE BRAKES
The vehicle is equipped with an ABS-system.
Optionally an ASR-system can be applied.
ABS (Anti Blocking System) brakes
The ABS unit prevents the wheels from lock-
ing during an emergency stop or when brak-
ing on a slippery road surface. As a result,
the vehicle with ABS remains fully steerable
under such circumstances and the direction
of the vehicle can be maintained.
6 Do not brake later or harder. This will only
effect the tyres and the brake system, as well
as the comfort of the passengers. Further-
more, you may endanger the other road us-
ers behind you who do not have ABS.
60 DRIVING
ABS warning light
This warning light on the instru-
ment panel lit if there is a fault in
the ABS system.
If the warning light is lit in
combination with warning
indicator A3 stop immediately
at a safe place!
In this case, check the fuses of
the ABS system. If the fault is
not corrected by inserting a
new fuse, the vehicle may only
be driven to the nearest VDL
Bus workshop. Have the fault
repaired immediately! The ABS
system will no longer function,
although the service brake will
still continue to function
correctly.
ASR
Optionally the vehicle can be equipped with
an ASR unit in combination with ABS and
cruise control.
The ASR unit prevents the wheels from spin-
ning when driving on a slippery surface. The
ASR only works on the driven wheels.
Attention:
Depending on the situation, the ASR
system either reduces the engine speed
or brakes the wheel which is spinning.
The information symbol I-C2 will be
visible on the main display when the ASR
system is in operation.
Note:
Do not adjust your driving style to the
presence of an ASR system.
SERVICE BRAKE (FOOT BRAKE)
The activity of the service brake (foot brake)
is combined with the retarder as well as the
engine brake.
The foot brake pedal has a travel "A" in which
the service brake is not active and a travel
"B" in which the service is active. The op-
eration of the retarder and the engine brake
begins a little bit earlier as the service brake
somewhere in the middle of the travel (A).
Driving with the combined brake
The vehicle is equipped with a retarder, ABS
and a combined engine brake. The retarder
and the engine brake only operate the rear
axle.
The foot brake pedal operates the service
brake, the engine brake and the "C" range
for the retarder at the same moment. In re-
gard to applying the retarder read in chapter
"DRIVING" the text automatic gearbox and
retarder manual engaging.
Operating instructions
1 On NON-slippery road surface it is
advisable to dose travel "A" well (is
fellable - less resistance) and use this
during maximum time (retarder and
engine brake) before pushing further to
range "B" in order to use the service
brake. This prevents break lining wear
and improves driving comfort.
2. When there is (a chance of) slippery road
surface you immediately have to switch
off the retarder by using switch 14 on the
instrument panel. Travel "A" of the foot
brake pedal initiates no longer brake
action. This is to avoid that at first only
the retarder together with the engine
brake operate the rear axle. This can
cause skidding!
Symbol I-E1 appears on the main
display when the retarder foot
control function is disengaged
using switch 14 on the instrument
panel.
3. When a slippery road surface takes you
by surprise and you didn't have time to
put switch 14 on the instrument panel to
the "OFF" position it is important to kick
down the foot brake pedal all the way. It
is necessary to get the foot brake pedal
quickly through travel "A" into "B" so that 6
the service brake of both axles is
activated quickly. The ABS system will
take care of the dosage and will so take
full advantage of the grip that is left.
DRIVING 61
 ENGINE (exhaust) BRAKE

Retarder foot control braking force

The braking force will gradually increase by
applying the service brake pedal. The
characteristic is depending on the gearbox.
See text below.

Foot control with GO manual gearbox and Foot control with Ecomat 2 automatic
ZF AS Tronic gearbox: gearbox:
Pedal angle 0o - 3o: Retarder not active Pedal angle 0o - 3o : Retarder not active
Pedal angle 4o-6o: 20% braking force From pedal angle 4o up to 10o gradually
Pedal angle 7o-9o: 40% braking force increasing from 30% up to 100% braking
6 Pedal angle 10o-32o: 70% braking force force, and continuing up to 32 degrees.

By pressing the engine brake’s control but-

ton, a valve in the exhaust is closed and the
fuel supply is stopped. This gives the engine
extra braking force.
The engine brake is mainly intended for pro-
longed braking, for example, when braking
from a high speed on a flat surface and when
descending. This reduces the wear on the
service brake.

The braking force reduces as the engine

speed drops. The most favourable range in
which the engine brake delivers the greatest
braking effect is the orange range on the
rev counter.

62 DRIVING

When using the engine brake, adjust your
gear selection so that the engine speed
remains in the most favourable range.
It is not permitted to use the red
area on the rev counter.
Exceeding the permitted
engine speed may cause
serious damage to the engine.
Depending on the legal requirements/de-
sign, the engine brake will be automatically
turned off when the engine speed drops be-
low 800 rpm, when the speed is less than 3
km/h or when the ABS system has observed
that the wheels have a tendency to lock.
Do not activate the engine
brake whilst driving on a
critical (slippery by loose
gravel, dirt, rain, snow, freezing
rain or similar) road surface.
Since the engine brake only
effects the driven wheels, it has
a limited braking capacity. The
wheels may skid, because the
engine brake is not equipped
with ABS.
HALT BRAKE
The halt brake operates automatically and Symbol I-D3 appears on the main
optionally a manual control can be applied. display when the halt brake is
The halt brake will operated at speed below engaged.
3 km/h. For the halt brake to operate, the
manual activation switch only needs to be If the halt brake is in use, the driver must
operated for a short time. If the halt brake is never leave the driver’s seat. Activate
turned on, the vehicle will slow down and parking brake first.
come to a standstill and the halt brake will
remain on. Therefore, the parking brake
should be used when stopping at a bus stop,
where passengers get on or off, before the
doors are opened (depending on fitted 6
options such as NBS etc.).
The halt brake can be turned off by using
the accelerator pedal.
The halt brake can also be used for short
stops, for example at a traffic light. The foot
brake does not need to be used and the
vehicle is prevented to “crawl”.
Depending on the type of construction, the
halt brake can be operated via one or more
doors.
If one or more doors are open, then it is not
possible to accelerate and the gearbox will
come to the NBS position (depending on
fitted options).
DRIVING 63
 SPEED LIMITER
The legal requirements state that all vehi-
cles above 12 ton G.V.W. (Gross Vehicle
Weight) must be equipped with a speed
limiter.
The speed limiter limits the maximum speed
of the vehicle on a (flat) road to a set speed
limit. During descents, it is possible that the
maximum speed is exceeded.
Careful!
6 The speed limiter has been set and locked
by an authorised calibration centre. Do not
try to alter, adjust or turn off the speed limiter.
Vehicles with a faulty speed limiter may not
drive on the road, unless:
- The vehicle is finishing a journey in which
the speed limiter has accidentally
become damaged.
- When the vehicle is driven to an
authorised calibration centre to have the
speed limiter repaired.
64 DRIVING
CRUISE-CONTROL
Engaging/disengaging conditions
cruise control
SET
A When the cruise control has been engaged,
there are various conditions on which it will
OFF
R
0
automatically disengage. When one or more
OFF
of the following conditions is met, the cruise
LIM control is disengaged:
SET
S
- The vehicle speed is outside the
R
RE
programmed limit value.
3
1 2 - The parking brake is engaged.
B - The clutch is operated.
03692 B
- The foot brake is operated.
- The engine brake is operated.
- The rotary switch (2) on the steering co-
Before engaging the cruise control some
lumn switch (1) is turned to "OFF".
conditions have to be met. So can cruise
- The ABS/ASR system carries out an
control be engaged when vehicle speed is
intervention.
above 30 km/h. For other conditions see
- The variable vehicle speed limiter is
engaging en disengaging conditions below.
activated in the "LIM" position.
- The retarder is operated.

Switching on cruise-control
The cruise control can be activated by
moving the steering column switch (1) once
briefly to the "SET+" position (direction A) or
to the "SET-" position (direction B) when the
required control speed is reached.
Switching off cruise-control
When the cruise control is active and is no
longer required, it can be disengaged by
turning the rotary switch (2) on the steering
column switch (1) briefly to the "OFF"
position.
Accelerator pedal function during cruise
control
When the cruise control is active, the vehicle
speed can be increased above the set speed
using the accelerator pedal. When the
accelerator pedal is released, the vehicle
speed will then return to the last valid speed.
VARIABLE VEHICLE SPEED LIMITER
Adjusting the cruise control speed The variable vehicle speed limiter (also know
When the cruise control has been activated, as foot-on cruise control) allows the vehicle
the driving speed can be increased by speed to be limited to a speed set by the
moving the combination switch on the stee- driver whilst the accelerator pedal is still
ring column in the up direction "SET+ and to operational.
hold it till the required driving speed is The variable vehicle speed limiter can be
reached. Decreasing driving speed in the activated once the vehicle speed is higher
same manner by moving the combination than 30 km/h.
switch in the "SET-"-position (direction B).
Re-engaging cruise-control
The cruise control can be re-engaged after A
6
SET
having been disengaged, provided the
conditions above are met, by: OFF
R
- Moving the steering column switch (1) 0 OFF
once briefly to the "SET+" position
LIM
(direction A) or to the "SET-" position
SET
(direction B) when the required vehicle R
RE
S
speed is reached and, as a result, the
current driving speed becomes the new 1 2
driving speed. B
03693 B
- By pressing the "RES" button (3). This
re-engages the cruise control at the last
driving speed used. If the current vehicle
speed is lower than this speed, the cruise
control will attempt to accelerate the
vehicle speed to the last used driving
speed.
DRIVING 65
 ENGINE REV CONTROL

Engaging variable vehicle speed limiter
When the rotary switch (2) is turned to the
"LIM" position, the vehicle speed at that mo-
ment is saved in the electronic unit as the
required vehicle speed limitation value.
When the vehicle speed is limited by the
electronic unit, the vehicle speed limit value
saved in the electronic unit can be increased
(A) or decreased (B) using switch (1).
Note:
6 When the variable vehicle speed limiter
Overruling variable vehicle speed limiter
The variable vehicle speed limiter will be
overruled when the accelerator pedal is fully
depressed, whereby the kick down switch
in the accelerator pedal sensor is operated.
Note:
If the vehicle speed later falls to the
previously saved vehicle speed limiting
value, the variable vehicle speed limiting
function is activated once again. In case
the acceleration continues unto the mo-
ment that the speed limiter function of the
The engine rev control makes it possible to
vary the engine rev between idling and
maximum rpm.
Ensure that parking brake is on and gear is
in neutral before engaging the engine rev
control.
A
SET

is engaged, the cruise control function is vehicle is engaged, the variable vehicle OFF
disengaged. speed function will be disengaged. R
0 OFF

Disengaging variable vehicle speed LIM

limiter SET
S
The variable vehicle speed limiter will be
R
RE

disengaged when the rotary switch (2) is 3

turned back to the centre position. 1 2
B
03692 B

66 DRIVING
Conditions for engaging/disengaging
engine rev control
When the engine rev control has been
engaged it will be disengaged when one or
more of the following conditions are met:
- the parking brake is disengaged
- the clutch is operated
- the foot brake is operated
- the engine brake is operated
- the retarder is operated
- the automatic gearbox is engaged in
position 1, 2, 3,D of R
If one or more of the above conditions are
met, it will also NOT be possible to engage
the engine rev control.
Activating engine rev control
The engine rev control can be activated as
follows:
- Pressing the "RES" button (3)
immediately increases the engine rev to
a value pre-programmed in the electronic
unit (UPEC).
- Moving the steering column switch (1)
once briefly to the "SET+" position
(direction A).
Deactivating engine rev control Accelerator pedal function during engine
If the engine rev control is active and is no rev control
longer required, it should be disengaged by When the engine rev control is active, the
turning the rotary switch (2) on the steering engine rev can be increased above the
column switch (1) briefly to the "OFF" controlled rev using the accelerator pedal.
position. When the accelerator pedal is released, the
engine rev will return to the last valid
Adjusting engine rev control controlled revs.
When the engine rev control has been
activated, the controlled engine rev can be
increased using the "SET+" position
(direction A) on the switch or be decreased 6
using the "SET-" position (direction B).
- Moving the steering column switch (1)
once briefly to the "SET+ or "SET-"
position the engine revs increases/
decreases with 25 rpm.
- Holding the steering column switch (1)
in the maximum "SET+ or "SET-" position
the engine revs increases/decreases
gradually.
DRIVING 67
 AIR CONDITIONING REV CONTROL
For this function the operating conditions are:
- the gearbox is in neutral,
- the parking brake is applied.
If an air conditioning unit is installed and it
turns on then the engine revs will be
automatically increased when the vehicle is
idling to prevent the engine from stopping.
This is pre-programmed in the vehicle
electronic.
6
68 DRIVING
STEERING
The steering gear is hydraulically assisted.
Do not continue to turn the steering wheel
when the wheels touch an obstacle or when
they have reached the maximum limit. If you
do so, the oil temperature will increase.
The vehicle can also be steered without the
power steering, but this requires a large force
and is only intended for safely parking the
vehicle when the power steering is not
working.
DIFFERENTIAL LOCK
General information
Optionally a differential lock can be applied.
The differential lock will be applied on the
driven axle.
The differential lock may only
be used when driving on loose
ground or on a slippery road
surface, but never on a surface
which provides good traction.
In case of a automatic gearbox
the vehicle should come to a
standstill and in neutral (N).

Operating instructions
The differential lock should be turned on:
- Whilst the vehicle is stationary or moving
very slowly.
- When the clutch pedal is depressed.
- Just before driving on loose ground or a
slippery road surface. Then, slowly drive
straight ahead towards the loose ground
or the slippery road surface.
- The differential lock may never be turned
on whilst the wheels are spinning. Wait
until the wheels are no longer rotating
before turning on the differential lock.
- The differential lock must be turned off
as soon as a surface offering good
traction is reached. If the warning light in
the switch remains lit, the vehicle must
be driven in reverse and forwards again
for a short distance, so as to release the
locking mechanism.
- When driving whilst the differential lock
is turned on, you should be prepared for
the vehicle to want to continue in a
straight line when driving through a cor-
ner. We recommend you to turn off the
differential lock when driving through
orners.
DRIVING WITH A TRAILER AXLE
Steering mechanism of the trailer axle
On vehicles with a trailer axle (second rear
axle) the trailing axle wheels are steerable
at vehicle speeds up to 30 km/h.
Driving the vehicle in forward or reverse
gears the trailer axle will automatically steer.
The steering angle of the 3e axle will be
determined by:
- The sensors of the front steering system
who are measuring the angle of the front
wheels and convert them to the vehicle
electronics and into the correct air
pressure controlling the steering of the
trailer axle. This determents whether the
wheels can turn to the left or the right.
- The friction between road and tires which
takes care of the exact trailing of the 3e
axle.
Automatic locking straight ahead
To obtain more stable handling the trailer axle
is locked in the straight ahead position as
soon as:
- speeds is above 30 km/h.
- ABS is activated
Manual locking straight ahead
Whilst driving on loose ground or on a
slippery road surface or using ferry lift the
locking system can be activated by applying
switch 16 on the instrument panel.
To eliminate tyre wear and
decrease the turning circle it is
important to de-activate the
manual lock as soon as possible
and continue using the automatic
system.
The information symbol I-E3 (un- 6
locked) appears on the main
display at speed up to 30 km/h to
inform the driver that the manually
locking system is de-activated
and working automatically .
DRIVING 69

Driving characteristics in corners
As long as the information symbol I-E3 (lock
open) remains visible (at a speed of less
than 30 km/h), you must drive carefully on
a wet or slippery road surface and slowly
depress the accelerator pedal and limited
the vehicle speed in corners.
Comfort in corners
For a large wheel turning angle in corners
where the driving speed is less than 30 km/
6 h, it is recommended to not increase the
speed to greater than 30 km/h before the
front wheels have almost returned to the
straight-ahead position. Automatically
activating the lock in a corner as soon as
the speed is increased to greater than 30
km/h can cause a jerking movement in the
rear axle and adversely affect the comfort of
the passengers.
70 DRIVING
Using the traction control/assistance
Vehicles with a trailing axle have a
switch for traction control and
traction assistance to make it easier
to negotiate slippery inclines
Activate the traction
assistance switch if the
vehicle comes to a standstill
due to a lack of traction
(preferably just before the
vehicle becomes stationary).
Do not leave the driver’s seat
when the vehicle is stationary
on a slippery and/or snowy
incline. Remain present in or-
der to apply the footbrake if it
appears that, as a result of the
slippery surface, the grip of
the wheels to which the par-
king brake is applied in order
to keep the vehicle stationary
is less than the force of gravity.
Keep a mobile telephone and
a local emergency number
close at hand in order to call
for help, if necessary.
TOWING A TRAILER
Higher demands are placed on the driver and
the vehicle whilst driving with a trailer.
Technical conditions
- If the vehicle is delivered from the
production line with a tow bar, then the
vehicle already satisfies all the technical
and legal requirements for driving with a
trailer (<3.5 ton).
- The tow bar is a safety component. Only
a tow bar which has been designed and
approved for use with this vehicle may
be used.
Instructions for use
- The permissible trailer weights (see
“Technical Information”) must not be
exceeded.
- For the pulling vehicle, select the tyre
pressure for a full load. Also check the
trailer’s tyre pressure.
- Always de-activate the instrument panel
by turning off main switch (20) before
connecting or de-connecting a trailer.
A self test is made automatically by
turning on the main switch (20).
General instructions
- The maximum speed when pulling a For a vehicle with a trailer and a pneumatic
trailer is 80 km/h. Reduce speed trailer connection, the trailer is not braked
immediately as soon as the slightest when the parking brake is applied.
swerving motion from the trailer is
observed.
- The trailer weights on the tow bar’s
identification plate are only test values.
The values applicable for the vehicle are
given on the vehicle’s registration
certificate and this instruction manual.
- When driving down long, steep descents, 6
a greater load is placed on the brakes
than normal. Change down to a lower
gear and adjust your speed.
- Do not keep the vehicle and trailer still
on a hill using the accelerator pedal. Use
the service brake or the parking brake.
- If the vehicle and the trailer are parked
on a hill, the precautions mentioned
below must be observed:
- Place chocks in front of and
behind thewheels of both the
vehicle and the trailer.
- Turn the wheels so that if the
vehicle does start to move, it will
not roll onto the road.

DRIVING 71
6

72 DRIVING
7. Inspections and maintenance 7

INSPECTIONS AND MAINTENANCE 73

 OVERVIEW SERVICE POINTS
Page
Service points rear side ........................ 74
Service points front side ....................... 75
DAILY MAINTENANCE
Page
Engine oil level ..................................... 77
Coolant level ........................................ 78
Air filter indicator ................................... 79
Wheels and tires .................................. 79
Screen wash reservoir ......................... 79
Lighting and instruments ...................... 79
Driver's chair and mirrors ..................... 79
Trailer ................................................... 79
7 Coolant system .................................... 86
WEEKLY MAINTENANCE
Page
Power steering fluid level ..................... 80
Hydraulic fan drive fluid level ................ 80
Batteries ............................................... 81
Brake system air dryer ......................... 81
Radiator ................................................ 81
ZF Automatic gearbox fluid level .......... 82
Hydraulic clutch fluid level .................... 82
74 INSPECTIONS AND MAINTENANCE
MAINTENANCE GENERAL
Page
First service .......................................... 83
Maintenance intervals .......................... 83
Influence of diesel fuel on the maintenance
interval .................................................. 83
Bleeding fuel system with
water separator .................................... 83
Cleaning the vehicle ............................. 84
MAINTENANCE WORK BEFORE THE
START OF THE WINTER
Page
Diesel fuel ............................................ 85
Screen wash reservoir ......................... 85
Check the degree of protection of the
coolant system ..................................... 86
MAINTENANCE WORK AT THE END OF
THE WINTER
Page
Coolant system .................................... 86
OVERVIEW SERVICE POINTS

Service points rear side

1. Coolant reservoir
2. Air filter
3. Coolant level gauge glass
4. Air filter indicator
5. Fan drive gauge glass hydraulic
oil reservoir
6. Engine oil filler opening
7. Engine compartment control panel
8. Engine oil dipstick
9. Power steering hydraulic oil
reservoir
10. Fuel fine filter 7
11. Water separator fuel system
12. Fuel coarse filter/ fuel hand pump
13. Fuel hand pump on engine block

INSPECTIONS AND MAINTENANCE 75

 Service points front side DAILY MAINTENANCE

14. Clutch hydraulic oil reservoir Overview daily maintenance to be executed

15. Batteries by driver:
16. Main switch box - Engine oil level
- Coolant level
- Air filter indicator
- Wheels and tyres
- Screen wash reservoir
- Lighting and instruments
- Driver seat and mirrors
- Trailer

Fluid levels must always be

7 and remain above the
minimum level. Fill up if
necessary.
Quick drop of level might
indicate a dangerous leak,
contact the nearest VDL Bus
workshop.

76 INSPECTIONS AND MAINTENANCE

ENGINE OIL LEVEL

7. Remove the dipstick again and read the Position oil filler cap XE-engine
1 oil level. The oil level must always be
somewhere between both marks.
For the difference between minimum and
maximum oil level see chapter
"TECHNICAL DATA"
8. If necessary, top up the oil via the filler
opening (see arrow). Use the specified
oil (see “TECHNICAL DATA”). Do not add
too much oil.
9. Wait for 1 minute and check the oil level
again.
03052B
M2 01 110
Position oil filler cap PE-engine 7
1. Check the oil level after the engine has
not been running for at least 5 minutes.
2. Make sure the vehicle is on a flat,
horizontal surface.
3. Make sure the vehicle is level both
crossways and long ways.
4. Remove the dipstick (1) from its holder.
5. Clean the dipstick with a lint-free, clean
cloth.
6. Put the dipstick back into the holder and
wait a couple of seconds.

INSPECTIONS AND MAINTENANCE 77

 COOLANT LEVEL
Important!
Check the coolant level when the engine
is cold.
7 running the engine at low revs.
The coolant level must always be
somewhere between minimum and maxi-
mum level. Top up the coolant to above the
minimum level, but not above the maximum
level.
Only use coolant specified by
VDL Bus, see chapter
"TECHNICAL DATA".
78 INSPECTIONS AND MAINTENANCE
When the coolant is hot there
is an overpressure in the
cooling system. Place a cloth
over the filler cap (pos. 3) and
unscrew it carefully to relieve
excess pressure. The filler cap
can then be fully unscrewed.
To prevent damage when top-
ping up a warm engine with
cold coolant, the coolant must
be topped up slowly whilst
Coolant is a toxic fluid. Contact
with the skin should therefore
be avoided. In the event of con-
tact with the eyes, skin or
clothing's rinse profusely with
plenty of water.
Topping up the coolant reservoir:
(only applicable when necessary)
1. Turn the heating rotary switch or slide
switch to “warm”.
2. Remove the filler cap (3) from the
expansion tank.
3. Idle the engine for a short period of time.
4. Turn off the engine and check the
coolant level.
5. The coolant level must be between the
MAX. and MIN. marks. If necessary, top
up the coolant via the filler cap (3).
This symbol will appear on the
main display when the sensor
at the bottom of the coolant re-
servoir (pos. 2) indicates a too
low coolant level. The symbol
will disappear approximately 1
minute after the coolant level
has been topped up.
AIR FILTER INDICATOR WHEELS AND TYRES
- Check the tyres for wear, imbedded
objects and other damage.
- Remove any imbedded objects from the
tread and from between the tyres (for
double assembly).
- Check the attachment of the wheels. For
torque see chapter "TECHNICAL DATA"
- Check the tyre pressure (including the
spare tyre). The tyre pressure must be
checked and, if necessary, corrected
when the tyres are cold. See chapter
"TECHNICAL DATA".
Note:
If a worn tire is under inflated by 2 bar,
the ABS control will be inoperative under
If the indicator is in the red area (with the extreme conditions!
text "CHANGE FILTER"), the air filter is Also see "changing the wheel" in the
seriously fouled and must be replaced. Con- chapter EMERGENCY REPAIRS".
sult a VDL Bus workshop.
Clogged air filters lead to increased fuel
consumption and loss of power.
A. Clean air filter
B. Clogged air filter, replace air filter.
SCREEN WASH RESERVOIR
Check the fluid level and top up if necessary.
LIGHTING AND INSTRUMENTS
- Check whether the lights, brake lights
and the instrument lighting work correctly.
- Check whether the horn, windscreen
wipers and windscreen spray work
correctly.
DRIVER'S CHAIR AND MIRRORS
- Place the driver’s chair and the mirrors
in the correct position.
TRAILER
- Check the attachment and operation of 7
the trailer’s connection.
- Check the connections for the lighting
and the brakes.
INSPECTIONS AND MAINTENANCE 79
 WEEKLY MAINTENANCE
Overview weekly maintenance to be
executed by driver:
- Power steering fluid level
- Hydraulic fan drive fluid level
- Batteries
- Brake system's air dryer
- Radiator
- ZF-automatic gearbox fluid level
- Hydraulic clutch fluid level
Fluid levels must always be
and remain above the
7 minimum level. Fill up if
necessary.
Quick drop of level might
indicate a dangerous leak,
contact the nearest VDL Bus
workshop.
80 INSPECTIONS AND MAINTENANCE
POWER STEERING FLUID LEVEL HYDRAULIC FAN DRIVE FLUID LEVEL
1. Check the fluid level when the engine is 1. Check the fluid level via the gauge glass
idling, (2) whilst the engine is idling.
2. Clean the area around the dipstick before
removing it.
3. Check the fluid level in the reservoir using
the dipstick.
4. the fluid level must reach the maximum
mark on the dipstick. The fluid level will
be 2 cm higher if the engine is not running
1
2. The fluid level should be between the
MAX maximum and minimum levels. If
necessary, top up the fluid via the filler
MIN
opening (1). Clean the area around the
01755B
filler cap before removing it.
5. If necessary, top up the fluid via the filler
opening (1). Note:
See “TECHNICAL DATA” for the
Note: hydraulic fluid specifications.
See “TECHNICAL DATA” for the
hydraulic fluid specifications.
BATTERIES
Avoid sparks and open flames
in the vicinity of batteries.
Battery acid is an aggressive
fluid. In the event of contact
with the eyes, skin or clothing's
rinse profusely with plenty of
water. Consult a docter in the
event of persistent redness or
pain.
- Check the electrolyte level. This should
be approx. 10 mm above the plates or
up to the level indicator, if present. If
necessary, top up the batteries with
distilled water.
- Check whether the battery poles and the
battery terminals are clean and greased.
If necessary, coat the battery posts with
an acid free petroleum jelly.
BRAKE SYSTEM’S AIR DRYER
The operation of the air dryer and the Damp air in the pneumatic
cartridge can be inspected by checking all brake system is a great danger,
the air reservoirs for condense water. because it may cause the brake
pressure to be lost if the brake
1. Check all the air reservoirs for condense valves freeze during cold
water and oil residues by pulling the ring weather.
on the drain valve.
RADIATOR
A wire screen is placed as an extra safety
guard in front of the radiators to prevent
contamination. Regularly check the wire
screen for contamination and clean it if
necessary. 7
Attention:
Prevent damaging the lamellae of the
radiators.
2. If repeatedly more than the normal
amount of water is drained off, the air
dryer cartridge will have to be replaced.
Consult your VDL Bus workshop.
3. Oil mist in the air flow may mean that the
air compressor is damaged.
INSPECTIONS AND MAINTENANCE 81
 ZF AUTOMATIC GEARBOX FLUID LEVEL
1. Make sure the vehicle is on a even and
horizontal surface.
2. Check the fluid level when the fluid is at
operating temperature (80 - 90°C).
3. Let the engine idle at 600 min-1 for ca. 2
minutes before checking the fluid level.
4. Move the gear lever into neutral.
5. Check the fluid level with the dipstick.
After 2 minutes the fluid level should be
between the two marks "A".
6. If necessary, top up the fluid via the filler
opening. See “TECHNICAL DATA” for
the fluid specifications.
82 INSPECTIONS AND MAINTENANCE
HYDRAULIC CLUTCH FLUID LEVEL
1. Check the fluid level. Check whether the Hydraulic fluid is poisonous
level lies between maximum and mini- and harmful for your health.
mum marks. Therefore avoid direct or indi-
rect skin contact. Hydraulic
fluid reacts aggressively with
the vehicle paint. Remove
spoiled fluid direct with a lot of
water.
2. If necessary top up the fluid. For specified
hydraulic fluid see chapter "TECHNICAL
DATA".
3. Check the bleed opening in the cap.
Always use new and clean
hydraulic fluid from a closed
container.
MAINTENANCE GENERAL INFLUENCE OF DIESEL FUEL ON THE BLEEDING FUEL SYSTEM WITH
MAINTENANCE INTERVAL WATER SEPARATOR
The durability, safety, trade-in value and
reliability of your vehicle largely depend on Diesel fuel Bleed the fuel system every 10.000 km.
the care you give it. This includes regular ser-
vice in accordance with the maintenance Sulphur Engine oil Water in the fuel system can
schedules specified by VDL Bus. content replacement interval damage the fuel system.
While bleeding the fuel system,
The driving style of the person at the wheel > 0,2% Halve interval, fuel will escape. Collect the fuel
and the care given to the vehicle will have with a maximum of to avoid the risk of fire.
direct influence on the condition of the 25.000 km
vehicle. The driver can often provide the 1. Put a collector under the water separator.
workshop with information which is very im- Biodiesel
portant for correct maintenance. When using biodiesel the standard
replacement intervals for engine oil and fuel
First service filters should be halved. 7
The first service should be carried out Extended replacement intervals are not
between the first 7500 en 10.000 km permitted when using biodiesel. 1
subsequent to the delivery of the vehicle.

Maintenance intervals
For service intervals and associated
maintenance work, refer to the maintenance 01518B
2
schedule.
2. Open the bleed screw (1) on the filter
housing.
3. Open the drain plug (2) a few turns.

INSPECTIONS AND MAINTENANCE 83


4. Bleed the water separator until
pure diesel oil appears.
5. Close the drain plug (2) and the bleed
screw (1).
6. To prevent environmental damage the
collected water/diesel mixture should be
delivered to the appropriated agency.
7 universal joint on the steering box. The
84 INSPECTIONS AND MAINTENANCE
CLEANING THE VEHICLE
Before cleaning the vehicle, make sure there
are no leaks from the engine, axles, gearbox,
etc. It is not possible to check this after the
vehicle has been cleaned.
Observe the following points when using a
high-pressure hose or steam cleaner:
- Make sure the doors, windows and roof
hatches are closed properly when
cleaning the vehicle.
- Do not spray directly onto seals. There
is a chance that these will be forced open
causing the grease to be washed away.
This can, for example, occur at the
cross piece will then become stuck and
the steering gear will jolt.
- A bleed opening is fitted to the steering
oil reservoir. Water may enter the tank
through this valve, causing damage to
the steering gear.
- Make sure that the lamellae of the cool-
ers and the wire screen in front of the
radiator/intercooler are not damaged
when cleaning with steam cleaner.
- Do not direct the jet of the high pressure
hose or steam cleaner for a long period
of time onto the air conditioning system’s
condenser. Heating will cause the pres-
sure in the system to increase too much,
which causes damage.
- Components of the air conditioning
system must not be cleaned using a high
pressure hose or steam cleaner,
because these may damage the seals.
- Make sure no water can enter via the
differential and gearbox bleed openings.
- Make sure no water can enter via the
reservoir bleed opening of the clutch,
brakes, etc. .
- The engine and engine compartment can
be cleaned with a high pressure hose or
steam cleaner. Make sure in this case
not to spray directly onto electrical
components, such as the starter motor,
alternator, etc..

- Clean the engine encapsulation and the
engine encapsulation components
carefully. Make sure any spilt oil or die-
sel is removed to avoid the risk of fire.
Keep cleaner nozzle distance minimum
50 cm from surface to avoid damaging
of encapsulation. Do not use high
pressure steam cleaner on
encapsulation!
- Do not aim the high pressure hose or the
steam cleaner directly at electrical con-
nections, such as connectors, feed
through connections for lighting, etc..
- Make sure no water can enter the air in-
take system via the air inlet or its flexible
seals when cleaning the vehicle.
- Make sure that no water can enter via
the dipstick.
- After cleaning, the vehicle must be
re-lubricated using a grease gun. This is
important to prevent moisture and dirt
from entering at the various rotating
points. See lubrication diagram in chapter
"TECHNICAL DATA".
MAINTENANCE WORK BEFORE THE
START OF THE WINTER
Your VDL Bus workshop can advise
you concerning the preparation of
your vehicle for the winter season.
DIESEL FUEL
If outside temperatures are persistently low,
only fill up with winter diesel oil produced by
a reputable oil company.
During the winter, an additive is often used
by diesel suppliers to prevent blockages
caused by paraffin deposits.
Comments:
Fuel additives for preventing paraffin
deposits are only preventative. They are
not able to dissolve the paraffin. Ensure that
there is always a spare fuel fine-filter so that
if there is a blockage (also due to paraffin
deposits), it can be replaced. See
"EMERGENCY REPAIRS".
Preferably fill the fuel tank as full as possible
in the evening (particularly in the winter) to
prevent the formation of condensation.
At extremely low temperatures, only in an
emergency case (standstill), a maximum of
20% petroleum or a flow improver (according
to instructions on the product description)
may be added. Never add petrol to the 7
diesel fuel.
SCREEN WASH RESERVOIR
- It is recommended to add a cleaning
product to the water in the screen wash
reservoir.
- Add a screen wash antifreeze to the
water.
INSPECTIONS AND MAINTENANCE 85
 COOLANT SYSTEM

The coolant system is filled with a ready to
use mixture, named Texaco Havoline XLC.
See chapter "TECHNICAL DATA".
Check before winter the degree of protection
offered by the coolant. For topping up read
in this chapter "topping up coolant reser-
voir".
Only use coolant Texaco
Havoline XLC in this vehicle,
not to jeopardise the warranty.
CHECK THE DEGREE OF PROTECTION MAINTENANCE WORK AT THE END OF
OF THE COOLANT SYSTEM THE WINTER
1. Remove the filler cap from the cooling Cooling system
system. The coolant (Texaco Havoline XLC) must
2. Check the degree of protection offered also remain in the cooling system during the
by the coolant. summer months.
3. Add coolant to the cooling system if the
level is too low.

7 Coolant is a toxic fluid. Contact

with the skin should therefore
be avoided. In the event of con-
tact with the eyes, skin or
clothing's rinse profusely with
plenty of water.

When the coolant is hot there

is an overpressure in the
cooling system. Place a cloth
over the filler cap and unscrew
it carefully to relieve excess
pressure. The filler cap can
then be fully unscrewed.

86 INSPECTIONS AND MAINTENANCE

8. Emergency repairs 8

EMERGENCY REPAIRS 87
 Page Page
Serious oil leaks ................................... 89 Inflating the tyres ................................ 102
Manual gearbox GO checking the Inflating the pneumatic system ........... 103
oil level ................................................. 89 Releasing the parking brake .............. 103
Automatic gearbox ZF AS Tronic Air suspension leak ............................ 104
checking oil level .................................. 90 Light bulbs replacement ..................... 104
Retarder Voith R115 E Fuses and relays ................................ 104
checking the oil level ............................ 90 Fuses/relays; on the engine ............... 105
Differential checking the oil level .......... 91 Fuses/relays; main switch box ........... 105
Alternator V-belt replacement ............... 92 Fuses/relays; instrument panel .......... 106
Poly-V-belt replacement ....................... 93 Fuses/relays; central e-panel front ..... 108
Fuel fine filter replacement ................... 93 Fuses/relays; central e-panel rear ...... 110
Fuel coarse filter cleaning .................... 95
Starting after the fuel tank has
been empty .......................................... 95
8 Spare wheel winch ............................... 96
Jacking up the vehicle .......................... 96
Jacking up the front wheels .................. 97
Jacking up the driven axle .................... 97
Jacking up the trailer axle .................... 97
Chassis support SB and SBR .............. 98
Centring of the wheel/ wheel hub ......... 98
Wheel changing's ................................. 99
Changing a wheel .............................. 100
Installing the disc wheel ..................... 100
Towing ................................................ 102
Tow starting ........................................ 102

88 EMERGENCY REPAIRS
SERIOUS FLUID LEAKS
If there is a (serious) fluid leak from one of
the transmission components, the vehicle
must, if possible, be driven to the nearest
VDL Bus workshop.
Fluid levels must always be
above the minimum level. Stop
the vehicle and turn the engine
off if the fluid threatens to drop
below the minimum level.
GO GEARBOX MANUAL
CHECKING THE OIL LEVEL
1. Position the vehicle on a horizontal
surface, both longways and crossways
2. The oil must be at operating temperature
when checking the oil level.
3. Remove the oil check/oil filler plug (1) and
the sealing ring (2).
The oil check/oil filler plug is
hot (oil temperature).
1 8
2
M+P-07A-1716
4. The oil level must reach the rim of the
level check/filler opening.
5. In the event of any lacking oil, check the
retarder for a possible external leak.
6. Top up any lacking oil slowly through the
hole for the oil filler plug (2) according to
oil specification in chapter "TECHNICAL
DATA".
7. Clean and fit the oil check/oil filler plug
(1) using a new sealing ring (2).
Tightening torque:
Oil check plug 47 Nm
EMERGENCY REPAIRS 89
 ZF AS TRONIC GEARBOX AUTOMATIC RETARDER VOITH R115E
CHECKING THE OIL LEVEL CHECKING THE OIL LEVEL

Preparing before checking oil level

Before checking the oil level, 1. Position the vehicle on a horizontal
DO NOT activate the retarder. surface, both longways and crossways.
2. Check the oil level when the oil is at
operating temperature.
1. Before checking the oil level switch OFF 3. Steering lock/contact/start switch should
the retarder foot control function by be turned off and on once.
activating the rocker switch on the dash- 4. Operate the retarder at stand still by
board. Do not activate the retarder by moving the right-hand combination
using the right-hand combination switch switch from the rest-position (E) to
on the steering column. position (A) and after approx. 5 seconds
2 Position the vehicle on a horizontal back again in the rest-position. Repeat
surface, both longways and crossways. this procedure twice.
7. In the event of any lacking oil, check the
3. Turn OFF the engine. 5. Switch the retarder off (rest position E)
retarder for a possible external leak.
and wait for 5 minutes before checking
8 4. has
Check the oil level after the gearbox oil
cooled down to <40°C.
8. Top up any lacking oil slowly through the
the oil level.
hole for the oil filler plug (A) according to
5. Remove the level check plug (A) and
oil specification in chapter "TECHNICAL
check the oil level. Checking the oil level
DATA".
6. The oil level must reach the rim of the 1. Unscrew after the preparations the oil
9. Clean and fit the level check plug (A),
level check/filler opening (A). check plug (1).
tightening it to the specified torque
The oil check and the oil filler
plug are hot (oil temperature).
Tightening torque:
The retarder may only be filled
Oil check plug 60 Nm
through the oil filler plug.

2. The oil level must reach the rim of the

level check/filler opening.

90 EMERGENCY REPAIRS
 DIFFERENTIAL
CHECKING THE OIL LEVEL

Comment: 3. The oil level is correct when it reaches

2
Do not check the oil level immediately
after a journey. Allow the oil to sink and
cool down for approximately half an hour.
Checking the oil level:
1. Place the vehicle on a flat, horizontal
surface.
2. Remove the oil check plug (A).
the lower edge of the oil check hole.
4. Fill in any lacking oil slowly through the
hole for the oil check plug (A) according
to oil specification in chapter
"TECHNICAL DATA".
5. Refit the oil check plug after the
inspection with special torx tool (DAF no.
1329493).

Tightening torque:
1 Oil check plug 85 Nm
M+P-07A-1713

3. In the event of any lacking oil, check the

retarder for a possible external leak. 8
4. Top up any lacking oil slowly through the
hole for the oil filler plug (2) according to
oil specification in chapter "TECHNICAL
DATA".
5. After the inspection, clean and refit the
oil check/oil filler plug using a new sealing
ring.

Tightening torque:
Oil check plug 65 Nm
Oil filler plug 100 Nm

EMERGENCY REPAIRS 91
 ALTERNATOR V-BELT REPLACEMENT
Comments:
Always fit the same type of V-belt as the
one being replaced.
If two V-belts are used for a drive, both
belts must be replaced.
Disassembly/assembly alternator V-belt:
1. Disconnect the earth lead from the
battery.
2. Unscrew the check nuts (2 and 4) on the
clamping block.
3. Unscrew the fixing bolts (5) from the
spindle on the water pump.
4. Unscrew the bolt (3) on the clamping
block.
5. Turn the sleeved nut (1) so that the
8 alternator is tilted towards the engine
block and remove the V-belt.
6. Inspect the pulleys for damage, rust and
grease deposits.
7. Fit the new V-belt.
8. Adjust the V-belt tension (read text
adjusting the V-belt tension).
9. Connect the earth lead to the battery.
92 EMERGENCY REPAIRS
Figure: V-belts XE-engine Adjusting the alternator V-belt tension
1. Unscrew the bolt (3) on the clamping
block.
2. Unscrew the fixing bolts (5) from the
spindle on the water pump.
3. Unscrew the check nuts (2 and 4) on the
clamping block.
4. Move the alternator by turning the
sleeved nut (1) until the correct V-belt
tension is obtained.
5. For the correct V-belt tension, it should
be possible to push the V-belt in between
10 and 12 mm when applying slight
pressure between the alternator and the
Figure: V-belts PE-engine crankshaft pulley (see arrow in figure).
6. Tighten the check nuts and the fixing nuts
of the alternator, the spindle and the
clamping block.
Comment:
Have the V-belt tension checked as
quickly as possible by a VDL Bus
workshop.
POLY V-BELT REPLACEMENT
Comments:
Always fit the same type of V-belt as the
one being replaced
1. First, remove the alternator V-belt, see
“Alternator V-belt replacement”.
2. Place a suitable spanner on the
automatic V-belt tensioner.
3. Slacken the poly V-belt by rotating the
spanner against the spring pressure of
the automatic belt tensioner.
4. Place a drift (4-5 mm) in the hole (A) so
that the spring tensioner is locked and
remove the POLY V-belt.
5. Inspect the pulleys for damage, rust and
grease deposits.
6. Fit a new poly V-belt.
7. Remove the drift and cautiously allow the
automatic belt tensioner to apply its
pressure to the new POLY V-belt.
8. Check that the poly-V-belt fits in all the
pulley grooves.
9. Assemble the alternator V-belt again, see
“Alternator V-belt replacement”.
FUEL FINE FILTER REPLACEMENT
Diesel is inflammable and must
not be exposed to an open fire
or another heat source, such
as a hot engine. A quantity of
fuel may be released when
removing the fuel filter. Collect
leaking fuel in a suitable con-
tainer.
Dirt in the fuel system can
cause serious damage to the
fuel system.
Disassembly and assembly
1. Unscrew the filter housing’s cap (2).
EMERGENCY REPAIRS 93

2. Remove the fuel filter from the cap.
3. Check the sealing rubber in the cap and,
if necessary, replace it.
4. Lightly lubricate the sealing rubber with
engine oil.
5. Fit a new fuel filter into the cap.
6. Fit the cap, together with the filter
element, onto the filter housing.
7. Tighten the cap to a torque of 25 Nm
using a torque spanner.
94 EMERGENCY REPAIRS
8. Pump for approximately 1 minute using
the primer pump (1) to partially fill the filter
housing with fuel.
First turn the button of the primer pump
(1) fully anti clockwise to operate the
pump.
9. Start the engine and run it at idling revs
for a few minutes, this will allow any air
in the filter housing to escape.
10. If the engine will not start up or runs very
erratically, follow the procedure "Starting
after fuel tank has run dry".
11. Check the fuel system for leaks whilst the
engine is running.
FUEL COARSE FILTER CLEANING
When removing the fuel coarse
filter a quantity of fuel will es-
cape. Collect the fuel to avoid
the risk of fire. Dirt in the fuel
system can lead to significant
damage in the fuel system.
1. Unscrew cover (4) from the housing by
turning anti clockwise.
2. Remove the filter element (2).
3. Clean the filter element.

4. Clean and check the O-ring for damages,
use a new sealing ring if necessary.
5. Apply a film of engine oil to the O-ring
(3).
6. Fit the cover with the cleaned filter ele-
ment to the housing by turning clockwise.
7. Turn the button of the primer pump fully
anti clockwise to operate the pump.
8. Fill the filter housing (4) with fuel.
9. Turn the button of the primer pump fully
clockwise afterwards.
10. Check the fuel system for leaks whilst the
engine is running.
If necessary retighten the cover by hand.
STARTING AFTER THE FUEL TANK HAS
BEEN EMPTY
Avoid having an empty fuel
tank. The procedure described
here is an emergency proce-
dure. The engine will only start
after being turned over for a
long time. Not following the
start procedure given below
can result in flat batteries and
the starter motor becoming
damaged.
1. Bleed the fuel system using the hand
pump (1). First turn the button of the
primer pump (1) fully anti clockwise to
operate the pump.
2. Operate the hand pump until a build-up
of pressure can be clearly felt.
3. Wait a couple of minutes and then pump
again until a build-up of pressure can be
clearly felt. For fixation turn the button of
the primer pump fully clockwise
afterwards.
4. Operate the starter engine continuously
until the engine fires. The maximum time
the starter motor can be turned on is 1
minute. If the engine does not fire in this
time, allow the starter motor to cool down
for 2 minutes.
5. Operate the starter motor continuously
again until the engine fires. As before, the
maximum time the starter motor can be
8
turned on is 1 minute. If the engine does
not fire in this time, allow the starter motor
to cool down for at least 30 minutes
before the above starting procedure can
be repeated.
6. When the engine has fired it will still not
run smoothly for a short period of time.
EMERGENCY REPAIRS 95
 SPARE WHEEL WINCH JACKING UP THE VEHICLE

Comment:
Regularly check the spare wheel winch’s
cable:
- For signs of ageing.
- For damage.
- To ensure that it is free of grease.
If necessary, replace the cable.
Regularly grease the grease-nipple of the
winch.
The spare wheel winch is self-braking.
Removing the spare wheel. Turn off the ECAS system by
1. Keep the area under the spare wheel free turning off the main switch,
to prevent injury. because the ECAS system will
2. Unscrew the nuts (A) from the spare otherwise try to correct the an-
wheel. gle of the vehicle.
Also see the instructions of the
jack supplied by the
manufacturer.
The vehicle may only be jacked
up at the locations as indicated
in this chapter (see figures).

3. Allow the spare wheel to drop by

operating winch (B).

Fitting the spare wheel

Always fit the wheel on the spare wheel
support so that the valve faces outwards and
retighten the nuts (A).

96 EMERGENCY REPAIRS
JACKING UP THE FRONT WHEELS
To jack up the front wheel, place the jack
under the knuckle carrier according to the
figure above.
JACKING UP THE DRIVEN AXLE
To jack up the driven axle, place the jack
under the yoke in the middle of the 4 U-bolt
nuts according to the figure above.
JACKING UP THE TRAILER AXLE
8
To jack up the trailer axle (optionally), place
the jack under the axle body according to
the figure above.

Place the jack under the knuckle carrier so The jack must not be placed directly under
that the vehicle cannot slide off of the jack. the axle beam or the differential housing in
order to prevent deformation of the axle
The jack must never be placed in the area beam.
between the two knuckle carriers, to prevent
damage to the wheel suspension and chas-
sis.

EMERGENCY REPAIRS 97
 CHASSIS SUPPORT SB AND SBR
Always use axle struts to
support the chassis whenever
carrying out maintenance work
under a vehicle which is
resting on a jack.
8 additional insert shaft (see figure).
98 EMERGENCY REPAIRS
CENTRING OF THE WHEEL/WHEEL HUB
VDL Bus applies wheel hub centring to its
vehicles, also with Alcoa aluminium wheels.
Characteristics of wheel hub centring are:
- Wheels with cylindrical bolt holes.
- Wheel nuts with a loose, non-removable,
flat thrust washer.
- The wheel rim fits tightly onto the cams
on the wheel hubs of the axles.
Warning
Only use the correct wheel hub centring
wheels and wheel nuts.
Attention
In case the vehicle has aluminium wheel
rims special wheel nuts are used with an
- On axles with a single tyre the insert
shaft (A) is approx. 12 mm (short
version)
- On axles with a twin tyre mounting
the insert shaft (B) is approx. 34 mm
(long version).
Also read instructions of supplier alumi-
nium wheel rims.
FRONT AXLE/ TRAILER AXLE WHEEL CHANGING'S
General information
- Only use original wheel rims permitted
for the vehicle concerned.
- Make sure the same type of tyres is fitted
on both sides of the axle.
- Cleaning contact surfaces sufficient and
tighten the wheel nuts even to prevent
vibrations during driving or braking.
- Replace all wheel bolts on the wheel
concerned when one must be replaced.
- Spacer discs and extended wheel
bolts are necessary on the front axle
when fitting 9.00" x 22.5" rims.
(spacer disc for aluminium wheels is
10 mm and for steel wheels 15 mm ).
DRIVEN AXLE Remove spacer discs and apply
shorter wheel bolts on the front axle
when 9.00" x 22.5" rims are replaced
by 8.25" x 22.5" rims.
Workshop must order and fit a
new type plate accordingly to
the tyres load capacity if the
tyre load capacity is less than
stated on the type plate.
Workshop must also check the
tachograph readings and the
maximum wheel turning angle
and, if necessary, correct it.
Difference in diameter between tyres
After changing a wheel/tyre, the difference
in diameter between the various tyres fitted
may be too large (for example, caused by a
difference in tread depth and/or tyre
pressure).
The ABS system cannot handle a large
difference and will turn itself off. This will
cause the ABS inspection light B2 to be
lit.
Depending on the type of tyres on the front
and rear axles, this may even happen due
to a worn tyre which is inflated to a pressure
which is 2 bar too low. Therefore, first check
the tyre pressure (page 130) if the ABS
warning light is lit after changing a tyre.
8
Under extreme circumstances, the ABS
will no longer work!
Furthermore, the braking force will no longer
conform to the legal requirements. This is
also the reason that the difference in tyre
diameter for new tyres may not be greater
than 14%. (This may occur when assembling
different tyre sizes on the front or rear axles).
EMERGENCY REPAIRS 99
 CHANGING A WHEEL INSTALLING THE DISC WHEEL

1. Block the vehicle so that it cannot roll 1. Clean the fitting edge of the wheel hub 2. Lightly lubricate the fitting edge of the
away. If necessary, place chocks in front by scraping off dirt and corrosion using wheel hub with grease.
of and behind the wheels. a scraper.
2. Clean the screw thread of the wheel bolts
using a wire brush.
3. Lightly lubricate the screw thread of the
wheel nuts with oil.
4. Unscrew the wheel nuts.
5. Fit a jack under the jacking point of the
wheel to be replaced, see in this chapter
"Jacking up vehicle".
6. Jack up the vehicle and place axle struts
under the vehicle, see in this chapter
"Chassis support".
7. Remove the wheel nuts and take the
wheel off of the hub.
8
When removing a wheel with a 3. Also apply a thin layer of grease to the
cracked or damaged wheel rim, fitting edge of the wheel rim.
always deflate the tyre (remove
the tyre valve) to remove any Attention
possible tension in the wheel With aluminium wheels a special
rim. Aluminium wheels may not lubricant is required; Freylube, see also
be heated by e.g. welding etc. "Technical Information".This grease layer
Mount a new wheel. should prevent the wheel rim and the
wheel hub from rusting together.

100 EMERGENCY REPAIRS

4. Clean the wheel nuts and then apply a
couple of drops of oil between the thrust
washer and the nut (see figure).
5. Also apply a couple of drops of oil to the
first turn of the wheel bolts screw thread.
6. Fit the wheel nuts and tighten these
evenly according to the sequence given
in the diagram. See chapter
“TECHNICAL DATA” for the correct
torque.
Comment
The wheel nuts should always be
tightened and retightened when cold.
However, tightening wheel bolts in ex-
treme cold should be avoided.
7. Check the tyre pressure.
8. Retighten the wheel nuts after 100 km.
If new wheel nuts are fitted, retighten
the wheel nuts again after 500 km.
Comment
When a wheel has been changed, the
wheel nuts should be tightened to the
correct torque by a VDL Bus workshop.
EMERGENCY REPAIRS 101
 TOWING
Towing is a complex issue. You
should therefore make use of
a specialised recovery
company that is approved by
your insurance company.
The vehicle is not suitable for
towing other vehicles and VDL
Bus does not approve such
actions.
With the engine stationary,
there is no power steering and
no air supply to the brake
system. Should the service
brakes be operated or an air
8 leak occur, then the parking
brake may be automatically
activated.
102 EMERGENCY REPAIRS
TOW STARTING
Towing the vehicle to start the
engine is not advisable. Repair
the fault and start the engine by
own means. VDL Bus does not
approve tow start actions and
it will jeopardise the warranty.
A vehicle with an automatic
gearbox must not be tow
started.
INFLATING THE TYRES
Inflating the tyres using the air from your
vehicle.
1. Remove the cap from the test connection
"Circuit 0" (B).
2. Connect a tyre filler hose.
3. Inflate the tyres. The engine must be
running and the supply pressure must be
at a maximum.
For correct air pressure of the tyres see
chapter "TECHNICAL DATA".
4. Fit the cap on test connection again after
inflating the tyres.
INFLATING THE PNEUMATIC SYSTEM RELEASING THE PARKING BRAKE
(in case of vehicle without air)
The entire pneumatic system can be
externally filled with air via the test connection Make sure the vehicle cannot b. Mechanic
"Circuit 0" (B). Make sure not to exceed the roll away before releasing the 1. Place chocks in front of and behind the
maximum system pressure of 9.8 bar. parking brake. wheels.
2. Using a box spanner, turn the bolt
a. Pneumatic anticlockwise until the stop.
1. Place chocks in front of and behind the
wheels. Make sure to have a box
2. Move the parking brake lever forwards spanner in the vehicle
(in the driving position). (European law).
3. The spring brake cylinders can be
released via the red coloured (A) filling
connection "circuit 3", using an external
air source and a filling hose. Air in one of
the tyres can be used to do this.
8
01521B

3. Repeat this procedure for all the spring

brake cylinders.

Important!
Reapply the parking brake as quickly as
possible by turning the bolts as far as
possible clockwise and tightening them with
a torque of 40 - 50 Nm.
4. For release the minimum system
pressure must reach approx. 6.5 bar.

EMERGENCY REPAIRS 103

 AIR SUSPENSION LEAK
If the air compressor is able to provide
enough air to keep the vehicle on driving
height the air leakage wont be noticed. Act
according to instruction below if the noise of
the leakage is heard to overcome, to prevent
the air compressor to be damaged.
Driving height will decrease when
the leakage increases and
information symbol I-E4 will appear
on the information-screen.
Stop immediately at a save place
and turn off the engine. Have the
error repaired as quickly as
possible by a VDL Bus workshop.
8
104 EMERGENCY REPAIRS
LIGHT BULBS REPLACEMENT
- See the instructions provided by the
bodywork builder for instructions on how
to replace the light bulbs. This applies for
the interior lighting, the exterior lighting
and for adjusting the headlights.
- Turn off the main switch before replacing
the light bulbs.
- When fitting a new light bulb, make sure
the cams on the light fitting fall into the
recesses in the reflector.
- Do not touch the glass of a halogen bulb
with bare hands. Always use a dry clean
cloth or plastic gloves.
FUSES AND RELAYS
The main fuses and relays can be found on
the:
- Engine
- Main switch box
- Instrument panel
- Central E-panel "Front"
- Central E-panel "Rear"
See the instructions provided by the body-
builder for the location.
Never replace a faulty fuse with
one of a higher value, because
this may result in a short-cir-
cuit or a fire.
Never replace a fuse when:
- main switch is in;
- ignition switch is activated;
- users are activated;
- engine is running.
If fuse keeps blowing
repeatedly, this indicates a
fault in the circuit. It needs to
be checked and the fault
remedied.
 MAIN SWITCH BOX

ON THE ENGINE The main switch box is fitted on the battery

carrier.

CODE DESCRIPTION ELECTRO

E223 Fuse 100A

power supply for ignition
E224 Fuse 100A
power supply for main switch
E279 Fuse 7,5A
check alternator voltage

G053 Relays main switch

8
The fuse E112 and the relays G014 are
mounted on the inlet manifold.

CODE DESCRIPTION ELECTRO

E112 Fuse 5A glow signal

G014 Relays glow plug

EMERGENCY REPAIRS 105

 INSTRUMENT PANEL

106 EMERGENCY REPAIRS

CODE DESCRIPTION ELECTRO INSTRUMENT PANEL

E001 Fuse 5/6A rear tail lights rhs

E002 Fuse 5/6A light dimmer instrument panel
E004 Fuse 5/6A dipped beam lhs 1e
E005 Fuse 5/6A dipped beam rhs 1e
E006 Fuse 5/6A main beam lhs 1e
E007 Fuse 5/6A main beam rhs 1e
E009 Fuse 5/6A fog lamp front lhs
E067 Fuse 5/6A main beam lhs 2e
E068 Fuse 5/6A main beam rhs 2e
E070 Fuse 5/6A fog lamp front rhs
E207 Fuse 5/6A dipped beam lhs 2e
E208 Fuse 5/6A dipped beam rhs 2e
E256 Fuse 5/6A rear lights lhs
E384 Fuse 5/6A side marker lights lhs
E385 Fuse 5/6A side marker lights rhs
8

G001 Relays dipped beam 1e

G002 Relays main beam 1e
G004 Relays fog lamp front
G252 Relays dipped beam 2e
G253 Relays main beam 2e
G415 Relays lights front

EMERGENCY REPAIRS 107

 CENTRAL E-PANEL FRONT

108 EMERGENCY REPAIRS

CODE DESCRIPTION ELECTRO CENTRAL E-PANEL FRONT

E017 Fuse 5/6A tachograph E380 Fuse 15A illumination front serial 1
E025 Fuse 15A windscreen wiper/ headlight wiper motor E381 Fuse 15A illumination front serial 2
E030 Fuse 5/6A air horn E386 Fuse 5/6A tachograph
E040 Fuse 5/6A ABS E388 Fuse 15A IOU 2
E041 Fuse 10A ABS E389 Fuse 20A central e-panel rear
E042 Fuse 10A ABS
E051 Fuse 5/6A ECAS G008 Relays windscreen wiper (speed II)
E061 Fuse 5/6A ECAS G009 Relays windscreen wiper (speed I)
E066 Fuse 5/6A tachograph G015 Relays ignition
E089 Fuse 3A Gauges CIPA instrument panel G416 Relays drive line units with switch off delay
E118 Fuse 15A engine management UPEC G484 Relays windscreen wiper (speed II)
E248 Fuse 10A Voith-retarder G485 Relays windscreen wiper (speed I)
E252 Fuse 40A contact bridge
E268 Fuse 15A to be appointed by body builder
E269 Fuse 50A power supply
8
E306 Fuse 15A IOU 2
E310 Fuse 15A CIPA instrument panel
E311 Fuse 15A CIPA instrument panel
E322 Fuse 15A to be appointed by body builder
E323 Fuse 15A to be appointed by body builder
E325 Fuse 15A diagnose connector 16p
E346 Fuse 60A power supply
E375 Fuse 15A central e-panel rear
E376 Fuse 15A central e-panel rear
E377 Fuse 40A power supply central e-panel rear

EMERGENCY REPAIRS 109

 CENTRAL E-PANEL REAR

110 EMERGENCY REPAIRS

CODE DESCRIPTION ELECTRO CENTRAL E-PANEL REAR

E000 Fuse 5/6A tail lights left hand side G000 Relays illumination rear
E010 Fuse 7,5/8A fog lights rear G005 Relays fog lamp rear
E011 Fuse 5/6A direction indicator lights lhs G007 Relays reversing lights
E012 Fuse 5/6A direction indicator lights rhs G011 Relays direction lights lhs
E013 Fuse 7,5/8A brake lights G012 Relays direction lights rhs
E016 Fuse 7,5/8A reversing lights G036 Relays brake lights
E029 Fuse 7,5/8A retarder/ engine brake G038 Relays start
E091 Fuse 7,5/8A air dryer element heating G126 Relays ESC-power supply
E101 Fuse 5/6A DNR-switch ZF G165 Relays retarder cooling fluid temperature
E134 Fuse 10A engine stop G322 Relays engine stop UPEC
E141 Fuse 7,5/8A electro-hydraulic fan G482 Relays gearbox
E184 Fuse 7,5/8A UPEC
E231 Fuse 7,5/8A oil level control
E232 Fuse 15A start relays
E249 Fuse 5/6A tail lights right hand side
8
E253 Fuse 5/6A brake lights lhs+rhs
E254 Fuse 5/6A brake lights lhs+rhs top
E255 Fuse 15A tail lights
E257 Fuse 5/6A tail lights top
E301 Fuse 15A VFC (Vehicle Function Controller)
E302 Fuse 15A VFC (Vehicle Function Controller)
E305 Fuse 15A IOU 1
E382 Fuse 15A level sensor cooling fluid
E383 Fuse 7,5/8A level sensor steering oil
E387 Fuse 15A IOU 1

EMERGENCY REPAIRS 111

8

112 EMERGENCY REPAIRS

9. Technical data 9

TECHNICAL DATA 113

 page
Component summary Unless otherwise stated, the information given below applies to the
SB(R)230+ PF en SB(R) 4000+ PF ......... 115 mentioned types en executions.
Component summary
SB(R) 4000+ XF ....................................... 116
Wheels ..................................................... 122
Trailer weights .......................................... 122
Fluids and lubricants specifications .......... 123
Engine oil ................................................. 124
Gearbox oil ............................................... 126
Retarder oil ............................................... 127
Differential oil rear axle ............................. 128
Hydraulic fluids ......................................... 128
Greases ................................................... 129
Diesel fuel ................................................ 130
Coolant ..................................................... 131
Tyre pressure table .................................. 132
Lubrication diagram .................................. 133
9

114 TECHNICAL DATA

COMPONENT SUMMARY SB(R) 230+ PF and SB(R) 4000+ PF
Max. unloaded engine speed ± 2.580 ± 30 rpm
Chassis-type SB SBR (trailer axle) Max. loaded engine speed 2.200 rpm
Engine PE228C - Screw thread used metric according ISO-standards
PE265C PE265C Valve clearance (for warm Inlet 0.50 mm
Gearbox GO 170 - or cold engine) Outlet 0.50 mm
ZF 6HP592C (PE228C) -
ZF 6HP602C (PE265C) ZF 6HP602C Lubrication system
Retarder Voith R115E (only GO170) - Contents, incl engine oil filter approx. 33 litres
Front axle RL75EC RL75EC Contents oil sump, max. level approx. 26 litres
Rear axle 1347HAS 1347HAS Contents oil sump, min. level approx. 18 litres
Tag axle - RL75A Oil see engine oil specifications
Steering gear TRW THP80 TRW THP80
Oil pressure
Engine Engine at operating temperature
Manufacturer DAF At idling speed 0.5 bar (min.)
Model Euro 3, water-cooled, four-stroke At max. loaded engine speed 3.35 - 4.35 bar
diesel engine with electronically controlled Optimal operating temperature 90° - 100°C
injection system, 4 valves per cylinder, Max. permissible temp. 115°C
and turbo-intercooling.
Max.power (P) PE 228C: 228 kW at 2200 rpm Cooling system 9
PE 265C: 265 kW at 2200 rpm Contents;excl. heating; approx. 70 litres
Max. torque (M) PE 228C: 1275 Nm at 1700 rpm incl. heating system approx. 100-140 litres
PE 265C: 1450 Nm at 1700 rpm Operating temperature max. 110°C
Coolant see coolant specifications
No. of cylinders 6
Bore x stroke 118 x 140 mm Fuel system
Total volume 9.2 liter injection sequence 1-5-3-6-2-4
Compression ratio 17.5 : 1 Fuel see fuel specifications
Idling engine speed 600 ± 25 rpm Contents fuel tank 715, 450 or 305 litres

TECHNICAL DATA 115

 Clutch Gearbox type ZF AS Tronic
Type Single, dry-plate clutch, hydraulically operated, Reductions 1st gear 12.33
air assisted 2st gear 9.59
Diameter ø 430 mm 3st gear 7.44
Fluid See hydraulic fluid specifications 4st gear 5.78
Thrust bearing Continuous touching 5st gear 4.57
6st gear 3.55
Gearbox type GO 170 7st gear 2.70
Reductions 1st gear 8.17 8st gear 2.10
2st gear 4.65 9st gear 1.63
3st gear 2.79 10st gear 1.27
4st gear 1.81 11st gear 1.00
5st gear 1.25 12st gear 0.78
6st gear 1.00 Reverse 11.41
Reverse 7.68 Capacity approx. 21 litres
Capacity approx. 12.5 litres Oil see gearbox oil specifications
Oil see gearbox oil specifications
Gearbox type ZF 6HP592C and ZF 6HP602C
Retarder (with primary retarder)
Type: Voith R115E Reductions 1st gear 3.43
9 Capacity approx. 7.0 litres 2st gear 2.01
Oil see retarder oil specifications 3st gear 1.42
4st gear 1.00
5st gear 0.83
6st gear 0.59
Reverse 4.84
Capacity approx. 15 litres
Oil see gearbox oil specifications

116 TECHNICAL DATA

Front axle Air suspension
Type RL75EC Electronically controlled air suspension
Camber 1° Front axle Two air bellows
KPI 8° Rear axle Four air bellows
Caster 2,5° Variable height setting
Toe-in 0-1 mm/m Front + Rear adjustable 60 mm above
Hub greasing wheel bearing grease, see spec. driving height (Ferry-lift)
Wheel deflection 275/70R22.5 inner = 56° outer = 46° Front adjustable 50 mm below driving
Wheel deflection 295/80R22.5 inner = 52° outer = 43,5° height (kneeling)
Wheel deflection 315/70R22.5 inner = 52° outer = 43,5°
Wheel deflection 315/80R22.5 inner = 51° outer = 41,5° Steering gear
Type hydraulically operated
Rear axle Type number TRW THP80
Type 1347HAS Fluid see hydraulic fluid spec.
Reduction 3.73:1, 4.56:1 and 5.13:1 Capacity approx. 8 litres
Capacity differential approx. 21.5 litres
Oil differential: see differential oil specifications Brake system
Hub greasing wheel bearing grease, see spec. Service brake Mechanical-air pressure, 2-
Trailer axle (only SBR) circuit system, fully separated
Type RL75A Front axle SN7000 disc brakes
Camber 0° ± 40' Rear axle SN7000 disc brakes 9
KPI 8° Trailer axle SN7000 disc brakes
Caster 0-40 min Parking brake spring brake cylinders
Toe-in 0-2 mm/m Air reservoirs, working pressure 8.6 -9.8 bar
Wheel deflection inner wheel = 15° Min. working pressure 7.5 bar
outer wheel = 13° Brake pads TEXTAR 7400 asbestos-free
Hub greasing wheel bearing grease, see DAF 1200 asbestos-free
specifications Compressor 2 cylinders, water-cooled head,
stroke volume 440 cc

TECHNICAL DATA 117

 Electrical unit 24V COMPONENT SUMMARY SB(R) 4000+ XF
Multiplex CANbus system with central management unit VFC and
two IOU's Chassis-type SB SBR (trailer axle)
Engine XE250C XE250C
Starter motor XE280C XE280C
Type Bosch JE XE315C XE315C
Power 4.0 kW Gearbox GO 170 (XE250/280)
GO 190 (XE315)
Dynamo - GO 210 (XE280/315)
Type Alternating current ZF 6HP602 (XE250) ZF6HP602C (XE250)
Capacity 24 V - 2 x 100 A Retarder Voith R115E (only GO) Voith R115E (only GO210)
Front axle RL75EC RL75EC
Battery Rear axle 1347HAS 1347HAS
Number 2 Tag axle - RL75A
Voltage 12 V Steering gear TRW THP80 TRW THP80
Capacity 2 x 200 Ah / 2 x 180 Ah
Engine
Manufacturer DAF
Model Euro 3, water-cooled, four-stroke
diesel engine with electronically controlled
9 injection system, 4 valves per cylinder,
and turbo-intercooling.
Max. power (P) XE250C: 250 kW at 1900 rpm
XE280C: 280 kW at 1900 rpm
XE315C: 315 kW at 1900 rpm
Max. torque (M) XE250C: 1600 Nm at 1500 rpm
XE280C: 1750 Nm at 1500 rpm
XE315C: 1950 Nm at 1500 rpm

118 TECHNICAL DATA

No. of cylinders 6 Fuel system
Bore x stroke 130 x 158 mm injection sequence 1-5-3-6-2-4
Total volume 12.58 litres Fuel see fuel specifications
Compression ratio 17.4 : 1 Contents fuel tank 715, 450 or 305 litres
Idling engine speed 550 ± 25 rpm
Max. unloaded engine speed ± 2270 ± 30 rpm Clutch
Max. loaded engine speed 1900 rpm Type Single, dry-plate clutch, hydraulically operated,
Screw thread used metric according ISO-standards air assisted
Valve clearance (for warm Inlet 0.50 mm Diameter ø 430 mm
or cold engine) Outlet 0.50 mm Fluid See hydraulic fluid specifications
Thrust bearing Continuous touching
Lubrication system
Contents, incl engine oil filter approx. 39.5 litres Gearbox type GO170/190
Contents oil sump, max. level approx. 33 litres GO210
Contents oil sump, min. level approx. 25 litres Reductions 1st gear 8,17 6,528
Contents oil filter approx. 1 litres 2st gear 4,65 3,711
Oil see engine oil specifications 3st gear 2,79 2,231
4st gear 1,81 1,443
Oil pressure 5st gear 1,25 1,000
Engine at operating temperature 6st gear 1,00 0,799
At idling speed 0.5 bar (min.) reverse 7,68 6,136 9
At max. loaded engine speed 3.1 - 4.1 bar Capacity approx. 12.5 litres
Optimal operating temperature 90° - 100°C Oil see gearbox oil specifications
Max. permissible temp. 115°C
Retarder
Cooling system Type: Voith R115E
Contents;excl. heating; approx. 70 litres Capacity approx. 7.0 litres
incl. heating system approx. 100-140 litres Oil see retarder oil specifications
Operating temperature max. 95°C
Coolant see coolant specifications

TECHNICAL DATA 119

 Gearbox type ZF AS Tronic Front axle
Reductions 1st gear 12.33 Type RL75EC
2st gear 9.59 Camber 1°
3st gear 7.44 KPI 8°
4st gear 5.78 Caster 2,5°
5st gear 4.57 Toe-in 0-1 mm/m
6st gear 3.55 Hub greasing wheel bearing grease, see spec.
7st gear 2.70 Wheel deflection 275/70R22.5 inner = 56° outer = 46°
8st gear 2.10 Wheel deflection 295/80R22.5 inner = 52° outer = 43,5°
9st gear 1.63 Wheel deflection 315/70R22.5 inner = 52° outer = 43,5°
10st gear 1.27 Wheel deflection 315/80R22.5 inner = 51° outer = 41,5°
11st gear 1.00
12st gear 0.78 Rear axle
Reverse 11.41 Type 1347HAS
Capacity approx. 21 litres Reduction 2.93:1, 3.31:1, 3.73:1, 4.56:1
Oil see gearbox oil specifications and 5.13:1
Capacity differential approx. 21.5 litres
Gearbox type ZF 6HP602C (with primary retarder) Oil differential: see differential oil specifications
Reductions 1st gear 3,43 Hub greasing wheel bearing grease, see spec.
2st gear 2,01
9 3st gear 1,42 Trailer axle (only SBR)
4st gear 1,00 Type RL75A
5st gear 0,83 Camber 0° ± 40'
6st gear 0,59 KPI 8°
reverse 4,84 Caster 0°
Capacity approx. 15 litres Toe-in 0- 2 mm
Oil see gearbox oil specifications Wheel deflection inner wheel = 15°
outer wheel = 13.2°
Hub greasing wheel bearing grease,
see specifications

120 TECHNICAL DATA

Air suspension Electrical unit 24V
Electronically controlled air suspension Multiplex CANbus system with central management unit VFC and
Front axle Two air bellows two IOU's
Rear axle Four air bellows
Variable height setting Starter motor:
Front + Rear adjustable 60 mm above Type Bosch HEF95
driving height (Ferry-lift) Power 6.2 kW
Front adjustable 50 mm below driving
height (kneeling) Dynamo:
Type Alternating current
Steering gear Capacity 24 V - 2 x 100 A
Type hydraulically operated
Type number TRW THP80 Battery:
Fluid see hydraulic fluid spec. Number 2
Capacity approx. 8 litres Voltage 12 V
Capacity 2 x 200 Ah / 2 x 180 Ah
Brake system
Service brake Mechanical-air pressure, 2-
circuit system, fully separated
Front axle SN7000 disc brakes
Rear axle SN7000 disc brakes 9
Tag axle SN7000 disc brakes
Parking brake spring brake cylinders
Air reservoirs, working pressure 8.6 -9.8 bar
Min. working pressure 7.5 bar
Brake pads TEXTAR 7400 asbestos-free
DAF 1200 asbestos-free
Compressor 2 cylinders, water-cooled head,
stroke volume 440 cc

TECHNICAL DATA 121

 WHEELS

SB 230 SB 4000+ SBR 230 SBR 4000+ SBR 4000+

single deck single deck double deck

Tyres size 275/70 R22,5 295/80 R22,5 315/80 R22,5 275/70 R22,5 295/80 R22,5 315/80 R22,5 315/70 R22,5

Rim size 7.50x22.5 8.25x22.5 9.00x22.5 7.50x22.5 8.25x22.5 9.00x22.5 9.00x22.5

Additional Spacer disc Spacer disc Spacer disc

parts *
Extended bolts Extended bolts Extended bolts

* Spacer discs are necessary when fitting 9.00"x22.5" rims on the front axle (IFS). The thickness of the spacer discs for steel rim
is 15 mm and for aluminium rims is 10 mm. Also fit the extended wheel bolts.

Retighten the wheel nuts using a torque spanner after 100 km if

they have been loosened. Retighten wheel nuts again after
500 km when new wheel bolts have been mounted.

9 Wheel nuts tightening

± 15
torque:
Front: 600 Nm
Rear: 700 ± 15 Nm TRAILER WEIGHTS

Type Permissible trailer

weights (kg)

with inertia brake

SB4000+ PF/XF 3,500 kg

122 TECHNICAL DATA

LUBRICANTS, COOLANT AND FUEL SPECIFICATIONS

In order to comply with the warranty terms and to guarantee Attention

the durability of VDL Bus International bv products, it is essential Never mix oil of differing specifications. This has a negative
that the correct lubricants, fuel and coolant fluid are used and effect on the quality of the oil.
that they are changed in accordance with the intervals specified.

Additives to lubricants, fuel and coolant fluid - of whatever type Avoid physical contact with:
- must not be used except in circumstances prescribed by VDL - Fuel
Bus. - Lubricants
- Coolants
Always follow the safety instructions of VDL Bus International - Battery acid
bv or of the manufactures of these products.
In the event of skin contact: remove substance with paper or cloth,
Ask your lubricant and fuel supplier(s) whether the products they rinse the skin with plenty of water.
supply comply with VDL Bus International bv specifications. Consult a doctor in the event of persistent irritation.

VDL Bus International bv is not responsible for any damage resulting
from the following:
1. Using oil of a lower quality than specified
2. Using oil of a lower/higher viscosity than specified
3. Exceeding the changing interval
4. Using a lubricant, fuel, coolant fluid or brake fluid which does not
meet the requirements set by VDL Bus.
In the event of contact with the eyes: remove substance with soft
cloth and rinse with plenty of water.
Consult a doctor in the event of persistent irritation.
9
If any is swallowed: do NOT induce vomiting. Rinse mouth, drink
two glasses of water and consult a doctor.
In the event of inhalation: get some fresh air and rest, consult a
doctor.

TECHNICAL DATA 123

 ENGINE OIL

The engine oil specification overview is related to the maintenance Additional information:
schedules as stated in the maintenance manuals. ACEA E2/E3: Mineral oil
ACEA E5: Further developed ACEA E3 oil, geared to possible
DAF specification list refer to international standards such as higher requirements on Euro 3 engines.
ACEA and API. ACEA E4 - Partially or entirely synthetic oil, specially
In addition, requirements are made as to viscosity. developed for extended oil-change intervals
and/or highly loaded engines.
If necessary, the engine oil can be subjected to additional
requirements. These are listed in the DAF HP (High Performance) Explanation of overview
specification. V = may be used
If the engine oil must meet the DAF HP specification, it is listed as HP... = may be used if listed specifications have been met.
such in the overview.
On the oil specification sheet pertaining to the specific oil company
and on the packaging, there is an indication as to whether the DAF
HP specifications are met. This means that the oil may be used for
the relevant application.

DAF HP (High Performance) specification for diesel engines

9- HP1: low-viscosity oil ..W30 E4/E5
- HP2: low-viscosity oil ..W40 E4/E5

124 TECHNICAL DATA

 Engine type ACEA E3 ..W-40 ACEA E4 ..W-40 ACEA E4 ..W-30 ACEA E5 ..W-40 ACEA E5 ..W-30

PE
Standard V HP1 V HP1
changing interval

PE
Extended V HP2 HP2 HP2
changing interval

XE
Standard V V HP1 V HP1
changing interval

XE
Extended V HP2 HP2 HP2
changing interval

9
Prescribed oil grade after an engine repair/overhaul
For engine repair/overhaul during which shortblock, piston rings and/
or cylinder linings are replaced, the engine must be filled with SAE
30 or 15W-30 grade oil.
Replace this oil after 7,500-10,000 km with the specified oil.

TECHNICAL DATA 125

 GEARBOX OIL

Gearbox oil for the GO gearboxes: Type of gearbox Oil type Oil class

Type of gearbox Oil type Automatic Shell donax TX 14B

gearbox Shell ATF XS 14C
GO 170 Veedol Synmesh-AT ZF Ecomat2 Shell donax TZ 14E1
GO 190 Castrol Syntrans-AT
GO 210 BP Energear SHX 30 (1) Ecomat2 plus transmissions with oil sump temperatures above
Shell Transmission MA 100°C may only be operated with fluids from the 14E lubricants
Deagear Synth category. Always use fluids according to 14E in borderline cases
or in the case of uncertainty with reference to transmission
operation temperature.
Gearbox oil for the ZF gearboxes:
ZF AS Tronic:
ZF Ecomat2: Explanation of overview V = may be used

Explanation of overview Type of gearbox Oil classification

V = may be used 02D 02E 02H 02L
(1) (2) (2)

9 Type of gearbox Oil classification ZF AS Tronic V V V V

14A 14B 14C 14E
(1) Lubricant class 02D can only be used after a total transmission
ZF Ecomat2 V V V mileage of:
540 000 km/3 years (long-haul/coach operation) or
360 000 km/3 years (local/distribution/service route operation,
heavy-duty operation).
(2) Use of class 02D or 02H oil is advised against as there may be
an increase in the required gear-changing forces at low
temperatures.

126 TECHNICAL DATA

 RETARDER OIL GO170/ G0190/ GO210
Low temperatures limits:
Type Viscosity Oil grade/supplier
Oil class Oil type/ Oil sump temp.
SAE viscosity grade mineral oil SAE-20W20 API- CC/SF of beter
or 10W or SAE-30
02D/02E/02L 75W/75W-80/75W-85 above -40°C
75W-90/ATF (semi-) SAE 0W40 API-CC/SF of beter
Voith synth. oil SAE 5W30
02H 80W/80W-85/80W-90 above -25°C R115 SAE 5W40
SAE 5W50
SAE 10W30
SAE 10W40
Oil type for ZF AS Tronic (robotised gearbox):
synth. oil SAE 75W/80W Ermgard MTF Henkel
Oil type Viscosity Oil class

Shell Transmission ZFLD 75W-80 02D

Total Transmission TI
Mobiltrans SHC 30
9
Castrol Syntrans Z MAX 75W-80 02E
ZF-Ecofluid M

TUTELA TRUCK ZC 90 80W-90 02H

BP Energear SHX 30 75W-80/75W-85 02L

Castrol Syntrans
Veedol Synmesh

TECHNICAL DATA 127

 DIFFERENTIAL OIL FOR REAR AXLE DAF 1347 HYDRAULIC FLUIDS

Oil change Oil type Viscosity Oil grade Hydraulically operated steering gear DEXRON III with valid
Interval approval number
Hydraulic fan drive DEXRON III with valid
Mineral see figure API-GL5 approval number
Standard
Synthetic see figure API-GL5 of GL4/GL5 Hydraulically operated clutch: Brake fluid DOT 4

Extended Synthetic see figure API-GL5 of GL4/GL5 Warning:

It is important that the brake fluid is replaced at least every two
years due to its tendency to absorb water

128 TECHNICAL DATA

GREASES

Front wheel hubs: Saponified lithium mineral Dry plate clutch:

- ZF RL75 oil-based multigrade grease,
NLGI class 2 (grease code
KP2K-30 in accordance with
DIN51825).
Rear wheel hubs: Maintenance free hub bearings
- DAF1347
Swivel king pin and Saponified lithium mineral
control arms oil-based multigrade grease,
- ZF RL-75 A/EC NLGI class 2 (grease code
KP2K-30 in accordance with
DIN51825).
- Clutch plate - prise-as
connection: Grease on lithium base NLGI 3
- Thrust bearings without
synthetic coating: Grease on lithium base NLGI 3
- Thrust bearings with
synthetic coating: No grease permitted, dry mounting
- Clutch lever with bearing
bush (manual gearbox) No grease permitted, dry mounting
- Clutch lever without bearing
bush (AS-Tronic gearbox) Lithium based grease, NLGI 3
Brake claw guide sleeves Fuchs Renolit HLT2 (white)
Aluminium rims Freylube Prema

Auxiliary pitmanarm Fuchs Renolit LX-OS 3,

FAG Arcanol L260
Steeringbox 9
- Space behind sealing Lithium-based grease with
EP additive, NLGI class 2 dirt and
water seal (or better), such as:
Exxon Unirex EP2

Drive shaft Shell Retinax LX2

Fuchs Renolit LX PEP 2B

TECHNICAL DATA 129

 DIESEL FUEL
Diesel fuel must comply with the requirements stipulated in EN 590.
At extremely low temperatures, exclusively in an emergency (for
example standstill), may a quantity (depending on the outside
temperature) of petroleum (maximum 20%) or a flow improver (follow
product instructions) be added. However should THE STATUTORY
REGULATIONS NOT PERMIT the use of the above then a maxi-
mum of 20% unleaded petrol may be added.
Only non-foaming diesel may be used for high-speed fuelling
systems.
Sulphur content of diesel fuel
Vehicles equipped with a CRT filter
- The sulphur content of fuels used for vehicles equipped with a
CRT filter may not exceed 50 ppm (0.005%).
- Lubricant oils may not be added to diesel fuel for vehicles
equipped with a CRT filter. The use of diesel fuel containing
lubricant oil will cause damage to the catalyser, in turn resulting
9 in non-compliance with the stipulated emission requirements.
Vehicles equipped without a CRT filter
- The sulphur content of fuels used for vehicles that are not
equipped with a CRT filter may not exceed 0.2%. If the content is
higher act according to table below.
Sulphur content Engine oil-change interval
> 0.2% Halve interval to a maximum of 25,000 km
130 TECHNICAL DATA
The fuel should possess a lubricity effect in accordance with the
following requirement (lubricity standard):
Test method: HFRR, in accordance with
CEC-F-06-A96 standard
Test value: < 460 µm
BIODIESEL APPLICATION
Biodiesel (according to standard EN14214) is only permitted for
the DAF PE engines with a biodiesel modification-kit.
Restrictions:
Oil changing interval:
- Is to be halved compared with the standard changing interval.
- Extended changing intervals are not allowed
Oil- and fuel filter replacement: halve.
Note:
Biodiesel has dissolving characteristics so that the change from die-
sel to biodiesel may cause deposits in the fuel system to dissolve
and thereby clogging the filter. When changing from diesel to
biodiesel it is wise to check the filters after 1 or 2 tank fillings and to
replace any clogged filters. At low temperatures biodiesel may cause
problems such as clogging of filters.
COOLANT SPECIFICATIONS

Coolant is a poisonous liquid. Flush and refresh the cooling system thoroughly every 4 years
Protect skin and eyes. Coolant is harmful to the envi- with a maximum of 400,000 km.
ronment and must be processed as industrial waste
after use. Water quality requirements:
- pH 7.0 - 9.0
Use solely TEXACO HAVOLINE Extended Life Antifreeze Coolant - Total solid matter content < 340 ppm (< 340 mg/litre)
(XLC). - Hardness* < 140 ppm (calcium and/or
Follow the coolant manufacturer's directions for use. magnesium carbonate)
- Chloride < 40 ppm (sodium chloride)
The VDL Bus vehicles are filled during their manufacture with: - Sulphate < 100 ppm (magnesium and/
TEXACO HAVOLINE XLC, coolant, which has a orange colour. or sodium sulphate)

Texaco Havoline XLC satisfies the VAG specification TL 774 D. Hardness* 140 ppm = 8° German hardness/
14° French hardness / 10° British hardness.
- The standard mixing ratio of Texaco Havoline XLC is 1 op 1,
or 50% Texaco Havoline XLC and 50% water which satisfies
the specifications opposite. This offers protection against
corrosion and frost up to -40° C.
- When using Texaco Havoline XLC coolant or equivalent, only 9
mineralised water or water which satisfies the specifications
opposite may be used.
- No other coolant, additive or antifreeze may be added to the
mixture. This may affect the corrosion protection, silt up lines
and cause blockages.
- The anti-freeze mixture may be left in the cooling system during
the summer months. The concentration of anti-freeze should be
maintained in order to protect against damage such as corrosion,
for example.

TECHNICAL DATA 131

 TYRE PRESSURE

The driving comfort and fuel consumption are influenced by the tyre
pressure. The required tyre pressures depends on the position of
the tyre on the vehicle, the axle load and the size of the tyre.

Tyre pressure table*

- The required tyre pressures are for cold tyres.
- Unnecessary tyre wear is frequently caused by vehicle operation
with tyre pressures which do not match the axle load.
- In case of double assembly:
- the tyres pressure of both tyres must be the same;
- the depth of tread must be near enough the same.

* The required tyre pressures in the tables are for vehicles used
under normal operating conditions.

TYRE PRESSURE TABLE

Pressure in bar.
9
SB 230 SB 4000+ SBR 230 SBR 4000+ SBR 4000+
single deck single deck double deck

275/70 R22,5 295/80 R22,5 315/80 R22,5 275/70 R22,5 295/80 R22,5 315/80 R22,5 315/70 R22,5

Front axle 9.0 8.5 8.0 9.0 8.5 8.0 9.0

Rear axle 9.0 7.75 6.75 8.0 6.75 6.0 7.75

Trailer axle 8.0 6.75 6.0 9.0

132 TECHNICAL DATA

LUBRICATION DIAGRAM
Multi purpose grease

Engine oil

Transmission fluid

Hypoïd oil

Brake fluid

Automatic
transmission fluid

9
1. Hydraulic clutch reservoir 9. Wheel bearings C = CHECK
2. Tyre winch 10. Retarder S = SYMMETRICAL
3. Lower control arm 11. Gearbox V = CHANGE / RENEW
4. King pins (top and bottom) 12. Engine
5. Wheel bearings 13. Fan drive reservoir
6. Upper control arm 14. Power steering reservoir
7. Differential x Propshaft (only SB)
8. (not applicable)

TECHNICAL DATA 133

9

134 TECHNICAL DATA

 VDL Bus International bv
is part of the VDL-group

A powerful combination of specialised companies

in the metal and plastic industries.
The VDL group activities vary from surface treatment,
to development, assembly and sales
of semi-manufactured and end products.