DRIVERS MANUAL

Ambassador ALE120-225
Hyvinkään Liikenne Oy Finland
Euro 5 EEV OBD2
1050 DD042700
Introduction Vehicle:

This drivers manual contains information how to use your vehicle.
Read it carefully before making your first journey, especially the
safety precautions, the operation and the maintenance
instructions. Make sure this handbook is in the vehicle at all times.
This handbook consist of several main sections. Each main
section is identified by a thumbnail with a digit in the margin
(e.g. ) and starts with a table of contents.
In the texts are possible cross references to other pages, such as
the reference: Information screen ( 28). The number behind the
notebook shows the page number to where the information
appears.
At the end of the handbook, there is a general alphabetical index,
so you can locate what you are looking for quickly.
Typea ...................................................
Date of first use ...................................................
VIN numberb ...................................................
Other ...................................................
Registration ...................................................
a. Stamped on the identification plate to the right of the
front entrance.
b. On the same plate (e.g. XMGDE02CSOH123456) the
last 8 figures are the chassis number.

Please ensure that you are fully familiar with the instructions
provided in this documentation, as correct operation of the vehicle,
together with regular preventive and scheduled maintenance, is
decisive for the vehicle’s re-sale value.
Furthermore in many cases this is a condition of the warranty
provided.
CONTENTS 1
1 INTRODUCTION........................................................................................1

2
2 INSTRUMENTS AND OPERATION ........................................................15

3
3 SAFETY PRECAUTIONS AND EMERGENCY PROCEDURES ............77

4
4 MAINTENANCE.......................................................................................87

5
5 REPAIRS WHILST ON THE ROAD ......................................................105

6
6 IDENTIFICATION ..................................................................................133

7
7 TECHNICAL INFORMATION ................................................................143
Disclaimer

© 1050 VDL Bus & Coach bv, Valkenswaard,

The Netherlands.

In the interest of continuous product development VDL Bus &

Coach 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, in digital format or in any way
whatsoever without the prior consent in writing of VDL Bus &
Coach.
This 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-Hertogenbosch in the Netherlands
Next remark is relevant if the text has been translated for your
convenience from the English original into an other language.
A translation, however, can have the consequence that
differences of interpretation arise with respect to the content and
meaning of the text.
In all cases, therefore, the English version of this document will be
regarded exclusively as the single and authentic source to
establish the content and the meaning of the text in case of a
dispute.
 1 INTRODUCTION 1
INTRODUCTION .......................................................................... 3

WARNING SYMBOLS ................................................................. 4

SAFETY INSTRUCTIONS ........................................................... 4

WARRANTY CONDITIONS ....................................................... 10

ENVIRONMENT ......................................................................... 10

GENERAL TIPS ..........................................................................11

AIR CONDITIONING SYSTEM .................................................. 13

Introduction 1
1

2 Introduction
INTRODUCTION
The Ambassador ALE120-225 has
outstanding driving characteristics and
performance, has a low fuel consumption
and high operational reliability with the
emphasis on safety and comfort.
Reliability, durability, safety and a
comfortable ride are the hallmark of VDL
Bus & Coach products.
Carefully read this manual before driving
the vehicle for the first time to allow
yourself to make the most of these
characteristics and to fulfil your
expectations.
Thorough knowledge of the maintenance
instructions will increase driver satisfaction
and will usually have a favourable
influence on the vehicle’s useful lifespan. It
will allow the driver to make full use of all
the integrated options and, what is more,
univocal operation will benefit safety.
Purpose
The objective of this instruction manual is
to allow the driver or user to become
familiar with the vehicle.
This means that VDL Bus & Coach wishes
to provide as much information as possible
Introduction
concerning the operation, use, safety and Make sure this manual is
maintenance of the vehicle.
This instruction manual includes
always kept in the vehicle and
1
read it carefully before driving
information about standard and optional the vehicle for the first time.
features.
Alternative equipment, for example manual
The tachograph’s instruction
or automatic transmission, is discussed.
This means that you may skip certain
manual must be included when
the vehicle is delivered.
sections in the manual which deal with
equipment not fitted to your vehicle.
Layout
The layout of the manual is designed to be
practical and to provide a clear overview.
There are 7 chapters in the manual.
Each chapter is numbered and is easy to
locate using the dark markings in the
margins.
Each chapter begins with a detailed
contents section, which will help you find
your way around the relevant chapter.
An index at the end of the
manual will allow you to
quickly locate topics.
3
 WARNING SYMBOLS
1 vehicle.
The instruction manual includes the
following symbols.
Take note of the tip or warning
accompanying the symbol!
This symbol gives useful tips
to simplify the work.
This symbol indicates a situa-
tion which requires extra atten-
tion.
This symbol indicates a situa-
tion which may result in
damage to the vehicle.
This symbol indicates a situa-
tion which may result in perso-
nal injury.
This symbol indicates a situa-
tion which may result in
damage to the environment.
4 Introduction
SAFETY INSTRUCTIONS other vehicles near by may enter the
The following safety instructions must be
strictly observed in order to prevent
Never allow the vehicle’s engine to idle for
endangering your own health and safety,
a long time. If you smell or observe
as well as that of others.
exhaust fumes, trace the cause of this and
Warnings and safety instructions rectify the problem as quickly as possible.
Always read the instructions and warnings
on labels and stickers.
The engine stops automatically after 15
minutes if the engine idles and the
Do not ignore them. They are there to
accelerator pedal is not depressed.
ensure your health and safety!
Engine Never allow the engine to idle without
there being a driver present who pays
Do not allow the engine to run in a
attention to the vehicle. This will avoid the
confined or unventilated space.
The exhaust fumes contain
risk of personal injury and/or damage to
the vehicle as a result of the engine
carbon monoxide, which is an overheating. An overheated engine may
invisible, odourless and extre- cause a fire.
mely poisonous gas. If inhaled,
this gas may cause unconsci- If the engine threatens to overheat, then
this will be indicated by the coolant
ousness or even death.
temperature indicator. Action must be
Make sure the exhaust fumes are properly
extracted.
taken immediately to rectify this.
Allowing the engine to idle
Carbon monoxide may enter the vehicle in
unattended, even during a
short period of time, may
the event of poor maintenance of, damage
cause serious damage to the
to or corrosion of the exhaust system. It is
engine or even a fire.
also possible that carbon monoxide from
Engine compartment
Keep away from moving parts.
Exhaust system
The vehicle is equipped with a catalytic
converter. The catalytic converter/exhaust
system becomes very hot when driving.
. original packaging.
NEVER park or stop the vehicle
on a surface which is easily
inflammable, such as dry lea-
ves or dry grass. This will
cause a fire risk.
EAS
The vehicle meets, and even exceeds, the
current Euro standard in accordance with
the European emission legislation. In order
to meet this strict legislation, the vehicle is
equipped with an Emission After-treatment
System (EAS). This system uses AdBlue.
Topping up the AdBlue tank is not part of
the standard maintenance program and
must, therefore, be carried out by the
driver when using the vehicle.
In order to prevent faults and damage to
the vehicle, it is important that the following
Introduction
precautionary measures are closely • The AdBlue’s supply is interrupted and
observed: the EAS system is turned off. 1
• It is recommended to top up the • There is a fault in the EAS system.
AdBlue tank from the official AdBlue
filling equipment or with AdBlue The reduction will be deactivated after the
provided by VDL Bus & Coach or fault has been repaired.
another supplier, but always from the The reduction is activated when the
vehicle is stationary or the engine idles and
• Always top up the system with 100% there is a fault with the vehicle speed
pure AdBlue according to DIN 70070/ sensor.
ISO22241. Never use contaminated
AdBlue or contaminated containers or
funnels when topping up the AdBlue.
• Make sure diesel and AdBlue are not
mixed together in the AdBlue tank;
always use containers and funnels
which are 100% clean and which have
not been used for other liquids, such as
diesel or petrol.
Due to legal requirements, the engine
torque may be reduced when the exhaust
gas emissions exceed the legal limits. The
engine torque will then be limited to 60% of
the maximum engine torque.
The engine torque is reduced under the
following conditions:
• The emission level is above the legal
limits.
• The AdBlue tank is empty.
5
 The reduction is deactivated when the
1 vehicle is stationary or the engine is idling
and the fault with the vehicle speed sensor
has been rectified.
Main switch
Only turn off the main switch after the
contact switch has been turned off and
after waiting a further 43 seconds. The
EAS (Emission After-treatment System)
control phase must be completed before
the main switch can be turned off.
If the main switch is turned off whilst
driving the vehicle, then all the
electrical systems and the engine will
be turned off. This may lead to an
extremely dangerous situation.
Never turn off the main switch
whilst driving.
Never turn off the main switch
when the contact switch is
turned on.
6 Introduction
Batteries
Disconnecting the battery
clamps whilst the engine is
running may cause damage to
the vehicle's electrical compo-
nents.
Never disconnect the battery
clamps whilst the engine is
running!
Always disconnect the batteries’ earth
connection before repair or maintenance
work is carried out on the electrical
installation.
Only disconnect the battery’s earth cable
after waiting at least 90 seconds after the
contact switch has been turned off.
Not observing this condition may result in
serious damage to the vehicle's various
electrical systems.
Never place tools on a battery. It may
cause a short circuit or may even cause
the battery to explode.
When disconnecting the bat-
tery clamps, see DTCO (Digital
tachograph) ( 51).
Charging the batteries
When charging the batteries, make sure
there is good ventilation and avoid sparks
and a naked flame.
Allow frozen batteries to thaw
and remove all the filler caps
before charging.
First connect the battery charger’s positive
clamp (+) to the battery’s positive terminal
(+) and then the negative clamp (-) to the
negative terminal (-).
When the batteries have been charged,
turn off the battery charger and then
disconnect the negative clamp (-) first
followed by the positive (+) clamp.
The battery cables may remain connected
for normal charging.
Only use a quick-charger in the event of
extreme urgency.
To avoid damage to the vehi-
cle’s electronics, both battery
cables must be disconnected
when quick-charging.
Do not use a quick-starter to
start the vehicle, as this may
damage the vehicle’s electro-
nics.
Starting the vehicle using an auxiliary
starting device
To start the vehicle using an auxiliary
starting device, see Starting with the aid of
auxiliary batteries ( 127).
Accessories
Never connect accessories or other
electrical components to the vehicle using
splices in the vehicle’s wiring or by
connecting them to electrical components.
If this condition is not observed, then this
may result in serious damage to the
vehicle's electrical system and may cause
a short circuit and/or a fire.
Battery capacity
When the engine is not running, the use of
electrical components in the vehicle will
draw electricity from the batteries.
Approximately half of the battery capacity
is needed to start the engine.
If electrical components are used for a long
period of time, then, in particular at cold
temperatures, they may use so much
energy that there is insufficient battery
capacity to start the engine.
Introduction
System voltage
The vehicle has a 24 V electrical system.
When replacing or adding electrical or
electronic components, ensure that they
are suitable for this voltage.
Xenon lighting
1
Xenon lights use a very high
voltage. The driver is, there-
fore, not permitted to replace
the xenon light bulbs himself.
Xenon bulbs may only be
replaced by well trained techni-
cians, because it is a very spe-
cialized procedure. For more
information, contact your
nearest VDL Bus & Coach
workshop.
Do not touch the glass of the
xenon lamps.
Xenon lamps are pressurized.
Handle them with care: risk of
shattering.
Xenon lamps contain mercury
and must be disposed off as
chemical waste.
7
 Welding
1 Contact a VDL Bus & Coach dealer for
welding instructions before welding the
vehicle and/or the bodywork.
Not observing the welding
instructions may result in seri-
ous damage to the electrical
components.
Coolant reservoir filler cap
Do not remove the coolant reservoir’s filler
cap whilst the engine is at the operating
temperature. Release the pressure first by
slowly removing the filler cap.
Warning triangle
Always have a warning triangle in the
vehicle (it is a legal requirement in some
countries) and possibly some other means
of marking.
Safety vest
When carrying out emergency repairs,
always wear a safety vest (it is a legal
requirement in some countries) and, if
necessary, also use other means of
marking.
8 Introduction
Fire extinguisher
Make sure there is always a fire
extinguisher in the vehicle. Its
location is marked by a sticker in
the vehicle’s interior.
Make sure the fire extinguisher is
inspected at least once a year.
If the fire extinguisher is used, it must be
refilled as soon as possible.
In the event of a fire
Certain plastic seals may form gases
which, if they come into contact with water,
form a corrosive acid. Therefore, do not
touch any fire extinguisher fluid on the
vehicle without wearing protective gloves.
First-aid kit
Make sure there is always a fully stocked
first-aid kit in the vehicle.
Winter conditions
Whenever severe winter conditions are
expected, make sure to fit winter tyres and
snow-chains.
It is NOT permitted to fit snow
chains on the front wheels due
to the possibility of the chains
making contact with the body
of the vehicle during heavy
suspension movement. Con-
tact your dealer or fit winter
tyres.
Luggage
All luggage must be stowed so that it
cannot shift or fly loose, even in the event
of an emergency stop.
Bear in mind that the driving
characteristics of a fully loaded vehicle
differ from those of an empty vehicle.
Fluids and lubricants
Certain fluids and lubricants may be
harmful to your health if they come into
contact with your skin, are ingested or are
inhaled. Therefore, avoid physical contact
where possible.
Spilled fluids may react aggressively with
other materials, so clear them up as
quickly as possible.
To avoid the risk of fire, the engine and its
surroundings must be kept free of (highly)
inflammable materials.
Starting the vehicle using an auxiliary
starting device
To start the vehicle using an auxiliary
starting device, see Starting with the aid of
auxiliary batteries ( 127).
Retrofitted equipment
All equipment retrofitted to a VDL Bus &
Coach vehicle which belongs to the
category of equipment which should
undergo a fire safety inspection is subject
to the fireproof regulations of EU Directive
95/28 EC.
Introduction
Mobile telephones and transmitters
The following precautions relate to the use
of mobile phones and transmitters.
• Mobile phones and transmitters must
not be used in the vehicle except via a
separate external aerial.
The use of mobile phones or
transmitters without a separate
external aerial may cause
excessive electromagnetic
fields (the resonance effect)
within the vehicle. It is possible
that this may lead to disturban-
ces to the vehicle electronics.
• In addition, the optimum range of this
equipment can only be achieved with
the use of an external aerial.
Always follow the operating
instructions for mobile telep-
hones and transmitters.
Installation of additional electrical/
electronic equipment
All electrical/electronic components
retrofitted to VDL Bus & Coach vehicles
must have type approval together with "E"
markings in accordance with EU Directive
95/54 EC. 1
Interfering with the electronic
system in any way may cause a
dangerous situation due to the
system malfunctioning. Such
action will affect the warranty.
Vehicle weights
Take care not to exceed the following
weights:
• Maximum axle weight.
• Maximum vehicle weight (GVW).
• Maximum combination weight (GCW).
• Maximum trailer weight.
See also the vehicle identification plate.
Furthermore, in accordance with EU
Directive 96/53 EC, it is not permitted to
drive internationally within the EU with a
GVW of >18 tons for a two-axle vehicle,
nor with a GVW of >26 tons for a three-
axle vehicle.
Original VDL Bus & Coach parts
All parts and components are carefully
matched to each other, which helps to
determine the original VDL Bus & Coach
quality. Do not modify your vehicle with
non-original VDL Bus & Coach parts.
9
 Bear in mind that any modifications to your WARRANTY CONDITIONS
1 VDL Bus & Coach vehicle using non-
Please ensure that you are fully familiar
original parts may adversely affect its
with the instructions provided in this
performance, safety, lifespan and the
documentation, as correct operation of the
warranty.
vehicle, together with regular preventative
Modifications may also conflict with legal
and scheduled maintenance, is decisive
requirements.
for the vehicle’s resale value. Furthermore,
in many cases, this is a condition for a
warranty claim.
The warranty conditions are described in
the “GENERAL TERMS AND
CONDITIONS OF SALE” and in the
“WARRANTY CONDITIONS”.
10
ENVIRONMENT
To prevent unnecessary damage to the
environment, you should observe the
following guidelines:
• Used liquids should be carefully
collected and separated, and should
then be handed over to an authorized
site for recycling or disposal.
• Improper disposal of liquids is a
criminal offence.
• Make sure the vehicle is regularly
maintained. A properly maintained
vehicle uses fuel more efficiently and
emits less harmful exhaust gases.
• Do not allow the engine to idle
unnecessarily and always drive using
the appropriate engine speed.
Introduction
GENERAL TIPS If the vehicle has ESC (Electronic Stability • Do not drive with a trailer attached.
Control), then the vehicle may suddenly 1
Take note of the following Following a cold start, use a
recommendations before using the
vehicle:
brake in certain situations. Therefore,
always wear a seat belt.
moderate engine speed and
Only a properly adjusted seat belt works avoid heavy acceleration until
correctly. Therefore, never use a seat belt the engine reaches the opera-
Tachograph
clamp or something similar to stop the seat ting temperature.
The tachograph’s instruction manual must
belt from being too tight.
be included when the vehicle is delivered. Pay attention to the instrument panel whilst
Running in driving and respond alertly when
Refuelling irregularities are observed.
It is recommended to avoid placing the
Switch off the engine before vehicle under a too heavy load during the
refuelling. running-in period.
Wheel nuts
The wheel nuts must be retightened using
Use only diesel which is of a suitable This also applies when a reconditioned a torque spanner when the vehicle has
quality. engine, gearbox or differential has been been driven 100 km following delivery of
Make sure the filler cap and the area fitted. the vehicle or after the wheel nuts have
around it are free of dust and avoid mixing been loose.
water with the fuel when refuelling. For the first 1,500 km, you should,
Fuel economy
therefore:
To prevent water condensa- Driving economically does not mean
tion, do not allow the level of
• Avoid driving with a full load.
• Change down gear in good time: a driving slowly. It requires the driver to
fuel in the tank to fall unneces- relatively high engine speed is less anticipate situations, to have a smooth
sarily low. harmful than overloading the engine driving style and to adapt his/her driving
with excessively low engine speeds. style to the conditions.
Seat belt
Keep the following in mind:
If there is a seat belt, then it should be
• Warm the engine as quickly as
worn.
possible by driving off as soon as
possible under a moderate load.

Introduction 11
 • Drive smoothly and avoid unnecessary
1 acceleration and harsh braking.
• Change gear in good time and keep
the engine speed in the optimal (green)
range.
The most significant factor in fuel
consumption is the driver himself and how
he uses the accelerator pedal, the brake
pedal and the gear lever.
Starting procedure
For instructions, see Starting
procedure ( 57).
The engine cannot be started if
the gearbox is not in neutral.
After the engine has started,
the engine speed should not
be increased until the oil pres-
sure warning light has gone
out.
Braking
The vehicle is equipped with an ABS
braking system.
The ABS braking system prevents the
wheels locking during braking on slippery
road surfaces or in an emergency stop.
12
The ABS system is only activated at
maximum braking at the moment when
one or more wheels lock and the vehicle
threatens to skid.
At that instant, the ABS system allows the
brake pressure to be reduced until the
wheel begins to rotate again and the grip
on the road surface is restored. The
braking force is then immediately
increased again until maximum braking is
achieved or until the wheel in question
locks up again and the cycle is repeated.
The vehicle remains fully steerable in such
conditions and a stable course is
maintained.
Do not adapt your driving and
braking to the ABS system.
In particular, do not brake later or harder.
This will cause the tyres to wear more
quickly and will put other road users at risk.
Braking distances with ABS
are sometimes, but not always,
shorter.
When the contact switch is turned on, the
ABS warning light will be lit whilst the
system checks are performed. The light
should go out after a few seconds.
If the light remains lit or comes on during a
journey, there is a fault in the ABS system.
The normal braking capacity will be
maintained, but it will then be possible for
the wheels to lock during heavy braking.
If the light remains lit during a journey,
have the ABS system tested in a
workshop.
Stopping
For instructions, see Stopping/turning off
the engine/turning off the instrument
panel ( 58).
Parking
Stop the vehicle.
Apply the parking brake by means of the
brake lever.
When parking on an incline, the following
should be considered:
• Place chocks in front of or behind the
wheels of the rigid axle.
• Turn the front wheels so that the
vehicle will not head out into the road if
it should move for some reason.
Switch off the contact switch and the main
switch.
Air leak
A rapidly falling air pressure reading whilst
the engine is idling indicates an air leak.
Introduction
The leak must be repaired without delay as Implementation is by means of a logbook
the safety of the braking system is and maintenance obligation. 1
impaired.
Always observe the local legal
regulations!
AIR CONDITIONING SYSTEM
Regularly turn on the air condi-
The Pressure Equipment Directive 97/23 EC
came into force on th May 2002. Also, tioning system (at least once a
European regulation no. 842/2006 month), even if no cooling is
regarding certain fluorinated greenhouse required, to prevent the com-
gases came into force on 4th July 2006 pressor from leaking.
and many of the requirements came into
force on 4th July 2007. The objective of this
legislation is, amongst other things, to
drastically reduce coolant emissions from
cooling installations.
This is achieved by applying the following
measures:
• The use of CFCs in new installations is
forbidden.
• Technical requirements are placed on
cooling installations.
• Work on cooling installations may only
be carried out by qualified personnel.

The responsibilities of the owner/operator

of the installation are being increased.

Introduction 13
1

14 Introduction
2 INSTRUMENTS AND OPERATION
STEERING COLUMN SWITCHES ............................................ 17

INSTRUMENT PANEL ............................................................... 20

2
WARNING LIGHTS .................................................................... 22

MAIN DISPLAY.......................................................................... 26

INFORMATION SCREEN .......................................................... 28

WARNING SCREEN .................................................................. 32

ERROR SCREEN....................................................................... 36

LEFT-HAND CONTROL PANEL ............................................... 40

RIGHT-HAND CONTROL PANEL ............................................. 45

DESTINATION EQUIPMENT OPERATING AREA ................... 47

DRIVER’S LEFT-HAND CONTROL PANEL ............................. 49

CONTROL PANEL ABOVE THE DRIVER ................................ 51

FRONT BOX CONTROL............................................................ 53

DRIVING AND OPERATION ..................................................... 55

15
2

16
 STEERING COLUMN SWITCHES

ILAh0279
1. Left-hand combination switch 18
2. Right-hand combination switch 19
3. Adjustable steering column 19
4. Brake pedal 19 2
5. Accelerator pedal 19
There are two switches on the steering
column. The functions of the left-hand
switch are as follows:
– Lighting (dipped beam/high beam/
headlight flash)
– Indicators
– Horn
– Windscreen wipers (interval/speed/
spray)

The functions of the right-hand switch are

as follows:
– Cruise control (optional)
– Variable vehicle speed limiter (optional)
– Engine speed control (optional)
– Retarder (optional)

Steering column switches 17


2 beam is operated by lifting the switch
1. Left-hand combination switch
H Centre position (dipped beam, when
the lights are turned on)
I Headlight flash
J High beam
L Indicators, left
K Horn
R Indicators, right
3 Windscreen wiper switch
O Wipers off
--- Intermittent wipe
I Wipers on, low speed
II Wipers on, high speed
S Windscreen washer Windscreen wipers
The windscreen washer is activated by
pressing the spring-mounted switch (S).
Dipped lights/high beam/headlight flash
The windscreen wipers are activated after
The combination switch is spring mounted.
2 seconds and will make 2 wiper strokes.
Position H is the neutral position. The high
Interval time for the intermittent wipe
upwards to position I. The standard interval is 2 or 10 seconds,
If the switch is pulled into position J depending on the factory setting.
(against the spring pressure), the
The windscreen wipers only
headlights will switch from dipped beam to
high beam or vice versa. When the switch work when the contact switch
is released, it returns to position H. has been turned on. Always
switch off the windscreen wip-
Indicators ers in winter conditions before
The indicators (L and R) only work when putting the contact switch in
the contact switch has been turned on. To the rest position in order to
operate the indicators briefly when prevent damage to frozen
changing lanes, the switch should be windscreen wipers.
pulled back until some resistance is felt.
The force of the spring will cause it to
spring back to the original position when it
is released.
Horn
Push the button (K) (the horn will only work
when the contact switch has been turned
on).

18 Steering column switches


ILBh0124
2. Right-hand combination switch
Various control functions can be switched
on and off using control functions 1, 2 and
3 on the combination switch:
– Cruise control
The cruise control can only be turned
on at a speed greater than 30 km/h,
see Cruise control (optional) ( 63).
– Variable vehicle speed limiter (LIM)
The variable vehicle speed limiter (also
known as foot-on cruise control) allows
the vehicle speed to be limited to a
speed set by the driver whilst the foot
can remain on the accelerator pedal,
see Variable speed limiter
(optional) ( 64).
– Engine speed control
Steering column switches
The engine speed control allows the
engine speed to be immediately
increased to a speed which has been
pre-programmed in the electronic unit.
The engine speed can be increased or
decreased to a required value, see
Engine speed control
(optional) ( 65).
– Retarder
The steering column switch can be
used to select a specific braking
torque, see Retarder
(optional) ( 67).
For more information on these
control functions, see Driving
and operation ( 55).
3. Adjustable steering column
The position of the steering column and
the height of the steering wheel are
pneumatically adjustable. The switch on
the floor of the bus must be pressed in
order to adjust the steering column. Both
settings (position and height) can be
adjusted at the same time. The steering
column is locked in position when the
switch is released.
Adjustment is only possible
when the parking brake has
been applied and, for some 2
vehicle specifications, when
the door is open.
4. Brake pedal
To operate the brakes, see Service brake
(footbrake) ( 60).
5. Accelerator pedal
The doors must be closed and the vehicle
must be at the driving height to operate the
accelerator pedal, see Operating the bus-
stop brake ( 61).
A kick-down switch is integrated in the
accelerator pedal. If it is necessary to
accelerate quickly, the accelerator pedal
must be fully depressed, see Kick-down
gear change ( 70).
19
 INSTRUMENT PANEL
The instrument panel will show the driver
all the information regarding the status of
the vehicle.
2 The information is displayed by means of
warning lights and symbols on the main
display.

A. Odometer/Trip meter 21
B. Fuel gauge 21
C. Main display 21
D. Coolant temperature gauge 21
E. Speedometer 21
F. Warning lights 21
G. Rev counter 21
H. Light dimmer switch 21

Turning on the instrument panel

After turning on the main switch, all the
warning lights will be lit for 3 seconds and ILAh0198
they will remain lit if the function they relate
to is active.
A buzzer will sound for a short period of
time.
The needles of the speedometer, rev
counter, fuel gauge and coolant
temperature gauge will move to their
maximum position and then return to their
zero position.

20 Instrument panel
The main display will appear as a black
screen and turn grey to indicate that the
display works correctly. The air pressure
gauges will appear.
Turning the instrument panel off
After turning off the main switch, the main
display will gradually dim (stand-by mode)
and, after some time, turn black (sleep
mode).
A. Odometer/Trip meter
Once the contact switch has been turned
on, the odometer/trip meter and the clock
will be displayed in the speedometer
display. The reset button (A1) for the trip
meter is located at the bottom of the
instrument panel. The display will switch
between the clock and the trip meter when
the reset button is pressed briefly. The
clock in the display is synchronized with
the DTCO/TSU clock. The clock can,
therefore, only be adjusted via the DTCO/
TSU, see DTCO (Digital
tachograph) ( 51). The trip meter is
reset by pressing the reset button for
longer than 4 seconds.
B. Fuel gauge
The fuel gauge only works when the
contact switch and the main switch have
been turned on. After the contact switch
Instrument panel
has been turned on, the fuel gauge needle
will indicate the actual fuel level after a
short delay. The amber warning light (B1)
under the fuel gauge lights up as soon as
the reserve level in the fuel tank has been
reached.
Refuel the vehicle as soon as
possible, see
Refuelling ( 55).
C. Main display
For more information regarding the main
display, see Main display ( 26).
D. Coolant temperature gauge
The engine must not be fully loaded when
the temperature gauge is at the bottom.
The engine is at operating temperature
when the temperature gauge needle is in
the middle of the range. The following
points must be checked if the coolant’s
temperature rapidly increases and/or the
gauge reaches the red region (warning
light (D1) below the gauge will be lit):
– The coolant level, see Coolant
level ( 95).
– The hydraulic fan drive oil level.
– The poly V-belt and the seals of the
water hoses.
The red warning light will also
be lit if the coolant temperature
is too high and a buzzer will
sound if the engine is running.
E. Speedometer 2
Depending on the type of speedometer,
the speedometer has a km/h scale or a
km/h scale and a mph scale.
F. Warning lights
These lights contain information and
warning signals. For their meaning and
use, see Warning lights ( 22).
G. Rev counter
Since the vehicle has an automatic
gearbox, the correct engine speed will be
automatically selected. As a result, the rev
counter does not have coloured regions on
the gauge.
H. Light dimmer switch
If the light switch is in position I or II, the
instrument lights and the warning lights of
the various switches will be lit. The
intensity can be set to five different levels
using the dimmer switch. When the lowest
intensity is reached, the light intensity will
be reselected. The last setting is saved
when the contact switch is turned off.
21
 WARNING LIGHTS
Description
The warning lights provide information and
warning signals.
2 After turning on the main switch and the
contact switch, all the warning lights will be
lit for a short time to check they work
correctly.

There are the following warning lights:

A. Dipped beam 23
B. Rear fog light 23
C. Main beam light 23
D. AdBlue reserve level 23
E. Central warning AMBER 23
F. Air pressure too low 23
G. Central warning RED 23
H. ABS fault 24
I. Trailer ABS fault 24 ILAh0199
J. Pre-glowing 25
K. Charging current/battery voltage 25
L. Indicators 25

22 Warning lights
A. Dipped beam
This warning light is lit when the
dipped beam is turned on.
B. Rear fog light
This warning light is lit when the
rear fog light is turned on.
C. Main beam light
This warning light is lit when the
main beam is turned on or when
a flash signal is given.
D. AdBlue reserve level
This light is lit briefly after the
main switch and the contact
switch have been turned on.
This warning light will be lit once
the AdBlue reserve is reached.
The light will go out after a couple of
seconds.
Warning lights
E. Central warning AMBER
The AMBER central warning
light is lit if a minor fault occurs
in a vehicle system. The main
display shows during 5 seconds
automatically which system has
caused the fault (for example, coolant level
low).
You may continue driving, but
action must be taken at the
first opportunity to rectify the
fault! Also read the descrip-
tion of the relevant symbol that
appears on the main display’s
warning screen.
F. Air pressure too low
This warning light is lit if the air
pressure in one of the service
brake circuits is too low. If the
engine is running, a buzzer will
sound. A flashing warning light indicates a
faulty connection that needs to be
repaired.
The parking brake lever in locked position
can only be disengaged when the warning
light B is off.
After a cold start, the build-up of air
pressure can be sped up by running the
engine at a slightly higher speed.
When this indicator appears
whilst driving, stop immedi- 2
ately at a safe place.
Only apply the parking brake
as an emergency brake if the
service brake does not work.
NB The ABS will not work!
G. Central warning RED
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 if:
• The temperature in the engine
compartment is too high.
23
 • The engine is running with a low
battery voltage and/or a low oil
pressure and/or a low coolant level
and/or a high coolant temperature and/
or an air pressure in the pneumatic
2 system of less than 6 bar. Optionally,
also when the retarder is turned off.
If a red warning light is dis-
played, stop immediately in a
safe location and turn off the
engine!
Also read the description of
the relevant symbols that
appear on the main display’s
error screen. Have the error
repaired as quickly as possible
by a VDL Bus & Coach work-
shop.
If there is a fault with the
engine, this will be indicated
by a flashing red warning light.
H. ABS fault
This light is lit in combination
with warning light C if there is a
fault with the ABS system. A
flashing warning light indicates
24
a faulty connection that needs to be
repaired.
Stop immediately in a safe
location. Check the ABS fuses
in the central fuse box.
If the fault is not rectified by
inserting a new fuse, the vehi-
cle may only be driven to the
nearest VDL Bus & Coach
workshop. Have the fault
repaired immediately!
The ABS system will no longer
function, although the service
brake will still continue to func-
tion correctly.
I. Trailer ABS fault
This light is lit in combination
with warning light C if there is a
fault with the ABS system. A
flashing warning light indicates
a faulty connection that needs to be
repaired.
Stop immediately in a safe
location. Check the ABS fuses
in the central fuse box.
If the fault is not rectified by
inserting a new fuse, the vehi-
cle may only be driven to the
nearest VDL Bus & Coach
workshop. Have the fault
repaired immediately!
The ABS system will no longer
function, although the service
brake will still continue to func-
tion correctly.
Warning lights
J. Pre-glowing
This light is lit after the main
switch and the contact switch
have been turned on. This light
indicates that pre-glowing is
taking place. Once this light has
gone out, the vehicle can be started. If
there is a fault with the pre-glowing
system, then the warning light will be lit
continuously. This indicates a fault that
must be rectified.
K. Charging current/battery voltage
The light should go out when
the engine is running.
If the engine does not turn over
when attempting to start the
engine and warning light A
lights up simultaneously with
amber light C or red light D, then
charge up the empty batteries or
replace them.
Warning lights
When the warning light A lights
up simultaneously with the red
warning light D when the vehicle
is being driven (or when the
engine is running), this indi-
cates that there is no charging
current. Since the batteries are
constantly being discharged 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 fault in the
alternator or wiring.
Have the fault repaired as
quickly as possible at a VDL
Bus & Coach workshop.
When the warning light A lights
up simultaneously with the red
warning light D when the vehicle
is being driven (or when the
engine is running) and if the
warning buzzer is also audible,
2
then the battery level is so low
that functionality may be lost.
Stop the vehicle as soon as pos-
sible and turn off the engine.
Have the fault repaired as
quickly as possible at a VDL
Bus & Coach workshop.
L. Indicators
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.
25
 MAIN DISPLAY
The main display will show the driver
information regarding the status of the
vehicle. The information is displayed using
symbols, which are described in this
2 chapter.
The main display is a graphic (LCD)
screen. Under cold circumstances (e.g. at
night below 4° C), the main display may be
displayed inverted. This behaviour is
considered normal and will gradually
disappear once the vehicle’s interior has
warmed up. The warming-up time will
depend on the overnight storage
temperature.
When the main switch is switched on, the
main display will be black to check whether
the symbols are working correctly. The
main display can display the following
three screens:
• Information screen
• Warning screen
• Error screen
26
You can switch between the
individual screens using the
menu switch on the instrument
panel.
ILAh0317
Information screen
The symbol <i> on the left-hand side of the
main display indicates the activated
information screen.
The air pressure gauges on the right-hand
side of the main display are always visible
regardless of which screen is displayed so
that the air pressure can always be read.
The symbols displayed in the individual
sections of the main display vary for each
screen. The function of each symbol is
described later in this chapter.
Main display
 2

ILAh0318 ILAh0319

Warning screen Error screen

The warning screen is displayed in the
event of a warning (the amber warning
light is also lit).
After 4 seconds, the warning screen will
switch back to the information screen
again.
The warning screen can be dis-
played again using the menu
switch.
The error screen is displayed in the event
of an error in the vehicle (the red warning
light is also displayed).
This error screen will be displayed until the
error is rectified.
When the screen is deactivated
using the menu switch, the error
screen will reappear after 5 sec-
onds.
Simultaneous error messages are
possible.
The activated screens will be displayed on
the bottom bar on the main display.

Main display 27
 INFORMATION SCREEN i-E5 Air conditioning on
The information screen is i-F1 ASR (Anti Slip Regulation)
indicated by the symbol
opposite, which is shown at the i-F2 Engine oil level low
bottom of the bar. i-F3 Variable vehicle speed limiter
2 The co-ordinates of the symbols in the i-F4 Kneeling prevention
matrix on the screen are defined using
letters along the left hand side and i-F5 Central lubrication grease level
numbers along the top. low
ILAh0329
The symbols only will be displayed if the i-G6 Retarder oil temperature
related option is installed.
i-C1 Stop signal i-G7 AdBlue level
i-C2 Door 1 open i-G8 Air pressure gauges
i-C3 Door 2 open i-H6 Digital speed display
i-C4 Emergency door open i-H7 Bus-stop brake
i-C5 Ramp activated i-H8 Parking brake activated
i-D1 Wheelchair stop signal
Description of the symbols on the
i-D2 Retarder off information screen
i-D3 Retarder activated i-C1 Bus stop signal
i-D4 Start control REAR This symbol appears when a
stop button has been pressed.
i-D5 Webasto heating
The symbol can only be reset
i-E1 Engine oil pressure low by opening a door. The symbol
i-E2 Cruise control then disappears.
i-E3 Speed limiter
i-E4 Vehicle not at the driving height

28 Information screen
i-C2 Door 1 open
This symbol appears when door
1 (entrance door) is open.
i-C3 Door 2 open
This symbol appears when door
2 (exit door) is open.
i-C4 Emergency door open
The vehicle may be equipped
with an emergency door as an
optional extra. This symbol is
displayed when the emergency
door is opened.
i-C5 Wheelchair ramp extended
This symbol appears when the
wheelchair ramp is extended.
i-D1 Wheelchair stop signal
This symbol appears when the
stop button has been pressed.
This can be reset by pressing
button 24 or by extending the
wheelchair ramp.
Information screen
i-D2 Retarder off
This symbol is displayed when
the retarder foot control function
is turned off. A buzzer will also
sound though.
i-D3 Retarder activated
This symbol is displayed when
the retarder is activated using
the foot control or the manual
control.
i-D4 Rear start
This symbol is displayed when
the FRONT/REAR switch in the
engine compartment is set to
REAR or when the engine
hatch is open.
i-D5 Webasto heating
This symbol is displayed when
the Webasto interior heating is
activated.
i-E1 Engine oil pressure low
This symbol is displayed when
the main switch is turned on
and the engine is NOT running.
The red warning light will also
be lit.
This symbol should disappear once the
engine has been turned on.
If this symbol is displayed whilst driving,
then the oil pressure is too low. Stop the
vehicle and turn off the engine
immediately. Check the oil level.
2
Check the oil level, see Daily
checks and
maintenance ( 94). If the
symbol remains visible, have
the error repaired as quickly as
possible by a VDL Bus &
Coach workshop.
i-E2 Cruise control
The vehicle may be equipped
with cruise control as an optional
extra. This symbol appears when
the cruise control is active.
i-E3 Speed limiter
The vehicle may be equipped
with a speed limiter as an
optional extra.
This symbol appears when the
speed limiter is activated.
i-E4 Vehicle not at the driving height
This symbol is displayed for a
short time when the contact
switch is turned on. The symbol
is displayed when the vehicle is
29
 not at the normal driving height. If
necessary, use the “Pneumatic
suspension, kneeling/raising ( 41)”
switch to return the vehicle to the normal
driving height.
2 speed limiter is active, see Variable speed
i-E5 Air conditioning on
The vehicle may be equipped
with air conditioning as an
optional extra. This symbol
appears when the air
conditioning has been turned
on.
i-F1 ASR (Anti Slip Regulation)
The vehicle may be equipped
with ASR as an optional extra.
This symbol is displayed when
the ASR has been activated.
i-F2 Engine oil level in tank too low
This symbol is displayed when
the contact switch has been
turned on, the engine is NOT
running and the oil level in the
oil tank is too low.
Carry out maintenance as soon as
possible!
30
i-F3 Variable vehicle speed limiter
The vehicle may be equipped
with a variable speed limiter an
optional extra. This symbol
appears when the variable
limiter (optional) ( 64).
i-F4 Kneeling prevention
This symbol is displayed when
the automatic kneeling
prevention has been activated.
Kneeling is then not possible.
i-F5 Central lubrication system grease
level low
The vehicle can be equipped
with a central lubrication system
as an optional extra.
This symbol is displayed when
the pump delivers grease.
i-G6 Retarder oil temperature
This gauge indicates the retarder oil
temperature. Symbol W-D3 will also
be displayed on the warning screen
if the temperature is too high.
i-G7 AdBlue level
The gauge works when the main
switch has been turned on. It indicates
the amount of AdBlue in the AdBlue
tank.
If the level of AdBlue in the
AdBlue tank falls to a certain
minimum level, then the symbol
shown opposite will be
displayed.
Top up the AdBlue as soon as possible,
see 2. Refuelling ( 55).
This symbol is displayed as
soon as the AdBlue level falls
below the legal minimum level.
The EAS system will then be
turned off. This will prevent the EAS unit
from drawing in air.
The engine torque will also be reduced.
i-G8 Air pressure gauges
The gauges work once the main
switch has been turned on. Each
gauge displays the pressure in
one of the service brake air
reservoirs.
Information screen
 released, provided
This warning light is also
displayed if the pressure drops
pressure.
below 6 bar. A buzzer will
sound if 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.
i-H6 Digital speed display
Above 5 km/h or 4 mph, the
speed is digitally displayed in
this location.
i-H7 Bus-stop brake
This symbol is displayed when
the bus-stop brake is applied. A
flashing warning light indicates
a faulty connection that needs
to be repaired.
i-H8 Parking brake applied
This symbol is displayed when
the parking brake is applied or if
the pressure in the parking
brake circuit is too low for the
parking brake to be released. The symbol
disappears when the parking brake is
Information screen
there is sufficient The following must take place
before the main switch can be
It is not permitted to drive the turned off:
vehicle if the parking brake The contact switch must be
symbol is visible. turned off. 2
The parking brake symbol will
Only apply the parking brake start to flash if the parking
as an emergency brake if the brake has NOT been applied.
service brake does NOT work.
Since the parking brake is only
The parking brake must be
applied.
applied to the driven wheels, it The red light will flash if the
has a limited braking capacity. main switch is turned off with-
The wheels may skid, because out the parking brake having
the parking brake is not been applied. A buzzer will
equipped with ABS! also sound.
The main switch cannot be
turned off unless the parking
brake has been applied. The
parking brake symbol will flash
if the contact switch has been
turned off and the parking
brake has NOT been applied. If
the main switch is turned off,
the red light will be lit and a
buzzer will sound.
31
 WARNING SCREEN
The warning screen is indicated
by the symbol opposite, which
is shown at the bottom of the
bar.
2 W-F3 Electrical system body
The AMBER col-
oured general warn-
ing light will also be
lit when the warning
symbols given below
are displayed.
It is permitted to continue driv-
ing, but action must be taken at
the earliest opportunity to rec-
tify the problem!
Also read the remarks beside
the description of the symbols!
The co-ordinates of the symbols in the
matrix on the screen are defined using
letters along the left hand side and
numbers along the top.
The symbols only will be displayed if the
related option is installed.
32
W-E4 Vehicle driving height fault
W-E5 Air conditioning fault
W-F2 Exhaust gas back pressure or
exhaust gas temperature too high
W-F4 Pneumatic suspension error
W-F5 Central lubrication system fault
ILAh0331
W-G1 Emission fault
W-G2 Brake lining wear indicator
W-C1 Engine fan fault
W-G3 Retarder temperature too high
W-C2 Door 1 fault
W-G4 Alternator does not charge
W-C3 Door 2 fault
W-C4 Emergency door fault
W-G5 Water in fuel
W-H6 Digital speed display
W-C5 Ramp malfunction
W-H7 Bus-stop brake activated
W-D1 Engine management
W-H8 Parking brake activated
W-D2 Gearbox
W-D3 Retarder fault Description of the symbols on the
W-D4 Engine inspection fault or warning screen
engine start block W-C1 Engine fan fault
W-D5 Webasto heating fault This symbol is displayed if the
engine fan does not work. A
W-E1 Emergency hammer missing
flashing warning light indicates
W-E2 Coolant level too low a faulty connection that needs
W-E3 Driveline electrical system to be repaired.
Warning screen
W-C2 Door 1 fault
This symbol is displayed if there
is a fault in the door system of
door 1.
W-C3 Door 2 fault
This symbol is displayed if there
is a fault in the door system of
door 2.
W-C4 Emergency door fault
The vehicle may be equipped
with an emergency door as an
optional extra. This symbol is
displayed if there is a fault in the
emergency door system.
W-C5 Wheelchair ramp fault
This symbol is displayed if there
is a fault with the wheelchair
ramp.
W-D1 Engine management
This symbol is displayed if the
engine management system
detects a fault. A flashing
warning light indicates a faulty
connection that needs to be repaired.
The engine may lose power.
Stop as quickly as possible in
a safe location.
Warning screen
This symbol may also be dis-
played if the water separator
contains too much water.
Check the water separator by
draining it (see “Mainte-
nance”).
W-D2 Gearbox
This symbol is displayed if the
gearbox is in a different gear
than the one chosen by the
driver (not applicable for an
automatic gearbox).
A flashing warning light indicates a faulty
connection that needs to be repaired.
W-D3 Retarder fault
This symbol is displayed if the
retarder is activated, but does
not work. A flashing warning
light indicates a faulty
connection that needs to be
repaired.
Pay attention to a loss of brak-
ing force and be careful to
avoid overheating the brakes.
W-D4 Engine inspection fault or engine
start block
This symbol is displayed if there
is a fault with the engine
inspection or if the engine has
2
been blocked from starting.
W-D5 Webasto heating fault
This symbol is displayed if the
Webasto interior heating is
faulty. A flashing warning light
indicates a faulty connection
that needs to be repaired.
W-E1 Emergency hammer missing
This symbol is displayed when
the hammer has been removed.
A buzzer will also sound.
The buzzer will be loud for 5
seconds and then become quieter.
When the vehicle is stationary, the symbol
in the warning screen will no longer be
visible, because the display will
automatically switch to the information
screen. The buzzer will still sound.
Make sure a new emergency
hammer is fitted as soon as
possible.
33
 W-E2 Coolant level too low
This symbol is displayed if the
coolant level is too low.
2 For checking and filling, see
Inspection and maintenance
checklist ( 92).
If the symbol remains visible,
have the fault repaired as
quickly as possible by a VDL
Bus & Coach workshop.
W-E3 Driveline electrical system
This symbol is displayed if an
error occurs in one of the
electronic units or in the
communication between them.
W-E4 Height control fault
This symbol is displayed when
the vehicle is not at the normal
driving height. This may be
34
because the air pressure is too low. If so,
carry out the following:
Stop the vehicle. Increase the
engine speed until the maxi-
mum air pressure is reached
and then turn off the engine
and the contact switch. Wait
five seconds before turning on
the contact switch and starting
the engine again.
W-E5 Air conditioning fault
Not applicable.
W-F2 Exhaust gas back pressure or
exhaust gas temperature too high
A soot filter can be fitted as an
optional extra. This symbol is
displayed as soon as the soot
filter monitoring system indicates
that the exhaust gas back pressure or the
exhaust gas temperature is too high.
A flashing warning light indicates a faulty
connection that needs to be repaired.
W-F3 Bodywork electrical system
This symbol is displayed if an
error occurs in one of the
electronic units or in the
communication between them.
If this warning light is lit and the light in the
mirror adjustment switch flashes
(frequency of 1 Hertz), then the doors will
not open when the vehicle comes to a
standstill and it will not be possible to bleed
them using the emergency taps near the
doors. It will then only be possible to open
the doors using the red button located in
the box above the doors.
W-F4 Pneumatic suspension fault
This symbol is displayed if there
is a fault in the pneumatic
suspension system. A flashing
warning light indicates a faulty
connection that needs to be repaired. For a
description of the operation, see
Pneumatic suspension, kneeling/
raising ( 41).
W-F5 Central lubrication system fault
The vehicle can be equipped
with a central lubrication system
as an optional extra.
A flashing warning light
indicates a faulty connection
that needs to be repaired.
Warning screen
W-G1 Emission fault
This symbol appears if an error
code is stored in the electronic
unit of the engine management
system or exhaust gas after-
treatment system.
The engine will then not meet
the emission legislation’s legal
requirements.
If this warning is ignored, the automatic
engine torque reduction may be activated.
The torque limiter is activated as soon as
the vehicle is stationary for two seconds.
Once the cause of the torque limit has
been rectified, the full engine torque will be
available again after the vehicle has once
again been stationary.
Investigation officers can read
error codes up to 400 days
after they have been saved.
W-G2 Brake lining wear indicator
This symbol is displayed when
the brake lining reaches the
minimum thickness.
Warning screen
W-G3 Retarder temperature too high
This symbol is displayed if the
oil temperature in the retarder
and gearbox is too high.
The retarder’s operation will
reduce as a result of the unde-
sired increase in temperature.
Use the footbrake to control
the speed of the vehicle.
W-G4 Generator 1 fault
Generator 1 charging current
fault. The other generator(s)
charge(s) normally, but (in the
long term) it may be insufficient.
W-G4 Generator 2 fault
Generator 2 charging current
fault. The other generator(s)
charge(s) normally, but (in the
long term) it may be insufficient.
W-G4 Generator 3 fault
Generator 3 charging current
fault. The other generator(s)
charge(s) normally, but (in the
long term) it may be insufficient.
W-G4 Generator fault
This symbol appears if an error
occurs in more than one
generator. This must be
rectified as quickly as possible.
2
W-G5 Water in the fuel
This symbol is displayed if there
is too much water in the fuel.
This water must be removed as
quickly as possible using the
fuel-water separator.
W-H6 Digital speed display
Above 5 km/h or 4 mph, the
speed is digitally displayed in
this location.
W-H7 Bus-stop brake
This symbol is displayed when
the bus-stop brake is applied. A
flashing warning light indicates
a faulty connection that needs
to be repaired.
W-H8 Parking brake applied
This symbol is displayed when
the parking brake is applied or if
the pressure in the parking
brake circuit is too low for the
parking brake to be released. The symbol
35
 disappears when the parking brake is
released, provided there is sufficient
pressure.
It is not permitted to drive the
2 vehicle if the parking brake
symbol is visible.
Only apply the parking brake
as an emergency brake if the
service brake does NOT work.
Since the parking brake is only
applied to the driven wheels, it
has a limited braking capacity.
The wheels may skid, because
the parking brake is not
equipped with ABS!
The main switch cannot be
turned off unless the parking
brake has been applied. The
parking brake symbol will flash
if the contact switch has been
turned off and the parking
brake has NOT been applied. If
the main switch is turned off,
the red light will be lit and a
buzzer will sound.
36
The following must take place
before the main switch can be
turned off:
The contact switch must be
turned off.
The parking brake symbol will
start to flash if the parking
brake has NOT been applied.
The parking brake must be
applied.
The red light will flash if the
main switch is turned off with-
out the parking brake having
been applied. A buzzer will
also sound.
ERROR SCREEN
The error screen is indicated by
the symbol opposite, which is
shown at the bottom of the bar.
The RED general warning light
will be lit at the same time as
the symbols given below.
If a red warning light
is displayed, stop
immediately in a safe
location and turn off
the engine! Turn off the main
switch and read the descrip-
tion given with the symbol.
The co-ordinates of the symbols in the
matrix on the screen are defined using
letters along the left-hand side and
numbers along the top. The symbols will
only be displayed if the related option is
installed.
Error screen

ILAh0332
E-C1 Engine compartment temperature
E-C2 Generator voltage too high
E-C3 Steering oil level too low
E-D1 Engine management fault
E-D2 Gearbox
E-E1 Oil pressure too low
E-E2 Coolant level too low
E-E3 Driveline electrical system
E-F2 Exhaust gas back pressure or
exhaust gas temperature too high
E-F3 Electrical system body
E-F4 Pneumatic suspension error
E-H6 Digital speed display
E-H7 Bus-stop brake activated
Error screen
E-H8 Parking brake activated
Description of the symbols on the error
screen
E-C1 Engine compartment temperature
too high
This symbol is displayed if the
temperature in the engine
compartment exceeds 110° C.
A buzzer will also sound.
Tip 1:
If the coolant temperature indi-
cates a cooling problem, allow
the engine to idle for a couple
of minutes and then turn off
the engine.
Tip 2:
If there is no indication of a
cooling problem, approach the
engine compartment carefully,
because there may be a fire.
Fire risk!
Use the main switch to turn off
the current. If there is a danger,
make sure the passengers are
safe. Have a fire extinguisher 2
at hand when approaching the
engine compartment. Do not
open the hatch when smoke is
visible, but try to extinguish
the fire via other openings. A
fire may flare up when the
engine compartment’s access
hatch is opened.
E-C2 Generator voltage too high
This symbol is displayed if the
loading current for the
alternating current generator
rises above 30 V. The battery
voltage is then too high and the
liquid in the battery may start to boil.
Turn on as many electrical con-
sumers as possible. The vehi-
cle must not be driven any
further if the symbol remains
visible! Have the fault repaired
by a VDL Bus & Coach work-
shop as soon as possible.
37
 E-C3 Steering oil level too low
This symbol is displayed when
the steering oil level is too low.
Check the oil level and, if nec-
2 essary, top it up. After topping
up the oil, check whether the
symbol is still displayed whilst
idling the engine. If so, turn off
the engine and have the fault
repaired by a VDL Bus & Coach
workshop as quickly as possi-
ble.
E-D1 Engine management error
This symbol is displayed when
there is a serious fault in the
engine management system
that might cause the engine to
cut out.
Have the fault repaired by a
VDL Bus & Coach workshop as
soon as possible.
38
E-D2 Gearbox error
This symbol is displayed when
there is a gearbox fault.
Have the fault repaired by a
VDL Bus & Coach workshop as
soon as possible.
E-E1 Engine oil pressure too low
This symbol is displayed when
the engine is running and the oil
pressure is too low. A buzzer
will also sound.
Check the engine oil level and,
if necessary, top it up. After
topping up the oil, check
whether the symbol is still dis-
played whilst idling the engine.
If so, turn off the engine and
have the fault repaired by a
VDL Bus & Coach workshop as
quickly as possible.
If the oil pressure in the engine
remains too low, the engine
will automatically turn off in
order to prevent damage.
E-E2 Coolant level too low
This symbol is displayed if the
coolant level is too low. This
may be caused by a serious
leak. A buzzer will also sound.
A flashing warning light
indicates a faulty connection that needs to
be repaired.
Allow the engine to cool down.
Find and rectify the cause and
then top up the coolant level. If
the symbol remains visible,
have the error rectified as
quickly as possible by a VDL
Bus & Coach workshop.
E-E3 Driveline electrical system
This symbol is displayed if an
error occurs in one of the
electronic units or in the
communication between them.
A flashing warning light indicates a faulty
connection that needs to be repaired.
Have the fault repaired by a
VDL Bus & Coach workshop as
soon as possible.
Error screen
E-F2 Exhaust gas back pressure or
exhaust gas temperature too high
A soot filter can be fitted as an
optional extra. This symbol is
displayed as soon as the soot
filter monitoring system indicates
that the exhaust gas back pressure or the
exhaust gas temperature is too high.
E-F3 Electrical system body
This symbol is displayed if an
error occurs in one of the
electronic units or in the
communication between them.
Have the fault repaired by a
VDL Bus & Coach workshop as
soon as possible.
E-F4 Pneumatic suspension error
This symbol is displayed if a
serious fault occurs in the
pneumatic suspension system.
A flashing warning light
indicates a faulty connection that needs to
be repaired. The symbols C4 and D4 may
be displayed on the information panel at
the same time as this symbol. D4 will only
Error screen
be displayed if a kneeling prevention
sensor has been fitted.
Have the fault repaired by a
VDL Bus & Coach workshop as
soon as possible.
E-H6 Digital speed display
Above 5 km/h or 4 mph, the
speed is digitally displayed in
the error screen's bar.
E-H7 Bus-stop brake
This symbol is displayed when
the bus-stop brake is applied. A
flashing warning light indicates
a faulty connection that needs
to be repaired.
E-H8 Parking brake applied
This symbol is displayed when
the parking brake is applied or if
the pressure in the parking
brake circuit is too low for the
parking brake to be released. The symbol
disappears when the parking brake is
released, provided there is sufficient
pressure.
It is not permitted to drive the
vehicle if the parking brake
symbol is visible.
2
Only apply the parking brake
as an emergency brake if the
service brake does NOT work.
Since the parking brake is only
applied to the driven wheels, it
has a limited braking capacity.
The wheels may skid, because
the parking brake is not
equipped with ABS!
The main switch cannot be
turned off unless the parking
brake has been applied.
The parking brake symbol will
flash if the contact switch has
been turned off and the parking
brake has NOT been applied.
If the main switch is turned off,
the red light will be lit and a
buzzer will sound.
39
 LEFT-HAND CONTROL PANEL

Control switches
1. Spare 41
2. Main switch 41
2 3. Contact switch/engine stop 41
4. Engine start switch 41
5. Webasto heating 41
6. Driver’s lighting 41
7. Spare 41
8. Pneumatic suspension, 41
kneeling/raising
9. Light switch 42
10. Spare 42
11. Rear fog lights switch 42
12. Spare 42
13. Front fog lights switch 42
14. Interior lighting 42
15. 1st fluorescent tube on the right- 43
hand side
16. Spare 43
17. External mirror heating 43
18. Stop signal buzzer button 43
19. Reset ramp request 43
20. Hazard warning lights 43
21. Entrance and exit door heating 43
22. Pitman arm warning light 43
23. Rear roof hatch 44
24. Front roof hatch 44
25. 24 Volt power connection 44
ILBh0579

40 Left-hand control panel

Description of the switches
1. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
2. Main switch
The electrical system is tested
when the main switch is turned
on. After 3 seconds, all the
warning lights will be lit
temporarily and the buzzer will sound.
When the main switch is turned off, the
electrical system is disconnected from the
power supply, with the exception of the
hazard warning lights and the TSU.
The main switch can only be
turned off if the parking brake
has been applied and the con-
tact switch has been turned off.
3. Contact switch/engine stop
This switch is used to turn on
the contact switch once the
main switch has been turned
on. If the contact switch is
turned off whilst the engine is
running, the engine will stop provided the
vehicle is stationary.
Left-hand control panel
4. Engine start switch
The engine is started by
pressing this button. The main
switch and the contact switch
must be turned on and the gear
lever must be in position N, see also
Starting procedure ( 57).
5. Webasto heating
This switch is used to turn on
the Webasto water heater. This
symbol will be displayed on the
main display at the same time.
The Webasto heating can be used if the
main switch has been turned on.
6. Driver’s lighting
This switch is used to turn on
the fluorescent light above the
driver’s seat. This switch works
when the main switch has been
turned on.
7. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
8. Pneumatic suspension, kneeling/
raising
This spring-mounted switch can
be used to adjust the driving
height of the vehicle (ground
2
clearance) under special
circumstances. The switch activates the
pneumatic suspension system.
a. The vehicle is kneeled by pressing the
lower part of the switch until the lowest
point has been reached. This is only
possible when the vehicle is stationary
and the doors are open.
The kneeling sensors will stop
the vehicle from kneeling fur-
ther and return the vehicle to
the driving height if they detect
an obstacle.
This symbol will be
displayed on the
main display at the
same time.
41

It is not possible to kneel the
vehicle if the air pressure is too
low. The CLS system only
2 works when the contact switch
has been turned on. If the con-
tact switch has been turned off
whilst the vehicle is in a raised
or kneeling position, the vehi-
cle will return to driving height
when the contact switch is
turned back on.
b. The vehicle is raised by pressing the
top of the switch for 1 second.
The vehicle is raised if the
vehicle’s ground clearance is
too small because of an obsta-
cle. The vehicle is returned to
the normal driving height by
briefly pressing the lower part
of the switch.
The vehicle automatically
returns to the driving height if
the vehicle speed exceeds 30
km/h.
42
9. Light switch
The light switch has three
positions:
0 Press bottom: lights are turned off.
I Parking lights and side-marker lights
are turned on.
II Press top: Dipped beam/main beam,
parking lights and side-marker lights
are turned on.
If the lights are turned on, the
light in the switch will be lit.
10. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
11. Rear fog lights switch
This spring-mounted switch is
used to turn on the rear fog
lights when the dipped beam or
main beam is 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 light in the switch and the light on the
instrument panel are lit when the rear fog
lights are turned on.
The legal requirements for the
use of fog lights vary per coun-
try.
12. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
13. Front fog lights switch
This switch can be used to turn
on the front fog lights when the
main beam switch is in position I
or II. The lights in the switch will
then be lit.
The legal requirements for the
use of fog lights vary per coun-
try.
14. Interior lighting
This switch sets the interior
lighting to half strength. The
interior lighting works when the
main switch is turned on.
The interior lighting will be lit at full strength
when the engine is running.
Left-hand control panel
15. 1st fluorescent tube on the right-
hand side
This switch can be used to turn
the 1st fluorescent light on the
right-hand side on and off when
the interior lighting is turned on.
16. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
17. External mirror heating
Turns the external mirror
heating on and off. The light in
the switch will be brightly lit
when this function is in use. The
external mirror heating works when the
contact switch has been turned on.
18. Stop signal buzzer button
The buzzer for the stop signal is
turned off by pressing this
button. The buzzer is turned
back on if the button is pressed
again.
19. Reset ramp request
If the blue button next to the exit
door on the exterior of the
vehicle, i.e. the ramp request
button, is pressed, then the
Left-hand control panel
wheelchair symbol (i-B1) on the dashboard
in the information screen will be lit. The
stop signal (i-A1) will also be lit.
This button can be used to reset an
incorrect ramp request. The stop signal (i-
A1) can be reset by opening a door, see
Driver’s left-hand control panel ( 49).
The signal can also be reset by extending
the wheelchair ramp.
20. Hazard warning lights
This switch turns on the
vehicle’s hazard warning lights.
The hazard warning system
can be used even if the main
switch and the contact switch have been
turned off. The red light in the switch will
flash. If the main switch has been turned
on, then the green indicator light on the
instrument panel will also flash. The
hazard warning lights are turned off by
returning the tumbler switch to the off
position.
The hazard warning lights flash
quickly if an indicator light is
broken.
Legal requirements on the use
of hazard warning lights vary
per country.
21. Entrance and exit door heating
Turns the entrance and exit
door heating on and off. The
light in the switch will be brightly
lit when this function is in use.
The entrance and exit door heating works 2
when the contact switch has been turned
on.
22. Pitman arm warning light
This light will flash slowly if the
entrance door is opened at a
speed of 3 km/h or less whilst
the front wheels are not in the
straight-ahead position. The buzzer will
also sound briefly. The light will flash more
quickly if the front wheels are turned to
such a large angle that the entrance door
will touch the wheel rim whilst it is being
opened. It will then not be possible to open
the entrance door.
If the wheels are turned whilst the entrance
door is open and there is a risk that the
front wheels will touch the door, the
warning light will flash quickly, the buzzer
will sound briefly and the entrance door will
close.
43
 23. Rear roof hatch
The front of the rear roof hatch
is opened by pushing this button
forwards.
The emergency hatch is closed
2 when this button is pressed again.
The back of the rear roof hatch is opened
by pushing this button backwards.
The emergency hatch is closed when this
button is pressed again.
24. Front roof hatch
The front of the front roof hatch
is opened by pushing this button
forwards.
The emergency hatch is closed
when this button is pressed again.
The back of the front roof hatch is opened
by pushing this button backwards.
The emergency hatch is closed when this
button is pressed again.

The roof hatches will close

automatically when the main
switch is turned off.

25. 24 Volt power connection

This is a power connection for
diagnosis tools.

44 Left-hand control panel

 RIGHT-HAND CONTROL PANEL

Control switches
26. Frontbox control 45
27. Gearbox selection switch 45
28. Menu switch 45 2
29. Spare 46
30. Spare 46
31. Spare 46
32. Spare 46
33. Destination equipment 46
operating area
34. Radio / CD player 46

Description of the panel

26. Frontbox control
The frontbox can be used to provide extra
heating for the driver’s area. For
instructions, see Front box control ( 53)
27. Gearbox selection switch
This switch can be used to select the
direction in which the vehicle is driven,
see Fully automatic Voith gearbox ( 70)
28. Menu switch
The three screens on the main
display can be individually
selected by pressing the menu
ILBh0580 switch on the instrument panel.
The main switch and the contact switch

Right-hand control panel 45

 must first be turned on. For instructions,
see Main display ( 26)
29. Spare
This position is not in use and can,
therefore, be used to operate an optional
2 preference settings.
instrument or accessory.
30. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
31. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
32. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
33. Destination equipment operating
area
See Destination equipment operating
area ( 47)
34. Radio / CD player
1. On/Off button
Press briefly: turns on the device.
When in use: mutes the sound.
Press and hold: turns off the device.
2. Volume control
3. BND-TS button
Press briefly: selects the following FM
memories: FM I, FM II and FM TS, as
well as the AM, MW and LW
wavebands.
Press and hold: starts the travelstore
function.
4. Programme memory buttons 1-5 and
CD function buttons
6. Function buttons
7. Menu button
Opens the menu for the user tone
8. CD open
9. Display
10. Eject button for ejecting a CD.
11. SRC button
Selects the radio or the CD player as
the source or (if connected and turned
on) a CD exchanger, an iPod or AUX.
See the supplier’s documenta-
tion for detailed operating
instructions.
35. Not applicable

5. TA button
Turns the traffic announcement option
on and off.

46 Right-hand control panel

DESTINATION EQUIPMENT 5. Check that the display is showing the
OPERATING AREA correct route number anddestination. If
using extra text proceed to step 6, else
MOBITEC ICU 400 stop here.
6. Press the blue button. The text "Extra:"
Mobitec display
is shown on the display. (Only if you
have defined any extra texts)
7. Enter the Extra code using the ”up” and
”down” buttons as before. The signs
will be updated automatically 3
seconds after the last key press. The
display will return to ”route” mode auto-
matically after 20 seconds.
Mobitec ICU 400 can control
the following type of signs:
Instructions Mobitec 7-segment route num-
1. Press the blue button until ”Route” is ber sign, mobitec full matrix
shown in the top left corner. This is route number– and destination
automatically shown when the power is sign.
put on.
2. Enter the route number using the ”up” The blue button controls if the
display on the Mobitec ICU400
and ”down” buttons in hundreds, tens
will control the route number,
and units digits.
the destination code or the
3. Press the blue button. The text "Dest:"
extra code.
is shown on the display.
4. Enter the destination code using the
Route number
”up” and ”down” buttons as before.
With the ”up” and ”down” buttons in units,
tens and hundreds the route number is
entered. The route number may consist of
Destination equipment area
a space (blank), numbers from 0-9 or let-
ters from A-F.
Keeping the button held down will automa-
tically increase / decrease the digit in that
position.
2
Destination text
With the ”up” and ”down” buttons a desti-
nation code is entered. This may be a
number between 0000 and 9999 and cor-
responds to the destination text that is
shown on the display and the signs.
Should an invalid code be entered (i.e. a
code for which no destination exists), the
display will be blank but the signs will still
show the last destination. When a new
destination code is entered the extra text is
automatically cancelled (see below).
Keeping the button held down will automa-
tically increase / decrease the digit in that
position.
Extra text
With the ”up” and ”down” buttons an extra
code between 000 and 999 can be ente-
red. This will select an extra text to com-
plement a destination. Code 000 means
that no extra text is included.
If an invalid extra text or a new destination
is entered, extra text will automatically be
assigned 000.
47
 Keeping the button held down will automa-
tically increase / decrease the digit in that
position.
Display
Mobitec ICU 400’s display shows the dri-
2
ver exactly what will appear on the exter-
nal signs. In case of alternating texts, the
text on the display and the text on the
signs may not change simultaneously but
the display time will be the same. The
external signs will be updated automati-
cally 3 seconds after the driver stops using
the control unit. This delay means that pas-
sengers do not witness destinations ”scrol-
ling”.

48 Destination equipment area

 DRIVER’S LEFT-HAND CON-
TROL PANEL
Control switches front side
36. Parking brake 49
37. Entrance door control button 49 2
38. Exit door control button 50
39. Traffic jam brake button 50
40. Cabin lighting switch 50
41. Spare 50
42. Spare 50
43. Reset emergency tap button 50
44. Emergency door-operated 50
brake release button
45. R36 emergency switch 50

Description of the panel

36. Parking brake
When the handle is in the driving direction,
the parking brake is not applied provided
the system has sufficient air pressure. For
instructions, see Parking brake/emergency
brake ( 59)
37. Entrance door control button
ILBh0581
This button is used to open and close the
entrance door. This only works if the bus is
travelling at less than 3 km/h and if the
main switch has been turned on. For
instructions, see Entrance door ( 81)

Driver’s left-hand control panel 49

 38. Exit door control button
This button is used to open and close the
exit door. This only works if the bus is
travelling at less than 3 km/h and if the
main switch has been turned on. For
2 instructions, see Exit door ( 82).
39. Traffic jam brake button
This button is used to manually
activate the traffic jam brake so
that the driver can rest his foot
when, for example, waiting at
traffic lights or when in a traffic jam. This
function only works if the vehicle is
travelling at less than 3 km/h. The brake is
released by depressing the accelerator
pedal. For instructions, see Operating the
traffic jam brake ( 62).
40. Cabin lighting switch
When this switch is pressed, the
payment counter lighting and
the cabin light will be lit (if the
main switch has been turned
on).
41. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
50
42. Spare
This position is not in use and can,
therefore, be used to operate an optional
instrument or accessory.
43. Reset emergency tap button
If somebody has operated the emergency
tap (near the exit door), either inside or
outside of the vehicle (this is only possible
at a speed of less than 3 km/h), the light in
the switch (push button) will be lit, the exit
door will be bled and the door-operated
brake will be applied (the central warning
light will flash and the bell will ring). If the
switch (push button) is pressed, the door
will be pressurized again and the door-
operated brake will be released.
Control switches rear end
44. Emergency door-operated 50
brake release button
45. R36 emergency switch 50
Description of the panel
44. Emergency door-operated brake
release button
The door-operated brake is
released by depressing the
accelerator pedal. If it is not
possible to depress the
accelerator pedal, than the door-operated
brake can be released by using this
emergency button.
Only use this button in the
event of an emergency.
45. R36 emergency switch
The switch can be used in
the event of an emergency to
turn off all the consumers.
The engine will be turned off
and the hazard warning lights will be
turned on.
Driver’s left-hand control panel
CONTROL PANEL ABOVE THE A. DTCO (Digital tachograph) for operating instructions.
DRIVER The DTCO tachograph saves
an error code if the power sup-
ply is turned off or the battery
is empty. In some countries, 2
the error code is interpreted as
a breech of the law. To prevent
the unit from saving an error
code when disconnecting the
battery cables, place a DTCO
workshop card in the unit
ILBh0510
whilst the battery is discon-
nected.
ILBh0586 1 Display
If an error code is saved, con-
2 Operation driver 1 tact a recognized DTCO work-
3 Card reader 1 shop to calibrate the DTCO and
to delete the code.
4 Connection for calibration and down-
load apparatus Depending on the chosen options, the
5 Operation driver 1 vehicle will be equipped with either a
DTCO (digital tachograph) or an MTCO
6 Sealing
(modular tachograph) or a TSU.
7 Card reader 2
See the supplier’s documenta-
8
9
Button for opening printer drawer
Printer
tion for the operating instruc-
tions.
10 Menu selection buttons

If DTCO: See the supplier's documentation

Control panel above the driver 51

 If an error occurs in the tacho- B. Webasto time clock C. Exterior mirror adjustment
graph, then this symbol will be The driver can use this to set the period of The mirrors can be
lit on the right-hand side below time that the heating system’s pre-heating electrically adjusted,
the odometer. This will occur, must start before the vehicle is driven. provided the main switch
for example, if one of the components, and contact switch have
2 such as the tachograph card, is missing. been turned on, by
A flashing warning light indicates a faulty moving the knob up,
connection that must be repaired. down, left or right.
Turning the knob to the right = adjust right-
hand mirror.
Turning the knob to the left = adjust left-
hand mirror.

D. Interior temperature setting

A Day
The driver can use this to
B In operation adjust the vehicle’s interior
C Increase temperature between 17º C
D Decrease and 25º C. The speed of
E Turn on immediately the heater fans is electroni-
cally controlled, as is the
F Select programme
choice of whether the vehicle must be ven-
G Clock tilated or not. If the switch is rotated as far
H Save back as possible, then the interior heating
I Alarm indicator is turned off.
J Time indicator

52 Control panel above the driver

FRONT BOX CONTROL

Speed (8) Increase (2) DISPLAY (10) Smog (5) Air distribution
On / Off (1) Decrease (3) AUTO / ESC (4) Airco (6) (9)
Defroster / Enter
(7)
1. On/off push button 2. Setting a higher temperature 3. Setting a lower temperature
When this button is pressed, the Use the push button to increase Use the push button to decrease
temperature is shown on the dis- the desired temperature setpoint. the desired temperature setpoint.
play. If the system is set to “auto”, The maximum is 27 degrees Cel- The minimum is 18 degrees Cel-
the "AUTO" LED is on. sius. sius.

Front box control 53

 4. Automatic temperature
The driver’s area is automatically
heated or ventilated (depending
on the set temperature and the
ambient temperature); A/C LED is
2 off.
5. SMOG – partial re circulation
Mixture of inside and outside air;
the air door is closed for 10 min-
utes. The corresponding LED is
lit.
6. A/C push button
Air conditioning push button. The
unit will begin cooling or heating.
The corresponding LED is lit.
7. Windscreen defogging
Windscreen defogging/defrost-
ing button. The corresponding
LED is lit.
8. Fan speed
Potentiometer for fan speed.
Continuously variable speed set-
ting.
If the potentiometer is turned,
the "AUTO" function is deactivated. The
corresponding LED will no longer be lit.
• Turn anti-clockwise to reduce the
speed.
• Turn clockwise to increase the speed.
54
9. Air distribution
Air to the driver
Turn anti-clockwise to direct air to
the driver.
Air to driver and windscreen
Turn the potentiometer to the cen-
tre to direct air to the driver and
the windscreen.
Air to the windscreen
Turn clockwise to direct air to the
windscreen.
10. Information on the display
When the system is off, the dis-
play shows the time.
When the system is on, the display shows
the set temperature.
The intensity of the display and the LEDs
is adjusted automatically to compensate
for the ambient lighting conditions.
Alarm symbols
Red alarm symbol
The red alarm symbol goes on if there is:
– a high- or low-pressure alarm
– an interface or wiring malfunction
In either case, the airco will not work.
Yellow alarm symbol
The yellow alarm symbol goes on if there
is:
– Temperature sensor error.
In this case the unit operates
with incorrect data from the
sensor.
To restart the unit, press the
on/off push button twice to
switch if off and on again.
Consult the service department
if the alarm comes on again.
Front box control
DRIVING AND OPERATION 1. General information If necessary, place chocks in
General information 55 Before setting out on a journey, always front of or behind the wheels
Refuelling 55 check: and turn the front wheels so
Starting procedure 57 – For any water or oil leaks. that if the vehicle were to start
Stopping/turning off the engine/ 58 – The engine oil level. moving, it will not roll out into
the road.
2
turning off the instrument panel – The fluid level in the screenwash
Parking brake/emergency brake 59 reservoir.
Service brake (footbrake) 60 – The air filter indicator. 2. Refuelling
Operating the bus-stop brake 61 – The wheel attachment and the tyre The vehicle has a tank for diesel and a
Operating the traffic jam brake 62 pressure. tank for AdBlue.
ABS 62 – The depth of tread on the tyres.
Before refuelling, turn off the
ASR
Cruise control (optional)
63
63
– Each tyre for an even wear pattern.
– The correct position of the seat and engine and all the power con-
Variable speed limiter (optional) 64 mirrors. sumers.
Engine speed control (optional) 65 – The lights and instruments. Turn off any mobile tele-
Air conditioning speed control 66 – The fuel level. phones.
Retarder (optional) 67 – The AdBlue level.
Steering gear 69 When refuelling diesel, it is
Speed limiter
Fully automatic Voith gearbox
69
70
After each journey, always check recommended to also top up
whether: the AdBlue tank with AdBlue
ZF gearbox, fully automatic 72 up to the maximum level.
– The main switch is OFF.
Engine compartment control panel 74
– The parking brake is applied.
– The doors of the vehicle are locked.

If the vehicle is parked on a hill,

pay attention to the incline and
the surface.

Driving and operation 55

 Diesel
Diesel is highly inflammable.
Avoid a naked flame, heat
3. Clean the fuel cap and the surrounding
sources or a lit cigarette close
2 to the fuel system: FIRE RISK!
4. Fill the fuel tank(s) until the fuel nozzle
Diesel is harmful to your
health. Prevent diesel from
coming into contact with skin,
eyes or clothing.
Do not inhale diesel fumes. If
diesel is swallowed, contact a
doctor immediately. Keep die-
sel out of the reach of children.
Only refuel using diesel which meets
European standard EN590, see
Fuel ( 150).
The use of other product or mixtures can
cause irreversible damage to the engine
and may result in the warranty no longer
being valid. In the unlikely event that
another fuel is used, the engine must not
5. Close the fuel cap.
be started and the fuel tank(s) must be
drained. If the engine has been started,
even for a very short period of time, then,
besides draining the fuel tank(s), also drain
all the fuel lines.
1. Turn off the Webasto.
56
2. Turn off the engine and the main
switch.
area.
Open the fuel cap. Prevent any foreign
objects from getting into the fuel tank.
turns off.
Always stop refuelling after the
fuel nozzle has stopped for a
second time. All the fuel which
is then added will fill the
expansion space in the fuel
tank(s), which may lead to the
fuel overflowing. Spilling fuel
may be dangerous for other
road users.
Never add AdBlue to the fuel
tank(s). This can lead to dam-
age to the engine and the fuel
system.
AdBlue
Avoid bodily contact.
In the event of skin contact:
rinse with plenty of water.
In the event of contact with the
eyes: rinse with plenty of water
for at least 15 minutes and
seek medical assistance.
If swallowed: rinse your mouth
with plenty of water. Do not
induce vomiting.
In the event of inhalation: get
some fresh air and take a rest.
Seek medical assistance.
Keep AdBlue out of the reach
of children.
Only use AdBlue which satisfies
DIN70070/ISO2224, see Fuel ( 150).
Adding another liquid may cause problems
to the EAS system and the vehicle will no
longer meet the European emission
legislation. In the unlikely event that
another liquid is used, the engine must not
be started and the AdBlue must be
drained. If the engine has been started,
even for a very short period of time, then,
Driving and operation
besides draining the AdBlue tank, also
drain all the AdBlue lines.
1. To minimize the risk of a mistake, the
AdBlue tank has a blue cap. The tank
mouthpiece and the tank opening are
also shaped so that other nozzles do
not fit.
2. Turn off the Webasto.
3. Turn off the engine and the main
switch.
4. Clean the blue tank cap and the
surrounding area.
Open the blue tank cap. Prevent any
foreign objects from getting into the
AdBlue tank.
If the AdBlue cap is opened at
a high exterior temperature,
then it is possible that ammo-
nia fumes may escape. Ammo-
nia has a strong, irritating
smell and affects the eyes, skin
and mucous membrane.
Therefore, turn your face away
when removing the cap from
the tank.
Driving and operation
5. Insert the fuel nozzle all the way into
the tank's filler neck so that the ring
magnet in the filler neck releases the
fuel nozzle for refuelling.
6. Fill the AdBlue tank(s) until the fuel
nozzle turns off.
Avoid AdBlue coming into con-
tact with painted components.
Spilt AdBlue can be easily
removed with water. If AdBlue
dries, it leaves a white film,
which can be removed with
water.
AdBlue corrodes metals, such
as copper and aluminium.
Alloys, such as brass, can also
be damaged.
7. Close the blue tank cap.
AdBlue is non-inflammable. If
AdBlue is exposed to high tem-
peratures, the solution breaks
down into ammonia and car-
bon dioxide.
AdBlue is neither toxic nor
harmful to the environment.
3. Starting procedure
Use the extraction unit or open
the doors of the building if the
engine is started in a confined
space. The exhaust fumes con- 2
tain carbon monoxide, which is
an invisible and odourless poi-
sonous gas. If inhaled, this gas
may cause unconsciousness
or even death.
a. Apply the vehicle’s parking brake.
b. Put the gearbox in “neutral” (N).
c. Turn on the main switch. The
instrument panel will perform
a self-test. During the test,
all the warning lights and the
instrument panel lights will be lit. The
needles on all the gauges will move
once and then return to their zero
position. This will confirm that the lights
and the gauges work correctly. The
buzzer in the instrument panel will also
sound briefly.
The main display and the milometer will
be lit after the self-test. The information
screen and the pressure gauges will be
displayed on the main display.
57
 d. Turn on the contact switch.
The engine management
system will check all of the
vehicle’s vital electronic
functions. At the same time, the
2 charging current light (A1) will be lit and
symbol I-C1 “idling engine oil pressure”
will be visible on the main display.
e. Start the engine by pressing
the switch shown. Release
the switch as soon as the
engine starts.
If the engine fails to start, the switch
must be released after 10 seconds.
Wait a couple of seconds and try again.
The engine may sound differ-
ent in cold temperatures after a
cold start, because a different
fuel injection strategy is then
used.
When the engine is running,
the engine speed may not be
increased before the “idling
engine oil pressure” symbol i-
E1 on the main display has dis-
appeared.
58
All warning lights and symbols
on the main display should dis-
appear after starting the
engine, with the exception of
the parking brake symbol. In
case the instrument panel
shows some warning lights or
symbols, follow the instruc-
tions given in Warning
lights ( 22) and Main
display ( 26).
Optionally, the engine can be
started using the “Start” button
on the control panel in the
engine compartment, see
Engine compartment control
panel ( 74).
been applied.
4. Stopping/turning off the engine/
turning off the instrument panel
Stop the vehicle. Apply the parking brake
by means of the brake lever. Put the
gearbox in neutral.
Allow the engine to idle for 5
minutes before turning off the
contact switch after a long
journey or when the engine
has been subjected to a high
load. It is important to allow the
engine to run for a while in
order to prevent the coolant
temperature from becoming
too high and to allow the turbo-
charger to cool down.
Turn the engine off by pressing the contact
switch to the off position.
The main switch can only be turned off
after the contact switch has been placed in
the off position and the parking brake has
After turning off the main switch, the main
display will gradually dim into the stand-by
mode and, after some time, will turn off
Driving and operation
completely into the sleep mode (black Parking brake as an emergency brake
display).
Only apply the parking brake
Optionally, the engine can be as an emergency brake if the
turned off using the “Stop” service brake does not work.
button on the control panel in Since the parking brake only 2
the engine compartment, see affects the rear wheels, it has a
Engine compartment control limited braking capacity. The
panel ( 74). wheels may skid, because the
parking brake is not equipped
Turning off the contact switch with ABS.
will activate the EAS system’s
Gradually pull the parking brake lever
(exhaust gas after-treatment
system) control phase. This backwards to stop the vehicle. Hold the
may be audible on the outside lever in the moveable (unlocked) section of
of the vehicle (a gurgling noise ILBi0003 the stroke. When pulled back as far as
in the AdBlue tank). possible, the maximum braking force is
5. Parking brake/emergency brake
applied to the rear wheels.
Always apply the parking brake
after parking the vehicle and
when leaving the driver’s seat.

Lift the locking ring (2) and push the

parking brake lever (1) forwards to release
the parking brake. To apply the parking
brake, the parking brake lever (1) must be
pulled fully backwards until it clicks. Check
whether it will hold by giving the parking
brake lever a small push. When the
parking brake is applied, a symbol will
appear on the main display.

Driving and operation 59

 Parking/stranded on a slippery incline
Never park the vehicle on a
slippery incline.
2 Do not leave the driver’s seat
when the vehicle is stationary
on a slippery and/or snowy
incline. Remain in the vehicle
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 park-
ing 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
order to call for help, if necessary.
60
ILCi001
6. Service brake (footbrake)
The operation of the service brake
(footbrake) is combined with the retarder.
The footbrake pedal has a stroke “A”,
where the service brake is not applied, and
a stroke “B”, where the service brake is
applied (see the diagram above). In the
last part of stroke “A”, the retarder will start
to brake and will continue to brake during
the whole of stroke “C”.
If the service brake is applied
for 3 seconds whilst the vehi-
cle is stationary, then the bus-
stop brake will be applied auto-
matically.
The NBS functiona in the gear-
box will then also be activated.
a. NBS (Neutral when stationary) is a
function in the automatic gearbox which
saves fuel. The NBS function
disconnects the gearbox from the
engine (semi-neutral). This allows the
engine to run whilst unloaded.
Driving with the combined brake
The vehicle is equipped with a retarder,
ABS and an engine brake. The retarder
and the engine brake are only applied to
the rear axle.
The foot brake pedal operates the service
brake and the stroke “C” for the retarder at
the same time.
For instructions concerning the use of the
retarder, see Driving and operation ( 55)
and the sections concerning the gearbox
and the retarder.
Driving and operation
Operating instructions
1. On NON-slippery road surfaces, it is
advisable to apply stroke “A” (can be
felt - less resistance) and use this (the
retarder) for as long as possible before
depressing further to stroke “B” in order
to use the service brake. This prevents
brake lining wear and improves driving
comfort.
2. When there is a (risk of a) slippery road
surface, you must switch off the
retarder’s foot operation immediately.
There will then be no braking force
applied through stroke “A” of the
footbrake. This prevents the retarder
and the engine brake first being applied
to only the rear axle. This can cause
skidding!
3. When the road suddenly becomes
slippery, it is important to kick down the
footbrake as far as possible. It is
necessary to get the footbrake quickly
through stroke “A” and into stroke “B”,
so that the service brake is quickly
applied to both axles. The ABS system
will take care of the dosage and will so
take full advantage of the grip that is
left.
Driving and operation
7. Operating the bus-stop brake The vehicle can be kneeled at a speed of
RThe bus-stop brake system <> 5 km/h. When the vehicle is kneeled,
can be optionally installed for an the bus-stop brake and the Antigas
automatic gearbox. function are automatically activated.
The bus-stop brake applies a The accelerator pedal can only be
braking force to the wheels of the driven depressed again once the vehicle has 2
axle. been returned to the driving height. If the
Use the footbrake to brake the vehicle until accelerator pedal is depressed, the bus-
it (almost) comes to a standstill when stop brake will be released and the vehicle
nearing a bus stop. It is possible to open will pull away.
the doors at a speed of <> 3 km/h. The
When the bus-stop brake is
bus-stop brake will be automatically
activated when the doors open. The
applied, do not leave the
driver’s seat without first
Antigas function will also be activated at
applying the parking brake.
the same time, so that it will not be
possible to depress the accelerator pedal.
The main switch must be
The NBS function1 in the gearbox will then
be activated at the same time.
turned on to apply the bus-
stop brake!
It will only be possible to depress the
accelerator pedal again after the doors
The gearbox must be in D for
have been closed. If the accelerator pedal
is depressed, the bus-stop brake will be
the Antigas function to be acti-
vated!
released and the vehicle will pull away.
1. NBS (Neutral when stationary) is a
function in the automatic gearbox which
saves fuel. The NBS function
disconnects the gearbox from the
engine (semi-neutral). This allows the
engine to run whilst unloaded.
61
 8. Operating the traffic jam brake
A traffic jam brake system can be
optionally installed for an automatic
gearbox.
2 The traffic jam brake can be
used for short stops, for exam-
ple at traffic lights or when in a
traffic jam. When this brake is
used, the footbrake no longer
has to be used after the vehicle
has been brought to a stand-
still so that the vehicle will not
start to roll.
The traffic jam brake is applied manually or
is activated automatically when the service
brake is applied for at least 3 seconds. To
manually apply the traffic jam brake, the
operating switch only has to be pressed
briefly.
It is possible to apply the traffic jam brake
at a speed of <> 3 km/h. The NBS
function1 in the gearbox will then be
activated at the same time.
1. NBS (Neutral when stationary) is a
function in the automatic gearbox which
saves fuel. The NBS function
disconnects the gearbox from the
engine (semi-neutral). This allows the
engine to run whilst unloaded.
62
If the accelerator pedal is depressed, the
traffic jam brake will be released and the
vehicle will pull away.
This symbol appears on the
main display when the traffic
jam brake is applied.
The driver must not leave the
driver’s seat whilst the traffic
jam brake is applied. Apply the
parking brake first.
9. ABS
The vehicle is equipped with an ABS
braking system.
The ABS system does not
relieve the driver of his obliga-
tion to alter his driving style to
meet the traffic conditions and
the state of the road surface.
The safety device to stop the
blocking of the wheels is not
able to prevent the conse-
quences of driving too close to
the vehicle in front or corner-
ing too fast.
The braking distance with ABS
is sometimes, but not always,
shorter. Disregarding this can
not only lead to an extremely
dangerous situation for the
driver, but also for the other
road users.
Do not adapt your driving style
because you have ABS.
Driving and operation
 Do not brake harder or later.
This will cause unnecessary
wear on the tyres. You may
also place other road users in
danger.
ABS (Anti-Blocking-System)
The ABS braking system prevents the
wheels locking during braking on slippery
road surfaces or in an emergency stop.
The ABS system is only activated at
maximum braking at the moment when
one or more wheels lock and the vehicle
threatens to skid. At that instant the ABS
system allows the brake pressure to fall
until the wheel begins to rotate and grip on
the road surface is restored. The braking
force is then immediately increased again
until maximum braking is achieved or until
the wheel in question locks up again and
the cycle is repeated. The vehicle remains
fully steerable in such conditions and a
stable course is maintained.
Driving and operation
Warning light ABS
When the contact switch is
turned on, the ABS warning
light will be lit while the system
checks are performed. The light
should go out after a few 2
seconds. If the lamp remains on, or comes
on during a journey, there is a fault in the
ABS system, see ABS fault ( 24).
10. ASR
Optionally, an ASR system can
be used. This symbol appears ILBh0139
when the ASR system is
activated. ASR is a fully 11. Cruise control (optional)
automatic system which is integrated with
The cruise control can only be
the ABS system and the engine
management system. The ASR prevents
engaged when vehicle speed is
above 30 km/h.
the wheels from spinning when pulling
away and driving on slippery roads
The cruise control can be activated by
(especially during acceleration in curves).
moving the combi-switch once briefly to A
If the wheels spin, depending on the
(SET+) or B (SET -) when the required
driving circumstances, the driven wheels
speed is reached.
are slowed down and/or the acceleration is
reduced. There are no controls or Only use the cruise control
interrupter for the ASR system. when traffic conditions permit
a steady speed. Do not use
cruise control in busy traffic,
on roads with many bends or
on slippery surfaces.
63
 Acceleration/deceleration
If a speed is required that is different to the
set speed, then moving the switch briefly
to A (SET+) or B (SET -) will raise or
reduce the speed by 1 km/h.
2 The speed can be gradually increased/
decreased by holding the switch in the A
(SET+) or B (SET -) position.
The vehicle speed can also be increased
whilst the cruise control is turned on by
depressing the accelerator pedal. The
vehicle speed will return to the last set
speed when the accelerator pedal is
released.
64
Resume function
Press the “RES” button (C) to activate the
cruise control at the last set speed.
If the current vehicle speed is lower than
this speed, the cruise control will attempt
to accelerate the vehicle speed to the last
set speed.
Turning off the cruise control
The cruise control is turned off by turning
the rotary switch (E) briefly to the OFF
position.
The cruise control is also switched off if:
• The vehicle speed is outside the
programmed limit values.
• The ABS/ASR system carries out an
intervention.
• The variable vehicle speed limiter is
activated in the “LIM” position.
• The service brake is applied.
• The parking brake is applied.
• The retarder is operated.
• The set/resume switch on the
combination switch is operated.
12. Variable speed limiter (optional)
The variable vehicle speed limiter (also
known as foot-on cruise control) allows the
vehicle speed to be limited to a speed set
by the driver whilst the accelerator pedal
remains operational. The variable vehicle
speed limiter can be activated once the
vehicle speed is above 30 km/h.
Turn rotary switch (E) to the “LIM” position.
The vehicle speed at that moment is saved
in the electronic unit as the required
vehicle speed limit 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 the
combination switch.
When the variable vehicle
speed limiter is engaged, the
cruise control function is dis-
engaged.
The variable vehicle speed limiter is
disengaged when the rotary switch (E) is
turned back to the centre position.
Overruling the variable vehicle speed
limiter
The variable vehicle speed limiter will be
overruled when the accelerator pedal is
Driving and operation
fully depressed, activating the kick-down
switch in the accelerator pedal sensor.
If the vehicle speed later falls
to the previously saved vehicle
speed limiting value, the varia-
ble vehicle speed limiting func-
tion will be activated again.
Driving and operation
13. Engine speed control (optional)
The engine speed control makes it
possible to vary the engine speed between
600 rpm and 800 rpm.
Ensure the parking brake is
applied and the gearbox is in
neutral before activating the
engine speed control.
Conditions for activating/deactivating
the engine speed control
When the engine speed control is
engaged, it will be disengaged when one
or more of the following conditions are
met:
• The parking brake is released.
• The clutch is applied.
• The retarder is operated.
• The automatic gearbox is engaged in
position 1, 2, 3, D or R.
Also, if one or more of the above situations
occur, it will NOT be possible to activate
the engine speed control.
Activating the engine speed control
By pressing the “RES” button (C), the
engine speed immediately increases to a
value pre-programmed in the electronic
unit.
The engine speed control is activated by
moving the combination switch once briefly
to the “SET+” position.
When the engine speed control is no
longer needed, it can be deactivated by
turning the rotary knob (E) briefly to the 2
“OFF” position.
Adjusting the engine speed control
When the engine speed control is
activated, the engine speed can be
increased or decreased by 25 rpm by
moving the combination switch to “SET+”
or “SET-”, respectively.
Accelerator pedal function during
engine speed control
When the engine speed control has been
activated, the engine speed can be
increased above the control speed using
the accelerator pedal.
When the accelerator pedal is released,
the engine speed will return to the last
control speed.
65
 14. Air conditioning speed control
There is an option to control the engine
speed in combination with an air
conditioning system.
The conditions for this function are:
2 – The gearbox is in neutral.
– The parking brake is applied.
If an air conditioning system is installed
and it turns on, then the engine speed will
increase automatically when the vehicle is
idling to prevent the engine from stalling.
This is pre-programmed in the vehicle’s
electronics.

66 Driving and operation

15. Retarder (optional) If the retarder’s braking opera- means of the right-hand combination

The cooling system’s tempera-

tion is reduced or the retarder switch or by applying the footbrake pedal
ture will increase as a result of is turned off as a result of over-
heating, then reduce the vehi-
(first stage of the pedal will activate the
retarder and applying further pressure to
using the retarder. To prevent the pedal will progressively activate the
cle’s speed by applying the
the cooling system from over-
service brake. service brake). 2
heating, the retarder’s braking
operation may be reduced or Reduce the temperature of the
the retarder may even be A retarder cannot be used as a
turned off. This may lead to a
cooling system by keeping the
engine speed high. parking brake. The retarder
dangerous situation. does not exert any braking
Depending on the situation, try force when the vehicle is sta-
to prevent the cooling system tionary or when travelling at a
from overheating by placing slow speed.
the right-hand combination
switch in no higher position
Use the retarder for prolonged
than 1 or 2 during long
descents. Brake in time by
braking, for example when
driving downhill. Use the brake
briefly applying the service
pedal for relatively short brak-
brake and do not allow the
ing actions. This will prevent
vehicle speed to increase too
overheating of the wheel
high.
brakes.
The retarder is a wear-free, hydraulic or
When ABS is in use, the
electrically operated continuous brake.
It is primarily intended for use during retarder will be switched off for
prolonged braking, for example when as long as ABS is in operation.
decelerating from high speed on a level
road or when driving downhill.
This reduces the wear on the service
brake. The retarder can be activated by

Driving and operation 67

 When driving on a critical road Symbols on the main display
surface (slippery as a result of This symbol (I-B3) appears on
loose gravel, dirt, rain, snow, the main display when the
black ice or similar), it is advis- retarder has been activated by
able NOT to activate the man- means of the foot control or the
2 ual retarder control and to manual control.
disengage the retarder foot
The braking force will decrease
control function.
if the temperature exceeds
110° C. In that case, slow the
When the retarder is activated,
the braking lights will be lit to
vehicle using the service
brake.
inform traffic. ILAh0311

This symbol appears

Manually activating the retarder
The retarder is turned on by pushing the
in combination with
the amber warning
combination switch on the steering column
light if an error
backwards from the rest position (E).
occurs in the
The retarder has three positions (A, B and
retarder. It is permitted to con-
C).
tinue driving, but action must
Also apply the footbrake if the be taken at the earliest oppor-
force of the retarder is insuffi- tunity to rectify the problem.
cient.
This symbol appears
Manually deactivating the retarder
on the main display
when the retarder
The retarder is deactivated by moving the
foot control function
switch (1) back to its rest position (E).
is deactivated.

68 Driving and operation

16. Steering gear
The steering mechanism is hydraulically
assisted.
In temperatures below 0º C, it
is recommended to run the
engine for several minutes
after a cold start before moving
the steering wheel.
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 too much.
The vehicle can also be
steered without the power
steering, but this requires a
large force. This is only
intended for safely parking the
vehicle when the power steer-
ing is not working.
Driving and operation
17. Speed limiter
The legal requirements state that all
vehicles above 12 ton G.V.W. (Gross
Vehicle Weight) must be equipped with a
speed limiter.
2
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!
The speed limiter has been set by an
authorized 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.
– The vehicle is being driven to an
authorized calibration centre to have
the speed limiter repaired.
69
 18. Fully automatic Voith gearbox
Optionally, a Voith D865.3 gearbox can be
fitted. This gearbox is described below.
This gearbox is equipped with an
integrated retarder, see Retarder
2 The automatic gearbox is electronically
(optional) ( 67).
Do not leave the driver’s seat
when the engine is running
and a gear has been selected
(gear lever in D or R).
To prevent the vehicle from
accidentally rolling forward,
the footbrake or parking brake
must be applied.
When the engine is running
and a gear has been selected,
the vehicle can pull away by
depressing the accelerator
pedal!
The gearbox automatically
selects neutral (N) when the
engine is turned off.
70
ILBh0161
operated via a set of switches on the
instrument panel.
The brake pedal must always
be lightly depressed when
selecting another gear from N
(neutral).
The positions
The automatic gearbox has the following
three positions: D - N - R.
Position D
In this position, the gearbox automatically
changes all forward gears UP and DOWN
(depending on the driving speed, engine
revolutions and the position of the
accelerator pedal).
Kick-down gear change
A kick-down switch is fitted under the
accelerator pedal. If it is necessary to
accelerate quickly, the accelerator pedal
must be depressed all the way down, so
that the automatic gearbox will
automatically change down to a lower gear
depending on the speed of the vehicle.
The gearbox does not change up to the
next gear until the maximum permitted
engine speed have been reached.
Position N
Only select neutral at a speed of less than
5 km/h or when the vehicle is stationary.
Selecting the N position whilst
the vehicle is being driven and
then selecting a forward gear
may result in serious damage
to the engine and the gearbox.
Only select the N position
whilst the vehicle is being
driven in emergency situa-
tions.
Position R
The reverse gear may only be selected
when the vehicle is stationary and whilst
idling the engine. The brake pedal must be
depressed before changing to position R
from position D and before pressing the
reverse button.
Never put the gearbox in reverse whilst
driving forward.
In position R, the reverse lights will be lit
Driving and operation
and the reverse buzzer will sound if the
contact switch has been turned on.

The retarder
The retarder is a wear-free, hydraulically
operated continuous brake and is 2
therefore highly suitable for braking on
slopes and for additional braking.
The retarder is operated using the
footbrake. If the retarder is used when
continuously braking (such as when on a
long decline), the info panel and the
instrument panel must be regularly
checked.
If the temperature rises above 150º C, the
AMBER warning light will be lit. If the
warning light is lit, you must avoid using
the retarder until the oil temperature has
fallen sufficiently.

Stopping
The vehicle can always be brought to a
standstill, regardless of which gear it is in.
Depending on the fitted options such as
NBS, EK-ABS, etc., the electronically
controlled automatic gearbox always
selects first gear after stopping. For short
stops, such as at traffic lights, the gearbox
can remain in position D, but the engine
must only idle.

Driving and operation 71

 19. ZF gearbox, fully automatic
A ZF Ecomat gearbox can be optionally
fitted. This gearbox is described below. It is
equipped with an integrated retarder, see
2
Retarder (optional) ( 67).
Do not leave the driver’s seat
when the engine is running
and a gear has been selected
(gear lever in D or R).
To prevent the vehicle from
accidentally rolling forward,
the footbrake or parking brake
must be applied.
When the engine is running
and a gear has been selected,
the vehicle can pull away by
depressing the accelerator
pedal!
The gearbox automatically
selects neutral (N) when the
engine is turned off.
72
ILBh0161
The automatic gearbox is electronically
operated via a set of switches on the
instrument panel.
The brake pedal must always
be lightly depressed when
selecting another gear from N
(neutral).
The positions
Position D
In this position, the gearbox automatically
selects the correct gear (depending on
different parameters such as the driving
speed and the position of the accelerator
pedal). In this position, the vehicle has a
tendency to crawl!
Position N
In this position, the gearbox is in neutral.
Only select this position when the vehicle
is stationary and the parking brake has
been applied.
Position R
This position selects the reverse gear. Do
not accelerate too hard when reversing.
When you wish to drive for-
wards, first stop the vehicle
and then shift to a forward
gear.
Starting
The engine can only be started if the gear
lever is in the N position. When using the
ZF automatic gearbox, pay attention to the
following. When the temperature is below -
15° C, start the engine and run it at 1,000
rpm for approximately 5 minutes with the
gear selector in the N position before
pulling away.
Pulling away
When the vehicle is stationary and the
parking brake and footbrake have been
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 remove your foot
from the footbrake. The large torque will
cause the bus to pull away immediately.
When a gear is selected, the
corresponding light will be lit. If it is not lit,
then the gearbox may not be in gear.
Driving and operation
A flashing light indicates a fault. Have the
fault repaired as quickly as possible by a
VDL Bus & Coach workshop.
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 gear-
box. The electronic shifting
mechanism will then select the
gear which corresponds to the
speed of the vehicle.
If this happens when the cruise
control is activated, then first
disengage cruise control. The
engine will start to idle. D can
then be selected whilst lightly
braking.
select the gear which provides the highest
pulling power.
Activating and deactivating the
integrated retarder of the ZF Ecomat
The warning given below is applicable
whilst driving with a ZF Ecomat2 automatic
gearbox on a critical road surface (e.g.
slippery due to loose gravel, dirt, rain,
snow or black ice).
It is advisable to disengage the
retarder foot control function.
The retarder integrated in the
ZF Ecomat gearbox is a pri-
mary retarder. This means that
the torques which are slowed
down by the retarder must be
multiplied by the transmission
2
of the gear the automatic gear-
box 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!

Kick-down shifting automatic gearbox

A kick-down switch is integrated in the
accelerator pedal. This switch is operated
in the accelerator pedal’s deepest position
after overcoming a perceptible spring
force. The kick-down function must be
used if the vehicle needs to pull away more
quickly. The gearbox will automatically

Driving and operation 73


2
ILBh0162
S1 Front/rear selector switch
S2 Engine start/stop button
20. Engine compartment control panel
For safety reasons and to help with certain
service work, the engine can be started
from the engine compartment.
When the FRONT/REAR switch is set to
REAR, it is not possible to start the vehicle
using the contact/start switch Engine start
switch ( 41), and vice versa.
Apply the parking brake first!
74
The conditions for starting the engine
from the engine compartment are:
– Main switch in the "ON" position.
– The contact switch in the "ON" position.
– The gearbox in neutral (N).
Starting the engine from the engine
compartment
Apply the vehicle's parking brake and put
the gearbox into neutral.
First, turn on the main switch and then turn
on the contact switch on the instrument
panel.
Place the selector switch S1 at the back of
the engine compartment to the “Rear”
position.
Start the engine by pressing switch S2
upwards.
Pressing switch S2 downwards will turn off
the engine.
Turn selector switch S1 to
position “FRONT” afterwards.
Driving and operation
 2

Driving and operation 75

2

76 Driving and operation

 3 SAFETY PRECAUTIONS AND
EMERGENCY PROCEDURES
ROOF HATCHES....................................................................... 79

THE ENTRANCE DOOR AND EXIT DOOR .............................. 80

MANUALLY-OPERATED WHEELCHAIR RAMP ..................... 83

FIRST-AID KIT ........................................................................... 84

3

EMERGENCY HAMMERS......................................................... 84

EMERGENCY PROCEDURES .................................................. 84

Safety precautions and emergency procedures 77

3

78 Safety precautions and emergency procedures

ROOF HATCHES
In an emergency, the driver and/or the
passengers may exit the vehicle via the
doors, windows or roof hatches.
Before setting off on a journey,
check whether the roof
hatches are closed properly.
Opening/Removing
In an emergency, the roof hatches can be
removed by rotating the handles in the
direction of the arrows. The roof hatch can
then be pushed outwards.
The roof hatches will remain attached to
the vehicle by a safety strap.

When being fitted, the hatch 3

The vehicle has two roof hatches.
The roof hatches have a ventilation must be locked using the han-
position and they can be removed if they dles.
are to be used as an emergency exit.
In an emergency, the roof hatches can also
A roof hatch must not be used
to climb onto the roof for
be removed from outside the vehicle by
pulling the handles.
cleaning work.

Ventilation position
The roof hatches may be in the ventilation
position whilst driving the vehicle, but if
only the front ventilation position is used,
the vehicle may not be driven at a speed
greater than 80 km/h.

Always keep the roof hatches

closed when the air condition-
ing is turned on.

Safety precautions and emergency procedures 79

 THE ENTRANCE DOOR AND pressing the buttons for the entrance door
EXIT DOOR and the exit door once.

General information
If the vehicle is started using the
main switch, then the entrance
door and the exit door will
remain unaerated.
Resetting the emergency tap
3 The entrance door and the exit door can
be aerated by pressing the button 43.
Reset emergency tap button ( 50) on
the panel to the left of the driver. The light
in the emergency tap reset button will
remain lit for as long as the entrance door
and the exit door are not aerated.
Once the main switch has been turned off,
the exit door will remain aerated and
usable for 1 hour.
The entrance door also remains aerated
and usable for 1 hour. If the entrance door
is bled, the button on the outside of the
vehicle near the windscreen wipers will no
longer work.

ILBh0585

After the doors have been aerated, the

doors must be put “in operation” by

80 Safety precautions and emergency procedures

Entrance door
If the entrance door is bled (light in the
emergency tap reset button is lit) when it is
closed using the emergency tap when the
main switch is turned on, then the entrance
door will close again after operating
(aerating) the button 43. Reset emergency
tap button ( 50) and the door will be “in
operation”.
If the entrance door is open and bled using 3
the emergency tap when the main switch is
1. Interior entrance door emergency tap 2. Exterior entrance door emergency
turned on, the entrance door will close
tap
after the emergency tap has been
operated (aerating), but the door will not
be “in operation”.
The entrance door is put “in operation” by
pressing 37. Entrance door control
button ( 49) once.

Safety precautions and emergency procedures 81

 Exit door
If the exit door is bled the light in 43. Reset
emergency tap button ( 50) is lit, when it
is closed using the emergency tap when
the main switch is turned on, then the exit
door will close again after operating
(aerating) the emergency tap and the door
will be “in operation”.
If the exit door is open and bled using the
3 emergency tap when the main switch is
turned on, the exit door will close after the 3. Interior exit door emergency tap 4. Exterior exit door emergency tap
emergency tap has been operated
(aerating), but the door will not be “in
operation”.
The door is put “in operation” by pressing
38. Exit door control button ( 50) once.

82 Safety precautions and emergency procedures

MANUALLY-OPERATED
WHEELCHAIR RAMP
There are the following buttons:
In the vehicle:
1 Function: request ramp, next to the
handicapped passenger’s seat (x2).
Yellow and blue button.
Safety precautions and emergency procedures
Outside of the vehicle:
After the ramp has been requested, the
wheelchair icon will be displayed on the
instrument panel.
The wheelchair ramp must be manually
extended and retracted. When the ramp is
extended, the door-operated brake will be
applied and it will not be possible to close
the exit door.
3
ILBh0177
1 Function: request ramp. Button (blue) in
the side wall towards the front of the
exit door.
Operation
The ramp can be requested in the
following ways:
– The yellow/blue button at the
handicapped passenger’s seat.
– The blue button for requesting the
ramp on the outside of the vehicle.
83
 FIRST-AID KIT
The first aid kit is located in the luggage
rack above the driver.
Ensure that you always have a complete
first-aid kit (obligatory in some countries).
Replace any of the contents as
soon as they are used.
3 a great deal to damage limitation. Since
84
EMERGENCY HAMMERS
In the event of an emergency, an
emergency hammer can be used to break
a window or to cut through a seat belt.
The emergency hammers are located on
the window frames.
Break the lock and hit the sharp point
against the window, preferably not in the
middle of the window.
Take into consideration that
the windows may be double
glazed.
If an emergency hammer is
removed from the holder, then
the ‘Emergency hammer miss-
ing’ warning light will be lit, see
W-E1 Emergency hammer
missing ( 33).
Safety precautions and emergency procedures
EMERGENCY PROCEDURES
Even a vehicle in good condition may be
involved in an emergency, a breakdown or
an accident. This almost inevitably leads to
a dangerous traffic situation, since the
vehicle may not come to a stop in a safe
location.
The behaviour of the driver can contribute
emergency situations are very diverse, it is
not possible to give a standard solution.
However, there are often similarities, so
that it is possible to give the following
general rules:
• First ensure your own safety, then that
of the passengers.
• Calm the passengers.
• Watch out for other traffic.
• Be careful where you stand and walk.
• Watch out for the release of hazardous
substances.
• Act quickly and decisively, but remain
calm and avoid panic reactions.
• Prevent accidents and the escalation of
accidents.
• Ensure that other road users are
warned by, for example, hazard
warning lights, the vehicle’s own
lighting, the warning triangle or similar
items.
• Switch off the engine and turn off the
main switch.
• Prepare fire extinguishers and, if
necessary, extinguish any fires which
may break out. 3
If necessary, notify the emergency and
rescue services.

Assist any injured persons.

Safety precautions and emergency procedures 85

86 Safety precautions and emergency procedures
 4 MAINTENANCE 1
GENERAL INFORMATION........................................................ 89

OVERVIEW OF THE SERVICE POINTS................................... 90

INSPECTION AND MAINTENANCE CHECKLIST.................... 92

DAILY CHECKS AND MAINTENANCE .................................... 94

WEEKLY CHECKS AND MAINTENANCE................................ 97

BEFORE THE WINTER ........................................................... 101

4
AFTER THE WINTER .............................................................. 101

Maintenance 87
1

88 Maintenance
GENERAL INFORMATION First Service
The first service should be carried out 1
The durability, safety, depreciation and
between the first 7,500 and 10,000 km
reliability of the vehicle is to a large extent
subsequent to the delivery of the vehicle.
dependent on the way it is cared for and
on the regular performance of the Service intervals
maintenance prescribed by VDL Bus & For service intervals and the
Coach. corresponding maintenance work, refer to
the appropriate maintenance schedule.
The driver’s driving style and his care of
the vehicle have a direct influence on the
vehicle‘s condition.
The driver can often give the workshop
information which is valuable for good
maintenance. 4
The vehicle should be maintained at the
intervals given in the maintenance manual.
However if the vehicle has to operate in
dusty areas or under difficult conditions the
frequency of maintenance should be
increased.

The maintenance discussed here refers to

activities the driver can carry out himself.

A checklist is provided listing the points to

be covered by the driver.

Maintenance 89
 OVERVIEW OF THE SERVICE
1 POINTS

Rear service points

1. Sump filling unit oil reservoir
2. Sump filling unit filler cap
3. Air filter contamination indicator
4. Coolant reservoir
5. Water separator/manual supply pump
6. Fan drive and steering mechanism
hydraulic reservoir
7. Coolant filler cap
8. Engine oil filler cap
4 9. Engine oil dipstick
10. Diesel filler cap
11. AdBlue filler cap
12. Coolant filler cap (optional)
13. Engine oil dipstick (optional)
14. Engine oil filler cap (optional)

ILAj0514

90 Maintenance
Front service points
1. Nato plug socket
1
2. Main switch box
3. Batteries

ILBh0163

Maintenance 91
 INSPECTION AND
1 MAINTENANCE CHECKLIST
Daily Weekly
Engine compartment
Possible oil, air or coolant leak b b
Check the engine oil levela b b
Check the oil level of the sump filling unit a b b
Check the fuel level b b
Check the AdBlue level b b
Check the fluid level of the hydraulic system’s fan/steering mechanism a b
Check the coolant level a b b
4 Check the air filter indicator a b b
Check the V-belts a b b
Drain the fuel system’s water separator a b
Underbody
Drain water from air tanks a b
Check transmission, rear axle and engine for leaks b
Sides
Check the wheel nuts visually b
Checking the tyre pressure. b
Check the tyres and rims for wear and damage b b
Remove stones from the tread and from between the double tyres b b
Check the closure of all side flaps b b
Check the radiator a b
Front

92 Maintenance
Check the windscreen and headlight washer reservoir a b b
1
Daily Weekly
Front
Check condition of windscreen wipers b
Checking the tyre pressure. b
Interior
Attachment of and damage to the seats b
Check if first aid kit, emergency hammers and fire extinguisher(s) are present b b
Check if doors, emergency exits and emergency valves open and close b b
Check spares, jack, tools and hazard triangle are present b b
Electrical system
Check all exterior lights (parking lights, main and dipped beam, brake lights, fog lamps, reversing lights, b b 4
clearance lights, registration plate lights, indicators and alarm lights)
Check the batteries’ fluid level a b
Check all interior lighting (main lights, dashboard, reading lamps and entry lighting) b b
Check dashboard instruments and signal lamps for operation and correct signal before and after starting b b
Check the operation of windscreen wipers and the horn b b
In freezing conditions
Windscreen washer antifreeze in reservoir b b
a. These operations are described in more detail on the following pages.

Maintenance 93
 DAILY CHECKS AND • Remove the dipstick from its housing.
1 MAINTENANCE • Clean the dipstick with a lint-free cloth
• Insert the dipstick in its housing and
Carry out daily checks and maintenance wait a few seconds.
as follows, see Inspection and • Remove the dipstick again and read
maintenance checklist ( 92). the level: it should always be between
the two marks.
Open the bonnet. • Add oil as necessary via the filler
Preferably, switch off the opening.
engine before opening the Avoid overfilling.
engine compartment. For the engine oil specifica-

Engine oil level

04224B
tion, see Lubricant
Specifications ( 148).
4
Make sure the vehicle is on a
flat, horizontal surface.

Vehicle height differences as a

result of air leaks will affect the
measurement.

An incorrect oil level may

cause serious damage to the
engine.

Avoid skin contact with oil. Oil

is bad for skin and health.

• Turn off the engine and wait 5 minutes

minimum.

94 Maintenance
 the oil level in the sump filling unit must be
checked. 1
• Read the oil level using the indicator on
the reservoir.
• The oil level must always be topped up
to the maximum.
• If necessary, add oil via the filler cap
(2).

For the engine oil specifica-

tion, see Lubricant
Specifications ( 148).
ILAj0004 ILBj0004

Sump filling unit Coolant level 4

Check coolant level when the engine is
Make sure the vehicle is on a
flat, horizontal surface.
cold.
The coolant level must always be
somewhere between minimum and
Avoid skin contact with oil. Oil
is bad for skin and health.
maximum level. If necessary, top it up (see
“Topping up”).

If the coolant must be topped

The engine oil level is automatically topped
up with oil from the sump filling unit if the up regularly or if there is a
level in the engine sump becomes too low. trace of a coolant leak, then
The engine oil level in the sump filling unit please contact a VDL Bus &
is checked by a sensor. If the oil level in Coach dealer.
the reservoir is too low (symbol i-D2 is
displayed on the information screen), then

Maintenance 95
 Topping up
1
When the coolant is warm, the
cooling system is pressurized.
When the filler cap is removed,
the pressurized hot steam and
coolant can escape. This may
lead to a serious burn or a seri-
ous injury.
Never remove the filler cap
whilst the engine is still hot.
4 Wait until the coolant tempera-
ture is less than 50º C. Next,
cover the filler cap with a thick
cloth and remove it slowly to
allow the pressure to escape.
Then remove it completely.
Coolant is a harmful liquid.
Avoid skin contact in order to
prevent poisoning symptoms.
Topping up with cold coolant
whilst the engine is hot may
damage the engine.
96
Top up when:
- The engine is not running.
- The engine is cold.
Topping up
Remove filler cap A from the reservoir.
Slowly top up the reservoir to the
maximum level.
For the coolant specification, see Lubricant
Specifications ( 148).
Bring the engine to the operating
temperature.
Switch off the engine and check the
coolant level.
This symbol will appear on the
main display when the sensor in
the coolant reservoir indicates a
too low coolant level. The symbol
will disappear approximately 1 minute after
the coolant level has been topped up.
Maintenance
Tyres and rims
• Check the tyres for wear, foreign
objects and other damage.
• Remove objects which are stuck in the
tyre tread or between the tyres (for a
double assembly).
• Check the attachment of the wheels.
For the specified torque, see
Torque ( 147).
• Check the tyre pressure (also check
the spare wheel). The tyre pressure
must be checked and corrected whilst
the tyres are cold, see Tyre
pressure ( 146).
If a tyre is worn and has a pres-
sure which is 2 bar too low,
then, under extreme conditi-
ons, the ABS will no longer
work.
See also Wheels and
tyres ( 146).
Maintenance
WEEKLY CHECKS AND
1
MAINTENANCE
Carry out weekly checks and maintenance
in accordance with the Inspection and
maintenance checklist ( 92).
If the level is below the mini-
mum mark, then this indicates
that there is a leak. Contact a
VDL Bus & Coach service dea-
ler as quickly as possible.
ILBe0001
Fan drive/steering mechanism
hydraulic oil 4
Check whether the hydraulic oil is between
both marks.
If necessary, top up the hydraulic oil via
filler cap A.
Only top up the hydraulic oil
when the engine is switched
OFF. Check the oil level when
the engine is running.
For the hydraulic oil specifications, see
Lubricant Specifications ( 148).
97
1
ILBi0005
Air filter
4 There is an indicator which indicates
whether the air filter needs to be replaced.
When the air filter is normal/clean, then the
yellow piston is in the green area (between
A and B).
When the yellow piston is in the red area
(above B), the air filter is heavily
contaminated and must be replaced.
Also clean the filter housing before the air
filter is put back. Reset the indicator by
pressing the button after the filter has been
put back in place (push to reset).
98
ILBf0001
Radiator
Check the gauze which is fitted in front of
the cooling unit as extra protection against
contamination. If necessary, clean the
ILBi0006 gauze.
Brake system air dryer Make sure the radiator’s lamel-
Drain the water from the air reservoirs by lae are not damaged.
pulling on the ring.
If more water than is to be expected is
regularly drained, then the air dryer’s filter
element must be replaced (contact a VDL
Bus & Coach service dealer).
Windscreen washer liquid
Check the fluid level and, if necessary, top
it up.
Add cleaning fluid in the summer.
Add special windscreen washer antifreeze
in the winter.
Maintenance

ILAh0009
Batteries
The batteries are located on the driver's
side at the front of the vehicle.
The batteries can be accessed by pulling
out the battery tray.
Avoid sparks and a naked
flame close to the batteries,
because they may cause an
explosion and a serious injury.
Battery acid is an extremely
aggressive and poisonous
substance. Bodily contact can
cause serious health pro-
blems.
Maintenance
1
The use of batteries other than
those specified may result in
damage to the electrical com-
ponents. Do not use batteries
other than those specified.
Drawing a currently directly
from the batteries may result in
damage to the batteries and
cause starting problems.
Therefore, do not make any
direct connections to the batte- 4
ILBh0165 ries.
Check the electrolyte level. It should be
topped up to the maximum level. If
necessary, top up with distilled water.
Battery acid is an aggressive
fluid. If it comes into contact
with your clothes, eyes or skin,
rinse with plenty of water.
Make sure the battery poles and the
battery clamps are clean and well
lubricated. If necessary, lubricate them
with acid-free Vaseline.
After checking, do not forget to refit the
battery tray’s lock pins.
99
 In the event of skin contact: Avoid sparks and a naked
1 remove the substance with flame near the fuel.
paper or a cloth and wash with
soap. Contact a doctor in the Dirt in the fuel system may
event of persistent irritation. cause serious damage to the
fuel system.
In the event of contact with the
eyes: wash for at least 15 Work in a clean environment
minutes with plenty of water
and visit a doctor.
when working on the fuel
system.
043232B
If swallowed: do NOT induce

4
Central lubrication installation
Check the grease level if central lubrication
is used. Top up the reservoir if the
minimum level is reached.
For the grease specifications,
Lubricant Specifications ( 148).
OVERVIEW OF THE MONTHLY
INSPECTIONS WHEN USING
BIODIESEL
Diesel is a poisonous substance. Physical
contact may lead to serious health
problems.
Avoid bodily contact.
100
vomiting. Rinse your mouth,
drink a lot of water and contact
a doctor.
In the event of inhalation: get
see some fresh air and take a rest.
Contact a doctor.
Fuel is highly inflammable and
can result in an explosion,
which may cause a serious
injury.
Collect any fuel which
escapes.
Clean the area around the fuel
system's components before
starting work on the fuel
system.
Visually check the components listed
below every month for the following:
• (Flexible) fuel hoses between the lines
and the engine for leaks. If necessary,
replace it.
• The contents of the fuel tank for water,
contamination and bacteria growth. If
necessary, clean it.
• The seal of the fuel tank’s filler cap for
leaks. If necessary, replace it.
Maintenance
BEFORE THE WINTER
Checking the antifreeze concentration
Check the coolant’s antifreeze
concentration
To avoid damage to the engine
block when adding cold cool-
ant to a warm engine, add it
slowly while the engine is run-
ning.
For the coolant specifications, see
Lubricant Specifications ( 148).
Windscreen and headlight washer
reservoir
Add antifreeze to the windscreen washer
fluid.
Air conditioning
Regularly (for example, once a month)
allow the air conditioning system’s
compressor to run for a couple of minutes,
so that the oil in the system is pumped
around. This will prevent the seals from
drying out.
Diesel
In the event of persistent cold outdoor
temperatures, only refuel using winter
Maintenance
diesel which is sold by a reputable oil AFTER THE WINTER
company. During the winter, the diesel 1
suppliers often use additives to prevent Windscreen and headlight washer
paraffin deposits, which cause blockages. reservoir
It is not permitted to use alternative It is recommended to add cleaning fluid to
additives in the fuel. the water.
Fuel additives for preventing paraffin
deposits only have a preventative function.
They are not able to dissolve paraffin.
Make sure there is always a
separate fuel fine filter availa-
ble so that the filter can be
replaced if there is a blockage
4
(also if it is caused by paraffin
deposits), see Replacing the
fuel fine filter ( 112).
Batteries
The demands that are placed on the
batteries in the winter are much higher
than in the summer, because the lights,
windscreen wipers, etc. are used more
often. Also, the battery capacity is lower at
lower temperatures.
A poorly charged battery can become
frozen if it becomes very cold.
Regularly check the charging state of the
batteries and, if necessary, lubricate the
battery poles with acid-free Vaseline.
101
 CLEANING THE VEHICLE
1 radiator/intercooler/oil
Check the vehicle for leaks from the
engine, the axles, the gearbox, etc. before
cleaning it. It is not possible to do this after
it has been cleaned.
Pay attention to the following when
using a high-pressure hose/steam
cleaner:
• Make sure doors, windows and roof
hatches are securely closed when
cleaning the vehicle.
• Do not spray directly at seals. There is
4 a risk that they will be forced open and
the grease behind them will be washed
away. This can happen, for example,
with the universal joint on the steering
housing. Its spider will then become
stuck and the steering mechanism will
jam.
• Do not spray directly at steering ball
joints.
• A bleed valve has been fitted on the
steering oil reservoir. Water may enter
the tank through this valve, causing
damage to the steering mechanism.
102
• Make sure that, when cleaning the • Thoroughly clean the engine
cooler, the encapsulation and the encapsulation’s
lamellae and the gauze in front of the parts. As a result of the fire risk, make
radiator/intercooler/oil cooler are not sure any spilt oil or diesel is removed
damaged by the steam cleaner’s high immediately. When spraying the engine
pressure. encapsulation with a high-pressure
• Do not direct the jet of the high- hose, maintain a minimum distance of
pressure hose/steam cleaner at the air 50 cm between the engine
conditioning system’s condenser for encapsulation and the spray nozzle to
too long. Heating will cause the prevent damage to the engine
pressure in the system to increase, encapsulation. Do not use a high-
which will cause damage. pressure steam cleaner for this.
• The air conditioning system’s • Do not aim the jet of a high-pressure
components may not be cleaned with a hose/steam cleaner directly at
high-pressure hose/steam cleaner, electrical connections, such as
because this may damage the seals. connectors, lighting feed-through
• Ensure that no water can enter the connections, etc.
differential or the gearbox via the bleed • Make sure no water can enter the air
openings. intake system via the air inlet or its
• Make sure no water can enter via the flexible seals when cleaning the
bleed screws on the reservoirs for the vehicle.
clutch, brakes, etc. • Make sure water cannot enter via the
• The engine and engine compartment oil dipstick.
can be cleaned with a high-pressure • After cleaning the vehicle, it must be
hose/steam cleaner. When doing so, lubricated with the aid of a grease gun.
do not spray directly at the electrical This is important, because it will
components, such as the pump units, prevent the penetration of moisture and
the electronic units, the starter motor, dirt at the various pivot points, see
the generator, the air conditioning Lubrication schedule ( 155).
system's compressor, etc.
Maintenance
 1

Maintenance 103
1

104 Maintenance
 5 REPAIRS WHILST ON THE ROAD 1
GENERAL INFORMATION...................................................... 107

SERIOUS OIL LEAK................................................................ 107

ENGINE COMPARTMENT .......................................................110

ABS INSTALLATION................................................................114

PNEUMATIC SUSPENSION LEAK..........................................114

WHEELS AND TYRES .............................................................115

SUPPORTING THE CHASSIS..................................................118

REPLACING LIGHT BULBS ................................................... 120

5
REPLACING FUSES ............................................................... 120

MAIN SWITCH BOX ................................................................ 123

CENTRAL FUSE BOX ............................................................. 124

STARTING WITH THE AID OF AUXILIARY BATTERIES ...... 127

TOWING ................................................................................... 129

RELEASING THE PARKING BRAKE ..................................... 130

ITS-VDL.................................................................................... 131

Repairs whilst on the road 105

1

106 Repairs whilst on the road

General information
Although the vehicle may be well
maintained, it is still possible that a
problem arises, such as a flat tyre or a
faulty headlight, that you will have to repair
yourself in order to continue your journey.
Safety
Before rectifying the problem,
you must ensure your own
safety and that of the passen-
gers. Therefore, stop and park
the vehicle in a safe place and,
if necessary, allow the passen-
gers to wait in a safe location
close to the vehicle.
from resulting in another fault due to
unnecessary contamination.
A clean work area also improves safety.
Once the fault has been rectified, make
sure to return the area to its original state.
Serious oil leak
In the event of a (serious) oil leak from a
1
transmission component, you must, if still
possible, drive carefully to the nearest VDL
Bus & Coach workshop.
Oil levels must always be
above the minimum level. If the
oil level threatens to fall below
the minimum level, stop the
vehicle and turn off the engine.
Avoid skin contact with
drained oil. Attention! There is
a danger of being burnt by hot
oil.

Safety vest
5
When carrying out emergency repairs,
always wear a safety vest (it is a legal
requirement in some countries) and, if
necessary, also use other means of visual
indication.

Cleanliness
It is extremely important that you make
sure you keep the work area clean when
repairing a fault, to avoid the repair work

Repairs whilst on the road 107

 6. Insert the dipstick in its housing and
1 wait a few seconds.
7. Remove the dipstick again and read
the level. It must be between the two
marks.
8. Add oil, if necessary, via the filler
opening B.
9. Always use the correct oil. Do not add
too much oil.

Only use gearbox oil that

ILBc0001
meets the VDL Bus & Coach
ILBc0002

VOITH automatic gearbox specifications, see Lubricant ZF automatic gearbox

Always check the oil level twice. If different
readings are obtained, check the
gearbox’s bleed valve.
Check the oil level (advice: at the end of
5 the day)
Check the oil level at the opera-
ting temperature (gearbox oil
temperature 80° C - 90° C).
Specifications ( 148).
Always check the oil level twice. If different
readings are obtained, check the
gearbox’s bleed valve.
Check the oil level (advice: at the end of
the day)
Check the oil level at the opera-
ting temperature (gearbox oil
temperature 80° C - 90° C).

1. Place the vehicle on a flat, horizontal 1. Place the vehicle on a flat, horizontal
surface. The vehicle must be at the surface whilst the vehicle is at the
driving height. driving height.
2. Select "N" (neutral). 2. Select "N" (neutral).
3. Idle the engine. 3. Idle the engine.
4. Remove the dipstick from its housing. 4. Wait approximately 2 minutes. Remove
5. Clean the dipstick with a lint-free cloth dipstick A from its holder.

108 Repairs whilst on the road

5. Use a lint-free cloth to clean the 5. Fit the oil spill plug and tighten it to a
dipstick. torque of 54 - 81 Nm. 1
6. Insert the dipstick in its holder and wait
a few seconds.
7. Remove the dipstick again and read
the level. It must be between the two
“HOT” marks.
8. Add oil, if necessary, via the oil dipstick
holder.
9. Always use the correct oil. Do not add
too much oil.
ILAc0042
Only use gearbox oil that
meets the VDL Bus & Coach Rear axle differential
specifications, see Lubricant Do not check the oil level immediately after
Specifications ( 148). a journey. Allow the oil to settle and cool
down for approximately half an hour.
10. Do not add too much oil. 1. Place the vehicle on a flat, horizontal 5
surface.
2. Remove the oil level plug A. The oil
level must reach the edge of the filler/
spill opening.
3. Add oil, if necessary, via the filler/spill
opening.

Only use rear axle oil that

meets the VDL Bus & Coach
specifications, see Lubricant
Specifications ( 148).

4. Do not add too much oil.

Repairs whilst on the road 109

 • Adjust the V-belt tension (see
1 “Adjusting the V-belt tension”).
• Tighten the lock nuts A.
• Reconnect the battery’s earth cable.

Check the setting of the new V-

04236B
Engine compartment
Replacing the full air conditioning
system V-belt
• Disconnect the earth cable from the
5 tension of 1,300 N is achieved.
battery.
• Unscrew the lock nuts A.
• Rotate the threaded spindle B until the
V-belt can be removed from the
pulleys.
Always fit the same type of V-
belt.
belt after the first 50 km and
have the V-belt tension chec-
ked as soon as possible by a
VDL Bus & Coach service dea-
ler.
Adjusting the full air conditioning
ILAj0515
system V-belt tension
• Unscrew the lock nuts A. Replacing the driver's air conditioning
• Tighten the V-belt by rotating the system V-belt.
threaded spindle B until a V-belt • Disconnect the earth cable from the
battery.
• Tighten the lock nuts A. • Place a pry bar (1/2”) in hole A.
Check the setting of the new V- • Hold the pry bar firmly, unscrew bolt B
belt after the first 50 km and
•
and slacken the V-belt.
Remove the V-belt from the pulleys.
have the V-belt tension chec-
ked as soon as possible by a Always fit the same type of V-
VDL Bus & Coach service dea-
ler.
belt.

• Inspect the pulleys for damage, rust • Inspect the pulleys for damage, rust
and grease deposits. and grease deposits.
• Fit the new V-belt. • Fit the new V-belt.

110 Repairs whilst on the road

• Adjust the V-belt tension (see
“Adjusting the V-belt tension”).
• Tighten the bolt (B).
• Reconnect the battery’s earth cable.
Check the setting of the new V-
belt after the first 50 km and
have the V-belt tension chec-
ked as soon as possible by a
VDL Bus & Coach service dea-
ler.
Adjusting the driver’s air conditioning
system V-belt tension
• Place a pry bar (1/2”) in hole A.
• Hold the pry bar in place and unscrew
the bolt B.
• Tighten the V-belt by rotating the pry
bar until a V-belt tension of 450 N is
achieved.
• Tighten the bolt B.
Check the setting of the new V-
belt after the first 50 km and
have the V-belt tension chec-
ked as soon as possible by a
VDL Bus & Coach service dea-
ler.
Repairs whilst on the road
• Place a new poly V-belt over as many
pulleys as possible. 1
• Tighten the automatic belt tensioner
and place the poly V-belt over the
remaining pulleys. Allow the automatic
belt tensioner to slowly spring back
against the new poly V-belt.
• Check that the poly V-belt lays in all the
pulley grooves.
• Reconnect the battery’s earth cable.
ILAj0516
Replacing the poly V-belt
Always fit the same type of
poly V-belt.
5
• Disconnect the earth cable from the
battery.
• Place a suitable pry bar with
a 3/8” connection in the arm of the
automatic belt tensioner.
• Slacken the poly V-belt so that it can be
removed from the pulleys.
• Allow the automatic belt tensioner to
carefully spring back to the stop.
• Inspect the pulleys for damage, rust
and grease deposits.
111

1 hand side of the engine next to the fuel
ILBj0005
Replacing the fuel fine filter
A quantity of fuel will be
released when removing the
fuel fine filter. Collect the fuel
5 and avoid the risk of fire.
Dirt in the fuel can lead to seri-
ous damage to the fuel system.
Diesel fuel is toxic and can,
therefore, have a damaging
effect on your health. Avoid
any direct or indirect physical
contact.
112
The fuel fine filter is located on the right-
pump.
Replace the filter according to the method
given below:
• Place a container under the fuel fine
filter.
• Remove the filter by turning it
anticlockwise.
The fuel fine filter is a disposa-
ble filter and may not be ILAj0094
cleaned and reused.
Bleeding the fuel system
• Lightly lubricate the sealing rubber with
clean engine oil (do not use diesel). When the hand pump is used,
• Fit the filter until the sealing ring the fuel system is bled automa-
touches and tighten it by hand a further tically.
1/2 - 3/4 of a revolution.
• Bleed the fuel system (see “Bleeding If the fuel tank becomes empty,
the fuel system”). the bleed nipple B can first be
• Start the engine and check for leaks. If unscrewed in order to bleed
necessary, retighten the filter by hand. the water separator. Tighten
the plug if fuel escapes.
• Rotate the hand pump’s button A
anticlockwise.
Repairs whilst on the road
• Pump by hand until a clearly higher separator.
resistance is felt. Stop pumping as • Remove the connector. 1
soon as the higher resistance is felt. • Unscrew the ring-shaped drain tap B at
Continuing to pump may cause internal the bottom of the water separator by
damage to the fuel system. rotating it anticlockwise.
• Tighten the button by rotating it • Drain the filter until pure diesel flows
clockwise. out of the drain tap A.
• Start the engine and allow it to idle for 1 • Rotate the drain tap B a further 1/8 - 1/
minute. 4 of a revolution once it touches.
• Check the drain tap B for leaks.
• To prevent environmental
ILBj0007 contamination, the drained water/diesel
mixture must be given to an
Draining the water separator appropriate authority for processing.

A quantity of fuel will be

released when draining the
water separator. Collect the
fuel and avoid the risk of fire.
5

Water in the fuel system can

cause serious damage to the
fuel system.

Diesel fuel is toxic and can,

therefore, have a damaging
effect on your health. Avoid
any direct or indirect physical
contact.

• Place a container beneath the water

Repairs whilst on the road 113

 ABS installation
1 If the red warning light is lit at a speed
greater than approx. 7 km/h, then there is
a fault in the ABS installation.
Check the ABS system’s fuses (see the
fuse list).
If the fault cannot be rectified by replacing
a fuse, the vehicle can still be driven
because that means that only the ABS no
longer works. The normal brake installation
still works.
It will then be possible for the
wheels to lock during heavy
braking.
Have the fault with the ABS installation
5
repaired by a VDL Bus & Coach service
dealer.
114
Pneumatic suspension leak the nearest VDL Bus & Coach service
If the air compressor is able to keep the dealer.
vehicle at the driving height, then a
problem will not be noticed. If the sound of
an air leak can be heard, then follow the
instructions given below, because
otherwise the air compressor will be
placed under a too heavy load.
If the air leak gets worse, the
vehicle will not remain at the
driving height (tilt) and the
information symbol i-E4 will
be displayed on the
information screen.
Stop the vehicle as soon as
possible in a safe location and
turn off the engine. Have the
fault repaired immediately by a
VDL Bus & Coach service dea-
ler.
If one of the air bellows becomes faulty,
the supply line to the air bellows must be
disconnected and plugged. The supply line
must be plugged in order to prevent too
much of the air supply, which is also
required for braking, from escaping. The
vehicle may be driven at a slow speed to
Repairs whilst on the road
 Characteristics of wheel hub centring are:
• Wheels with cylindrical bolt holes.
• Wheel nuts with a loose, non-
removable, flat thrust washer.
The workshop must order and
fit a new type plate after fitting
tyres with a lower load capa-
city.
If the difference in diameter of
the various tyres is too great,
ILBd0002
then the ABS brake symbol will
be lit.
Wheels and tyres
Furthermore, if there is a diffe-
General information rence in diameters, check and,
• Only fit original rims which are if necessary, correct the tacho-
permitted for the vehicle.
graph and the maximum wheel
• Make sure the same type of tyre is turning angle.
fitted to both sides of an axle.
• Insufficient cleaning of the contact Larger tyres result in a higher
surfaces and/or uneven tightening of
the wheel nuts may cause vibrations
vehicle height. Check the vehi-
cle height.
during driving or braking.
• When one wheel bolt needs replacing,
the other wheel bolts on the same tyre
must also be replaced.
VDL Bus & Coach uses wheel hub
centring on its vehicles.
Repairs whilst on the road
Changing wheels
There may be tension in a torn or
1
otherwise damaged wheel rim which still
has an inflated tyre.
An inflated, damaged tyre/rim
may tear or break when chan-
ging a wheel. This can lead to a
dangerous situation or a seri-
ous injury.
Deflate the tyre and remove the
valve if there is a torn or other-
wise damaged wheel rim/tyre
which must be removed.
• Park the vehicle in a safe location on
an asphalted, horizontal road surface.
5
• Block the wheels so that the vehicle
cannot roll away.
• If necessary, turn on the hazard
warning lights and place a warning
triangle a distance of at least 30 m
behind the vehicle.
• Clean the wheel nuts and apply a drop
of oil to the screw thread.
• Unscrew the wheel nuts half a turn.
115
 • Place the jack near the wheel to be
1 replaced, see Support points ( 118)
and jack up the vehicle until the wheel
comes off the ground.

Read the documentation supp-

lied with the jack before using
it.

ILBd0003
• Remove the wheel nuts and remove
the wheel.
• Carefully clean the wheel hub's fitting
edge, the cams on the wheel hubs and
the inner edge of the wheel to be fitted
and remove any burrs or paint.
5
ILBd0004
• Apply a thin layer of grease to the rim’s
fitting edge. This grease layer should
prevent the wheel rim and the wheel
hub from rusting together.
• Apply a thin layer of grease to the
wheel hub’s fitting edge.

116 Repairs whilst on the road


ILBd0005
• Clean the wheel nuts and then apply a
drop of oil between the thrust washer
•
and the wheel nut.
Clean the wheel bolts and apply a drop
of oil to the first turn of the screw
thread.
• Fit the wheel and tighten the nuts.
• Remove the jack and tighten the nuts
evenly in the order shown in the
diagram. For the specified torque, see
Torque ( 147).
Repairs whilst on the road
ILAd0025
Wheel nuts must always be
tightened and retightened
when they are cold. However,
tightening wheel bolts in
extreme cold should be avoi-
ded.
• Check the tyre pressure.
• Tighten the wheel nuts after 100 km. If
new wheel nuts are fitted, retighten the
wheel nuts again after 500 km.
• Do not forget the warning triangle.
When a wheel has been repla-
ced, have the wheel nuts tigh-
tened to the correct torque by a
VDL Bus & Coach workshop.
1
ILBi0001
Inflating a tyre
• Make sure the storage pressure on the
pressure gauges is not at the
maximum, but between 8 - 9 bar.
• Remove the cap from the test 5
connection K2.
• Connect the tyre inflating hose.
• Idle the engine. Pump up the tyres to
the correct tyre pressure, see Tyre
pressure ( 146).
• Fit the test connection cap K2.
• Check the tyre pressure at the first
available opportunity.
117
 Filling the pneumatic system Supporting the chassis
1 The entire pneumatic system can be filled
Turn off the CLS system by tur-
from an external source via the test
connection K0. When doing so, pay
ning off the main switch, other-
wise the CLS system will
attention to the correct system pressure
attempt to correct the angle of
(8.6 - 9.8 bar).
the vehicle.
The conditions for placing the vehicle’s
pneumatic system under a sufficient
Always use axle supports
pressure air:
• The pressure regulator must be set to
when working under a jacked
up vehicle.
fill (drain).
• The external pressure must not be 04242B
Read the documentation supp-
higher than the cut-out pressure of the
vehicle's pneumatic system.
lied with the jack before using Support points
• The air dryer must not be set to blow- it. The support points shown above have
off. It will then not be possible to fill the been included for supporting the vehicle.
system and the system will probably be
5 bled even more.
Always work safely and follow
the (safety) instructions supp-
lied with the axle supports you
are using.

• FRONT support points

• If the support points have not been
indicated by the bodybuilder, place the
axle support under the crossbeam in
front of or behind the front axle.

118 Repairs whilst on the road


04243B
• REAR support points
• If the support points have not been
indicated by the bodybuilder, place the
axle support under the crossbeam in
front of the rear axle.
Always use axle supports
when working under a jacked
up vehicle.
Read the documentation supp-
lied with the axle support
before using it.
Repairs whilst on the road
ILAd0147
Front axle jack points
When jacking up the front axle, place the
jack under the axle beam as shown in the
diagram.
1
ILAd0148
Rear jack points
Place the jack under the spring attachment
as shown in the diagram.
To prevent deformation of the
axle beam, never place the jack
5
directly under the axle beam or
the differential housing.
119
 Replacing light bulbs
1 All the common fuses are located in the
General information
Never touch the glass of a light bulb with
bare fingers. Traces of grease, oil or other
irregularities will adhere to the glass and
reduce the lifespan of the lamp.
The reflector will be affected by
vaporization of the irregularities.
Use the light bulb’s packaging
as protection between your fin-
gers and the glass.
Check the headlight setting
when the headlight's bulb is
replaced.
5
If the vehicle has xenon ligh-
ting, see Replacing xenon light
bulbs ( 120)).
120
Replacing xenon light bulbs Fuse locations
General information
central fuse box.
Provided the lights are not turned on and Main fuses are located in the central fuse
off very often, xenon lamps have a very box and the main switch box.
long lifespan and there is a very low risk of • If necessary, see the information
a faulty bulb. provided by the bodybuilder for the
However, if the bulbs are faulty, the vehicle location of the central fuse box.
can still be driven using the fog lights, but • The main switch box is attached to the
only if the local legislation allows this. battery tray and is rotated outwards
Xenon lights use a very high
together with the battery tray.
voltage. The driver is, there-
fore, not permitted to replace
the xenon light bulbs himself.
Xenon bulbs may only be
replaced by specifically trained
technicians, because it is a
very specialized procedure.
For more information, contact
your nearest VDL Bus & Coach
service dealer.
Replacing fuses
General information
If an electrical component does not work,
this may be due to a fuse which has blown
as a result of a temporary excessive load.
Repairs whilst on the road
Replacing a fuse
Observe the following safety procedures
when replacing a fuse.
Only replace fuses when:
- The engine is no longer run-
ning.
- The contact switch has been
turned off.
- The consumer has been
turned off.
This will prevent damage to electrical
components and the electronics.
• Locate the faulty fuse.
There is a pair of pliers in the fuse box
which make it easy to replace fuses.
Repairs whilst on the road
ILBh0167
• Pull the fuse out in a straight line and
look on the inside to see whether the
wire loop has burnt out.
1
ILBh0166
• If necessary, fit a new fuse of the same
colour and with the same amperage as
the previous fuse.
The amperage is stated on the fuse.
5
Always check whether the fuse
capacity corresponds with the
value stated on the label in the
fuse box.
Never replace a faulty fuse with
one of a higher capacity.
This can lead to a short circuit
or a fire.
121
 If a number of fuses blow in the
1 same location, then there is a
fault in the electrical installa-
tion. In that case, contact your
nearest VDL Bus & Coach ser-
vice dealer.

If a number of fuses blow in the same

location, then there is a fault in the
electrical installation and the vehicle must
be inspected by a VDL Bus & Coach
service dealer.

Spare fuses are located in the

fuse box in the central fuse
box.

Do not forget to replace the pli-

5 ers after use.

122 Repairs whilst on the road

 MAIN SWITCH BOX
1

04249B
E223 Fuse 200A Power supply for contact
E224 Fuse 150A Power supply for the main switch
E279 Fuse 6A Checking the generator voltage
E286 Fuse 500A Main fuse
G053 Relay Main switch

Repairs whilst on the road 123

 Central fuse box
1

04530B
A Fuses
B Fuses
C Fuses
D Fuses
E Main fuses
S Fuse test button

124 Repairs whilst on the road

Fuses A Fuses B Fuses C
1

04531B 04534B 04532B

E041 10A ABS E025 15A Wiper E318 20A IOU 4

E042 10A ABS E351 5/6A FMS E317 20A IOU 3
E248 7.5A/ Retarder E040 5/6A ABS E319 20A IOU 5
8A E029 10A Retarder E232 15A Start relay
E403 15A EAS pump clamp 30 E404 5/6A EAS pump clamp 15 E303 20A VFC
E118 30A UPEC power supply E091 7.5/8A Heating air dryer E315 20A IOU 1
E347 5/6A Generator clamp 15 E316 20A IOU 2 5
E336 7.5/8A Engine compartment E412 5/6A Brake pedal sensor
lighting E324 7.5/8A BAT interface panel
E413 5/6A Water in fuel sensor E407 5/6A FMS
E050 7.5/8A Central lubrication system E030 10A Horn
E053 5/6A OBD clamp 15 E311 10A Instrument panel
E386 5/6A Tachograph clamp 15 E321 30A Bodybuilder clamp 30
E333 30A BB clamp 15

Repairs whilst on the road 125

 Fuses D Main fuses E
1

04533B
04535B
E410 20A Spare Spare1 5A Spare
E429 7,5/8A Exhaust Datalogger Spare2 7.5A Spare E320 100A Power supply after the
E058 15A Heater Spare3 10A Spare main switch (bodybuilder)
E059 15A Heater Spare4 15A Spare E334 100A Power supply after the
E307 15A IOU 3 Spare5 20A Spare main switch (bodybuilder)
5 E406 50A Battery + (bodybuilder)
E231 7.5/8A Sump filling unit Spare6 30A Spare
E308 15A IOU 4
E309 15A IOU 5
E304 15A VFC 1
E305 15A IOU 1
E306 15A IOU 2
E325 10A BAT OBD
E312 5/6A Instrument panel
E326 5/6A BAT tachograph
E310 5/6A Instrument panel

126 Repairs whilst on the road

Fuse test button (S)
04536B
Turn on the main switch and the contact
switch to test the fuses.
When the test button is pressed, the lights
next to the fuses will be lit. If a light is not
lit, then this indicates a fault.
If necessary, replace any faulty fuses.
Repairs whilst on the road
ASSISTED START
Starting with the aid of auxiliary batte-
ries
If the vehicle is started with a separate bat-
tery (approx. 24 V) or with the aid of
another vehicle whose engine is running
(approx. 28 V), then the battery cables
must not be disconnected.
Do not use a quick-starter to
start the vehicle, as this may
damage the vehicle’s electro-
nics.
Make sure the device being
used to start the vehicle does
not have a voltage greater than
28 V. This will prevent damage
to the vehicle’s electronics.
Do not cause sparks, because
that may cause the batteries to
explode.
Prevent the two vehicles from
touching each other.
Connect the start cable to the positive (+)
battery clamp first and then to the negative
(-) battery clamp. When removing the
cables, remove the cable connected to the 1
negative (-) clamp first before removing the
cable connected to the positive (+) clamp.
If the battery is fully discharged and the
engine is running, it is important that the
start cables are not removed immediately.
To prevent damage to the electrical system
due to voltage peaks, the engine must run
for at least 5 minutes before the start
cables are removed.
Never disconnect the battery
clamps when the engine is run-
ning. This will prevent
damage to the vehicle’s elec-
tronics.
5
Carry out the following if the engine is run-
ning and the batteries have been charged
for at least 5 minutes.
• Turn on as many power consumers as
possible (e.g. headlights, fog lights,
heater, fan, etc.).
• Disconnect the start cables.
• Turn off the power consumers.
Do not use a quick-starter to
start the vehicle, as this may
damage the vehicle’s electro-
nics.
127
 It is permitted to start the engine with auxi- • Connect the battery charger’s positive Push start
1 liary aids or emergency starting aids if a clamp (+) to the battery’s positive (+)
It is NOT recommended to
voltage limiter (max. value 32 Volt) is used.
•
clamp.
Connect the battery charger’s negative
push start the vehicle. Rectify
Charging the battery system clamp (-) to the battery’s negative (-) the problem so that the engine
clamp. starts. The VDL Bus & Coach
Avoid sparks and a naked
flame close to the batteries,
• Turn on the battery charger. warranty is not valid if the vehi-
cle is push started.
because this may cause an
• Turn the battery charger off once the
explosion and result in a seri- A vehicle with an automatic
ous injury.
•
battery has been charged.
Disconnect the negative (-) clamp first. gearbox may never be push
• Next, disconnect the positive (+) clamp. started.
Always remove all the filler
caps from the battery before
• Fit all the filler caps.
charging it. The battery cables may remain
connected during ‘normal’
Always ensure there is suitable charging of a battery as long

5
ventilation when charging bat-
teries.
If a battery is frozen, allow it to
defrost before charging it.
Charging a frozen battery may
cause an explosion. This may
lead to a serious injury.
• Make sure the battery is located in a
well ventilated space.
• Remove all the filler caps from the
battery.
as the vehicle is in a well venti-
lated
area.
Only use a quick-charger in the
event of extreme urgency.
When ‘quick’ charging, both of
the battery cables MUST be
disconnected in order to pre-
vent serious problems to the
vehicle’s electronics.

128 Repairs whilst on the road

Towing
Do not tow the vehicle whilst
there are passengers onboard.
Towing is a complex proce-
dure. Therefore, have the vehi-
cle towed by a specialist
company
that is recognized by your
insurance company.
The vehicle is not technically
suitable to be towed by another
vehicle and VDL Bus & Coach
does not give permission to do
so.
Procedure
• Always place the gearbox in neutral
(N).
• Always use a tow rod when towing.
This may only be deviated from in an
emergency situation.
• In an emergency, VDL Bus & Coach
recommends a maximum speed of 5
km/h for a maximum distance of a
couple of hundred metres.
Repairs whilst on the road
• To avoid damage to the gearbox, the
drive shaft must always be
OR
disconnected from the differential.
• Remove the axle shafts on both sides
of the rear axle.
• Fit the special tool (see TI4-B-0-004).
The maximum speed and the maximum
distance vary per country.
General information
• To prevent damage to the chassis, the
angle at which the vehicle is towed
must not be greater than 30 degrees
with regard to the road surface.
• When being towed, an error message
may be displayed on the main display if
the contact switch is turned on.
High forces and tensions in the
vehicle’s chassis and the dri-
velines may result in the vehi-
cle becoming damaged. To
prevent this from happening,
the vehicle may not be towed
at an angle greater than 20
degrees with regard to the
vehicle’s centre line.
A vehicle that is being towed
may e located asymmetrically
1
(left or right) behind the towing
vehicle. Towing at an angle
greater than 20 degrees with
regard to the vehicle’s centre
line may result in unstable
vehicle behaviour during diffi-
cult driving conditions, both
for the vehicle being towed and
the towing vehicle. This may
lead to an extremely dange-
rous situation.
When the engine is not run-
ning, there is no power stee-
ring and there is no air supply
for the brake installation. If the 5
service brake is applied or if
there is an air leak, the parking
brake may be applied as a
result.
• Always release the parking brake when
towing the vehicle for a short distance.
Also do this if there is insufficient
pressure in the air reservoirs, see
Parking brake/emergency
brake ( 59).
129
 • Contact a recognized recovery service Rectify the operation of the spring brake
1 if the vehicle must be towed a longer cylinders as soon as possible by rotating
distance. the bolts clockwise as far as possible and
tightening them to a maximum torque of 70
Towing if the differential is damaged Nm.
Hoist the vehicle from the rear and block
To release the parking brake,
the steering wheel.
the system must be pressuri-
Push start zed to a pressure of at least 6.5
bar.
Vehicles with an automatic
transmission may not be push
started. ILAi0299
Releasing the parking brake

Make sure there is a ring span-

ner in the vehicle (European
legislation).
5
Make sure the vehicle cannot
roll away as soon as the par-
king brake is released.

Mechanical
• Place chocks in front of and behind the
wheels.
• Rotate the release bolt until the stop
using a ring spanner.
• Repeat this for all the other spring
brake cylinders.

130 Repairs whilst on the road

 The maximum pressure in the
parking brake must not be gre-
ater than 8.1 bar.
ITS-VDL
ITS-VDL deals with all emergency
1
situations and breakdowns free of charge,
24 hours a day, 7 days a week.

ITS-VDL can be contacted via the

following telephone number: +31 (0)40
294 80 80.
(The international access code for the
Netherlands is 00-31 for most EU
ILBi0001 countries.)

Pneumatic If you contact ITS-VDL, you must provide

• Place chocks in front of and behind the the following information. This information
wheels. is included on the vehicle’s registration
• Push the parking brake lever forwards papers and on the identification plate on
(to the “drive” position). the right-hand side of the entrance bay.
• The spring brake cylinders can be 5
released via the (red) pneumatic
emergency filler connection K3 with the
aid of an external air source and a filler
hose.

To release the parking brake,

the system must be pressuri-
zed to a pressure of at least 6.5
bar.

Repairs whilst on the road 131

 Make sure you have this information If the local dealer gives a payment
1 available before you call. guarantee for a repair, then the costs
• Vehicle type. incurred by the dealer when carrying out
• Vehicle’s year of construction. the repair will be
• Owner of the vehicle. forwarded to the vehicle’s owner via the
• Chassis number. local dealer. This is also the case for all the
• Registration number. VDL Bus & Coach parts delivered.
• Name of the workshop where the The driver, therefore, does not have to pay
vehicle undergoes periodic for any repairs and can explain in his own
maintenance language what the cause of the problem is.
(local dealer). Once a driver has contacted ITS for help,
• The exact location where the vehicle is he
located (ask somebody who knows the must not leave the specified location
area). without first informing ITS.
• Telephone number which you can be
Component delivery
reached at.
• The expected cause of the problem. In a number of countries, a DAF dealer can
5 • Proof of warranty. deliver both VDL Bus & Coach
• ID card for identifying components. components and DAF components from
stock.

132 Repairs whilst on the road

 6 IDENTIFICATION 1
VEHICLE IDENTIFICATION .................................................... 135

ENGINE NUMBER ................................................................... 137

ENGINE IDENTIFICATION PLATE ......................................... 137

VOITH GEARBOX IDENTIFICATION PLATE ......................... 139

DANA FRONT AXLE IDENTIFICATION PLATE..................... 139

DTCO IDENTIFICATION PLATE............................................. 140

MASTER CARD ....................................................................... 141

Identification 133
1

134 Identification
 VEHICLE IDENTIFICATION
1
The vehicle identification plate is usually
fitted by the bodybuilder in the entrance
bay.

A Manufacturer’s name
B (Type) approval number
C Chassis number
D Commercial type indication
E Type indication
F Maximum permitted weight in the
country of acceptance (see country
code)
G Technical maximum permitted
weights (all countries)
H Engine number
ILAz0023
I Engine capacity
J Emission class
K Tyre type
6
L Construction (conversion) number
M Construction (conversion) type
N Spare
O Spare
P Spare

Identification 135
1

ILAf0015 ILAf0016

Chassis number XMG Manufacturer’s company Rear module

code The last eight digits of the VIN code (serial
Front module
The chassis number is fitted in the front D The engine is located at the number) are punched in the right-hand
module's right-hand wheel arch. The rear chassis crossbeam of the rear module for
chassis number is constructed in the benefit of official authorities.
E 4 x 2 (two axles, of which
accordance with the international V.I.N. one is driven).
standard (Vehicle Identification Number)
Example XMGDE02FS0H123456 02 Chassis type
6 F Engine: Cummins
The last eight positions of the VIN code S Turbo + intercooling
form the serial number.
Always state these last eight positions with 0H123456 Serial number
any correspondence or when ordering
components.

136 Identification
 some adjustment information are also
stated on the identification plate. 1
If the engine identification
plate is no longer readable,
then the engine’s serial
number can be read on the
engine block at the top of the
lubrication oil cooler’s hous-
ing. Additional information can
be found on the ECM identifi-
cation plate.
ILAj0527 ILAj0531

ENGINE NUMBER ENGINE IDENTIFICATION

The engine number is punched in the
engine block at the top of the lubrication oil
cooler’s housing.
PLATE
The engine’s identification plate is located
on the cylinder head cover.
Besides the engine’s specification number,
the engine type, the engine number and

Identification 137
1

ILAj0532 ILAj0529 ILAj0530

ENGINE IDENTIFICATION ECM IDENTIFICATION PLATE FUEL INJECTION PUMP

PLATE An identification plate is located on the IDENTIFICATION PLATE
The engine identification plate states engine's Electronic Control Module. The fuel injection pump identification plate
various engine details, such as: The ECM identification plate contains the is located at the top of the fuel injection
• Engine type following information: pump.
• Engine number • ECM part number (PN) The identification plate contains the
• Reference number • ECM serial number (SN) following information:
• Production date • ECM date code (DC) • Serial number
6 • Idling engine speed • Engine serial number (ESN) • Cummins component number
• Valve clearance • ECM code: indicates the serial number • Manufacturer code
• Smoke level for free acceleration of the software in the ECM. • Bosch component number
Make sure you have the • Date code
engine’s ECM number availa-
ble when contacting a VDL Bus
& Coach workshop.

138 Identification
 1

ILAc0020 ILAd0130

ILAc0019
ZF GEARBOX IDENTIFICATION DANA FRONT AXLE
VOITH GEARBOX PLATE IDENTIFICATION PLATE
IDENTIFICATION PLATE The identification plate for the ZF Ecomat The identification plate for the DANA front
gearbox is located on the right-hand side axle is located on the axle beam.
The identification plate for the Voith Diwa.5
gearbox is located at the top of the of the gearbox.
flywheel housing.

Identification 139
1

ILAd0131

ILAh0011 ILAj0519
DANA REAR AXLE
IDENTIFICATION PLATE TSU IDENTIFICATION PLATE DTCO IDENTIFICATION PLATE
The identification plate for the The TSU identification plate is located at The TSU identification plate is located at
DANA 10.24 rear axle is located on the the top of the device. the top of the device.
axle beam next to the differential housing. a. Manufacturer a. Manufacturer
b. Device type b. Device type
c. Serial number c. Serial number
d. Production date/year d. Production date/year
e. Quality marks e. Quality marks
6 f. External component number f. External component number
g. Version

140 Identification
 1

ILBz0009

MASTER CARD
Each vehicle has a master card. This card
is used to determine the components from
which the vehicle is constructed. If
alterations are made to the vehicle at a
later date, then they must be recorded on
the master card. VDL Bus & Coach must
also be informed of any alterations.The
master card is important if help is required 6
from ITS, as well as for
finding the correct component numbers
during repairs.

You must have the master card

available when contacting ITS
and when stranded.

Identification 141
1

142 Identification
 7 TECHNICAL INFORMATION
ENGINE.................................................................................... 145

WHEELS AND TYRES ............................................................ 146

LUBRICANT SPECIFICATIONS ............................................. 148

ELECTRICAL COMPONENTS ................................................ 154

LUBRICATION SCHEDULE .................................................... 155

Technical information 143

7

144 Technical information

ENGINE

Make Cummins
Type ISB6.7E.. 205B ISB6.7E.. 225B
Location Vertically behind the rear axle
Construction method 4-stroke diesel engine, direct injection, 6
cylinders in line, turbo and intercooler.
Number of valves 24
Bore x stroke 107 x 124
Volume 6.7 litres
Compression ratio 17.3 : 1
Max. power 151 KW (205 hp) at 166 KW (225 hp) at
2,300 rpm 2,300 rpm
Unloaded engine 600-800 rpm
speed
Max. unloaded engine 2,850 rpm
speed
Max. torque 750 Nm at 1,100 850 Nm at 1,100
rpm rpm
Emission Euro 5/EEV
Valve clearance Inlet Exhaust 7
Hot/cold 0.254 mm 0.508 mm

Technical information 145

 WHEELS AND TYRES Tyre pressure
The stated tyre pressures are suitable for the stated maximum
Tyres Michelin 245/70R19.5 Michelin 265/70R19.5 axle loads, provided the vehicle is used under normal conditions.
Profile XZE2 (single XDE2 (double XZE2 (single XDE2 (double In all other cases, see the tyre manufacturer’s table.
mounting) mounting) mounting) mounting)
Type TL TL Tyre and rims sizes
Ply Rating
Chassis SB180/200
Load and 136/134M- 136/134M 140/138M 140/138M
speed-index 136/135J Tyre size 245/70 R19.5 265/70 R19.5
Tyre pressure (bar) with the additionaly load (kg) each axle, measured cold Wheel size 6.75 x 19.5 6.75 x 19.5
Pressure in By single By double By single By double
mounting mounting load mounting load mounting load
bar load each each axle in kg each axle in kg each axle in kg Winter tyres
axle in kg
The maximum speed specified by the tyre manufacturer must not
4,75 2900 5490 3230 6110
be exceeded.
5 3030 5740 3380 6390 When determining the correct winter tyres, the specified load
5,25 3160 5990 3530 6660 index and speed index of the tyres must be observed.
5,5 3290 6240 3670 6940 When using winter tyres, we recommend that you observe the
5,75 3430 6480 3820 7220 guidelines, assembly instructions and tyre pressures specified by
the tyre manufacturer.
6 3560 6730 3970 7500
6,25 3690 6980 4110 7770
6,5 3820 7230 4260 8050
6,75 3950 7480 4410 8330
7 4080 7730 4550 8610
7 7,25 4220 7980 4700 8880
7,5 4350 8230 4850 9160
7,75 4480 8480 5000 9440

146 Technical information

Snow chains
As the driver of a vehicle on wintry roads, you must
observe the legal regulations, such as road traffic
sign no. 268.
This sign makes the use of snow chains
compulsory on a snowy or slippery road surface.
The chains must consist of small links and must not protrude so as
to prevent them from scratching against the wheel mounting or
other components.
It is NOT permitted to fit snow chains to the front
axle, because they may rub against the chassis.
Contact your dealer or fit winter tyres.
The maximum speed when snow chains are fitted is
50 km/h.
Do not use snow chains unnecessarily when there is no snow on
the road surface, because that will wear down the snow chains
and the tyres very quickly.
Avoid spinning the wheels. Pull away carefully and drive up hills
slowly.
If a link of the snow chain breaks, stop immediately and replace
the link or the snow chain.
Follow the instructions provided by the snow chain supplier.
Technical information
Wheels
A wheel that comes off a vehicle may result in a dan-
gerous situation, may lead to serious injury and may
damage the vehicle.
Retighten the wheel nuts after 100 km, after changing
a wheel or if the wheel nuts have become loose.
If new wheel nuts are fitted, retighten the wheel nuts
again after 500 km.
Comment
After replacing a wheel bolt, check the other wheel bolts on the
wheel hub concerned and, if necessary, replace the other wheel
bolts.
Check the wheel nut of the wheel bolt which is replaced. If in
doubt, replace the wheel nut.
Torque
The tightening torque for the wheel bolts is 480 - 560 Nm.
When replacing a wheel, the wheel bolts must be tightened to the
correct torque by a VDL Bus & Coach service dealer.
7
147
 LUBRICANT SPECIFICATIONS Safety

The fluids in the vehicle can

General information
In order to comply with the warranty terms and to guarantee the
cause serious injury and/or
serious health problems in the
durability, safety and reliability of VDL Bus & Coach products, it is
event of bodily contact.
essential that the correct lubricants, coolant and fuel are used and
that they are changed in accordance with the specified changing
Avoid bodily contact with fuel,
intervals.
Never use additives with lubricants, coolant and fuel, except in the
lubricants, coolant, battery
cases specified by VDL Bus & Coach. acid and AdBlue.
Always follow the safety instructions below and the instructions
In the event of bodily contact, always observe the following
that are supplied with the product.
instructions:
Ask your lubricant and fuel supplier(s) whether the products they
• In the event of skin contact: remove the substance with paper
supply comply with the VDL Bus & Coach specifications.
or a cloth and wash with soap and water.
In the following cases, no claims may be made against the VDL
If the irritation persists, contact a doctor.
Bus & Coach warranty:
• In the event of contact with the eyes: remove the substance
• Using oil of a lower grade than specified.
with a soft cloth and rinse with water.
• Using oil of a lower/higher viscosity than specified.
If the irritation persists, contact a doctor.
• Exceeding the changing interval.
• If swallowed: do NOT induce vomiting. Rinse the mouth, drink
• Using lubricant, fuel, AdBlue or coolant which does not meet
two glasses of water and contact a doctor.
the requirements set by VDL Bus & Coach.
• In the event of inhalation: get some fresh air and take a rest.

148 Technical information

Battery acid
In the event of skin contact: rinse the skin with plenty of water.
If redness or pain persists, contact a doctor. Remove any
contaminated clothes and rinse them with water.
In the event of contact with the eyes: wash the eyes for at least 15
minutes with plenty of water and contact a doctor.
If swallowed: do NOT induce vomiting. Rinse the mouth, drink two
glasses of water and contact a doctor.
In the event of inhalation: get some fresh air and take a rest.
AdBlue
Storage instructions
• Only use original storage tanks.
• Store in a cool, dry, ventilated area.
• Protect storage tanks against freezing.
• Observe the manufacturer’s storage and usage instructions.
Safety regulations
• Avoid bodily contact.
• In the event of skin contact: rinse with plenty of water.
• In the event of contact with the eyes: rinse with plenty of water
for at least 15 minutes and seek medical assistance.
• If swallowed: rinse your mouth with plenty of water. Do not
induce vomiting.
• In the event of inhalation: get some fresh air and take a rest.
Seek medical assistance.
• Use in a ventilated area.

Procedure after a spillage

• Rinse with plenty of water.

AdBlue is neither toxic nor harmful to the envi-

ronment.

The percentage of ureum in the ureum solution (AdBlue) must be

32.5% + 0.7% and meet DIN 70070 and ISO 22241.
Capacity of the ureum tank: + 20 litres. 7

Technical information 149

 Fuel
Diesel must comply with the EN 590 specifications.
It is not permitted to add petroleum (kerosene), petrol or other
additives to diesel.
Engines with a soot filter may only use ultra low
sulphur diesel (ULSD) with a sulphur concentration
of no more than 15 ppm. A higher sulphur content
will cause damage to the exhaust gas after-treatment
system.
Fuel sulphur content
• Max. 5,000 ppm for engines without an exhaust gas after-
treatment system.
• Max. 15 ppm for engines with a soot filter (DPF).
• Max. 50 ppm for engines with only a catalytic converter (SCR).
See the Cummins service bulletin no. 3379001-xx for the fuel
specifications for Cummins engines.
Fuel must have a lubricating quality which meets the standard
given below (lubricity standard):
Test method: HFRR in accordance with CEC-F-06-A96.
Test value: < 460 µm
Turn off the engine and the Webasto water heater
before refuelling.
7 Capacity of the fuel tank: Approx. 250 litres
150
Biodiesel
Contact your VDL Bus & Coach service dealer for
information concerning the use of alternative fuels
(e.g. biodiesel) and any consequences this may
have.
Biodiesel must comply with the EN 14214 specifications.
Contact your VDL Bus & Coach service dealer for the conditions
placed on the use of biodiesel.
Depending on its origin, biodiesel which satisfies EN 14214 may
contain chemical elements which may have a negative effect on
the exhaust gas afte treatment system.
Therefore, it is the user’s responsibility to carefully choose his
biodiesel supplier.
Comment
Biodiesel has solvent properties so that changing from diesel to
biodiesel may cause any deposits in the fuel system to become
unstuck and the filter to become blocked. When changing from
diesel to biodiesel, it is recommended to check the filters after 1 or
2 refuellings and to replace any blocked filters. Biodiesel can
cause problems at low temperatures, such as blockages to filters.
The use of biodiesel requires extra checks (see “Overview of the
monthly checks when using biodiesel”, Overview of the monthly
inspections when using biodiesel ( 100)).
Technical information
Engine

Type Cummins ISB6.7E..

Engine oil specifications ..W-40 / ACEA-E5, E7a
Volume of the lubrication oil Approx. 19.5 litres
system, including the filters and oil
cooler
Sump capacity, maximum level Approx. 17.5 litres
Sump capacity, minimum level Approx. 15 litres
a. See the Cummins service bulletin no. 3810340-xx for the oil
specifications for Cummins engines.

Technical information 151

 Cooling system

Gearbox
Coolant Texaco Havoline XLC
specifications
Type Voith Diwa.5 ZF Ecomat
Cooling/ Approx. 45 litres (depending on the vehicle type)
heating Lubricant specifications Voith H55.6336.xx ZF TE-ML 14
system Volume when changing Approx. 22 litres Approx. 18 litres
volume
Number of gears 4 6

Only top up with demineralised water.

Front axle

Type DANA NDS56LF

No other coolant, additives or antifreeze may be
added to the mixture. Grease nipples NLGI Class 2 EP grade

The anti-freeze mixture must be left in the cooling Rear axle

system during the summer months.
Type DANA 09.24
The antifreeze concentration and, as a result, the
protection against, for example, corrosion, must also Rear axle oil specifications SAE 85W-140 / API GL-5
be kept at the correct level during the summer Volume when changing Approx. 12 litres
months.

Coolant is poisonous. Protect the skin and eyes.

7
Coolant is harmful to the environment and must, the-
refore, be processed as industrial waste after use.

152 Technical information

Steering mechanism Lubricant used during manufacture

Type TRW THP 60 Component Lubricant specifications

Hydraulic oil specifications ATF Type Shell Donax TX Engine Shell Rimula super 15W40
Volume Approx. 25 litres (combined with Voith gearbox Shell Donaz TX
fan drive). ZF gearbox Shell Donaz TZ
Wheel turning angle 53º Rear axle Shell Spirax AX 85W140
Gear ratio 1:20,4 Steering mechanism ATF type Shell Donax TX
Hydraulic drive ATF type Shell Donax TX
Hydraulic drive

Fan
Hydraulic oil specifications ATF type Shell Donax TX
Volume Approx. 25 litres (combined with
steering mechanism).

Central lubrication

Front axle
Type Vogel
Grease specifications NLGI Class 2 EP grade
7

Technical information 153

 ELECTRICAL COMPONENTS
Generators

Type Alternating current

Number 2
Power 110 A
Voltage 24 V

Batteries

Number 2
Voltage 12 V
Capacity 2x 180/200/230 Ah

154 Technical information

LUBRICATION SCHEDULE

7
ILAz0076

1 Steering box

Technical information 155

 2 Central lubrication reservoir

3 Kingpins (top and bottom) Multi-purpose grease

4 Differential
Engine oil
5 Gearbox

6 Engine
Gearbox oil
7 Power steering and fan drive
reservoir
Rear axle oil

Automatic transmission oil

C = Inspection
S = Symmetrical
V = Change/replace

156 Technical information

A - Front module . . . . . . . . . . . . . . . 136
ABS description . . . . . . . . . . . . . . . . . 62
Accelerator pedal . . . . . . . . . . . . . . . . 19
AdBlue . . . . . . . . . . . . . . . . . . . . . . . 149
Additional electric/electronic equipment 9
Adjustable steering column . . . . . . . . . 19
Air conditioning speed control . . . . . . . 66
Air conditioning system . . . . . . . . . . . . 13
Air filter . . . . . . . . . . . . . . . . . . . . . . . . 98
Air leaks . . . . . . . . . . . . . . . . . . . . . . . 12
Air pressure gauges . . . . . . . . . . . . . . 30
ASR description . . . . . . . . . . . . . . . . . 63
B Fire extinguisher . . . . . . . . . . . . . . . . . . 8
Batteries . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging . . . . . . . . . . . . . . . . . . . . . 6
Battery
specifications . . . . . . . . . . . . . . . . 154
Before departing . . . . . . . . . . . . . . . . . 55
Bleeding the fuel system . . . . . . . . . . 112
Brake pedal . . . . . . . . . . . . . . . . . . . . . 19
Brake system air dryer . . . . . . . . . . . . 98
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 12
C Emergency door-operated brake release
Cabin lighting switch . . . . . . . . . . . . . . 50
Central fuse box . . . . . . . . . . . . . . . . 124
Central lubrication . . . . . . . . . . . . . . . 100
Chassis number
- Rear module . . . . . . . . . . . . . . . 136
Checking the oil level
- Rear axle differential . . . . . . . . . 109
- Voith automatic gearbox . . . . . . 108
- ZF automatic gearbox . . . . . . . . 108
Cleaning the vehicle . . . . . . . . . . . . . 102
Contact switch/engine stop . . . . . . . . . 41
Coolant level . . . . . . . . . . . . . . . . . . . . 95
Coolant temperature gauge . . . . . . . . 21
Cooling system . . . . . . . . . . . . . . . . . 152
Cruise control
operation . . . . . . . . . . . . . . . . . . . . 63
switch . . . . . . . . . . . . . . . . . . . . . . . 19
D Fluid specifications . . . . . . . . . . . . . . 148
Dipped beam/high beam/light signal . . 18
Draining the water separator . . . . . . . 113
Driver’s lighting . . . . . . . . . . . . . . . . . . 41
Driving and operation . . . . . . . . . . . . . 55
E Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ECM identification plate . . . . . . . . . . 138
Emergencies . . . . . . . . . . . . . . . . . . . . 84
50
Emergency hammers . . . . . . . . . . . . . 84
Engine compartment control panel . . . 74
Engine identification plate . . . . . . . . . 137
Engine number . . . . . . . . . . . . . . . . . 137
Engine oil level . . . . . . . . . . . . . . . . . . 94
Engine speed control . . . . . . . . . . . . . . 65
Engine start switch . . . . . . . . . . . . . . . 41
Entrance door . . . . . . . . . . . . . . . . . . . 81
Entrance door control button . . . . . . . . 49
Environment . . . . . . . . . . . . . . . . . . . . 10
Error screen . . . . . . . . . . . . . . . . . . . . . 27
Exit door . . . . . . . . . . . . . . . . . . . . . . . 82
Exit door control button . . . . . . . . . . . . 50
External mirror heating . . . . . . . . . . . . 43
F
Fan drive hydraulic oil . . . . . . . . . . . . . 97
First-aid kit . . . . . . . . . . . . . . . . . . . . . . . 8
Fog lights
- Front . . . . . . . . . . . . . . . . . . . . . . 42
Front roof hatch . . . . . . . . . . . . . . . . . . 44
Front service points . . . . . . . . . . . . . . . 91
Frontbox control . . . . . . . . . . . . . . . . . 45
Fuel gauge . . . . . . . . . . . . . . . . . . . . . 21
Fuel pump identification . . . . . . . . . . 138
G
Gearbox selection switch . . . . . . . . . . 45
General tips . . . . . . . . . . . . . . . . . . . . . 11
Generators . . . . . . . . . . . . . . . . . . . . 154
157
H Light switch . . . . . . . . . . . . . . . . . . . . . 42
Hazard warning lights . . . . . . . . . . . . . 43
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 18
I
Identification
- Dana front axle identification plate .
139
-Dana rear axle identification plate 140
-DTCO identification plate . . . . . . 140
-TSU identification plate . . . . . . . 140
-Voith gearbox identification plate 139
-ZF Ecomat gearbox identification plate
. . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Indicators . . . . . . . . . . . . . . . . . . . . . . 18
Inflating a tyre . . . . . . . . . . . . . . . . . . 117
Information screen . . . . . . . . . . . . . . . 26
Instrument panel . . . . . . . . . . . . . . . . . 20
Interior lighting . . . . . . . . . . . . . . . . . . 42
Intermittent wipe . . . . . . . . . . . . . . . . . 18
J
Jack points . . . . . . . . . . . . . . . . . . . . 118
K Replacing the poly V-belt . . . . . . . . . 111
Kick-down gear change . . . . . . . . . . . 70
L
Left-hand combination switch . . . . . . . 18
158
Lighting track with 1st fluorescent tube,
right . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Luggage . . . . . . . . . . . . . . . . . . . . . . . . 8
M Pitman arm warning light . . . . . . . . . . . 43
Main display . . . . . . . . . . . . . . . . . 21, 26
Main switch . . . . . . . . . . . . . . . . . . . . . 41
Main switch box . . . . . . . . . . . . . . . . . 123
Maintenance
- After the winter . . . . . . . . . . . . . 101
- Weekly checks . . . . . . . . . . . . . . 97
- winter . . . . . . . . . . . . . . . . . . . . . 101
-checklist . . . . . . . . . . . . . . . . . . . . 92
-Daily checks . . . . . . . . . . . . . . . . . 94
Manually activating the retarder . . . . . 68
Manually deactivating the retarder . . . 68
Master card . . . . . . . . . . . . . . . . . . . . 141
Menu switch . . . . . . . . . . . . . . . . . . . . 45
Mobile telephones . . . . . . . . . . . . . . . . . 9
O tem V-belt. . . . . . . . . . . . . . . . . . . . . . 110
Odometer/Trip meter . . . . . . . . . . . . . . 21
Operating the door-operated brake . . . 61
Operating the traffic jam brake . . . . . . 62
Original VDL Bus & Coach parts . . . . . . 9
P Reset ramp request . . . . . . . . . . . . . . . 43
Parking brake . . . . . . . . . . . . . . . . . . . 49
- releasing . . . . . . . . . . . . . . . . . . 130
Parking brake as an emergency brake 59
Parking brake/Emergency brake . . . . . 59
Parking or remaining stationary on a slip-
pery incline . . . . . . . . . . . . . . . . . . . . . 60
Pneumatic suspension, kneeling/lifting 41,
. . . . . . . . . . . . . . . . . . . . . . . . 42, 43, 46
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . 98
Rear fog lights switch . . . . . . . . . . . . . 42
Rear roof hatch . . . . . . . . . . . . . . . . . . 44
Rear service points . . . . . . . . . . . . . . . 90
Release ramp . . . . . . . . . . . . . . . . . . . 46
Replacing
light bulbs . . . . . . . . . . . . . . . . . . . 120
xenon lamps . . . . . . . . . . . . . . . . 120
Replacing fuses . . . . . . . . . . . . . . . . . 120
Replacing light bulbs . . . . . . . . . . . . . 120
Replacing the driver's air conditioning sys-
Replacing the fuel fine filter . . . . . . . . 112
Replacing the full air conditioning system
V-belt . . . . . . . . . . . . . . . . . . . . . . . . . 110
Replacing xenon light bulbs . . . . . . . 120
Reset emergency tap button . . . . . . . . 50
Resetting the emergency tap . . . . . . . 80
Retarder
operation . . . . . . . . . . . . . . . . . . . .
Rev counter . . . . . . . . . . . . . . . . . . . . .
Right-hand combination switch . . . . . .
Roof hatches . . . . . . . . . . . . . . . . . . . .
Running in . . . . . . . . . . . . . . . . . . . . . .
S Variable vehicle speed limiter (LIM) . . 64
Safety instructions . . . . . . . . . . . . . . . . . 4
Safety vest . . . . . . . . . . . . . . . . . . . . . . 8
Service brake (footbrake) . . . . . . . . . . 60
Service documentation reply form . . 161
Snow chains . . . . . . . . . . . . . . . . . . . 147
Speed limiter . . . . . . . . . . . . . . . . . . . . 69
Speedometer . . . . . . . . . . . . . . . . . . . 21
Starting help . . . . . . . . . . . . . . . . . . . 7, 9
- push start . . . . . . . . . . . . . . . . . 128
Starting procedure . . . . . . . . . . . . . . . 57
Steering mechanism . . . . . . . . . . . . . . 69
Stop signal buzzer button . . . . . . . . . . 43
Stopping vehicle . . . . . . . . . . . . . . . . . 12
Stopping/turning off the engine . . . . . . 58
Symbols on the error screen . . . . . . . . 37
Symbols on the information screen . . . 28
Symbols on the warning screen . . . . . 32
System voltage . . . . . . . . . . . . . . . . . . . 7
T Winter tyres . . . . . . . . . . . . . . . . . . . . 146
Temperature setting On/Off . . . . . . . . 52
Touch screen operation . . . . . . . . . . . 46
Towing . . . . . . . . . . . . . . . . . . . . . . . . 129
67 Transmitters . . . . . . . . . . . . . . . . . . . . . 9
21 Turning off the instrument panel . . . . . 58
19 Tyre pressure . . . . . . . . . . . . . . . . . . 146
79 Tyres and rims . . . . . . . . . . . . . . . . . . 97
11
V
Vetag stop button . . . . . . . . . . . . . . . . 50
W
Warning lights . . . . . . . . . . . . . . . . 21, 22
Warning screen . . . . . . . . . . . . . . . . . . 27
Warning symbols . . . . . . . . . . . . . . . . . . 4
Warning triangle . . . . . . . . . . . . . . . . . . 8
Warranty conditions . . . . . . . . . . . . . . 10
Webasto heating . . . . . . . . . . . . . . . . . 41
Webasto time clock . . . . . . . . . . . . 51, 52
Welding . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wheel . . . . . . . . . . . . . . . . . . . . . . . . 115
- replacing . . . . . . . . . . . . . . . . . . 115
Wheel nuts . . . . . . . . . . . . . . . . . . . . . 11
Wheelchair ramp . . . . . . . . . . . . . . . . . 83
Wheels and tyres . . . . . . . . . . . . . . . 146
Windscreen washer liquid . . . . . . . . . . 98
Windscreen washers . . . . . . . . . . . . . . 18
Winter conditions . . . . . . . . . . . . . . . . . . 8
159
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DOCUMENTATION REPLY FORM
If you have any suggestions and/or comments concerning this manual or if you find any faults, please fill out this form and send it to:
VDL Bus & Coach
Training and Documentation Company name : .....................................................................................

P.O. box 645

5550 AP Valkenswaard Name : .....................................................................................

The Netherlands
Fax: +31 (0)40 2084499 Signature : .....................................................................................

Chassis number .........................................................

Applicable
document order number: ......................................................... Version: .........................................

Driver Climate
Type of document: Maintenance Electrical diagrams
(set marker If applicable) Workshop Training
Parts Others
Kind of inaccuracy Linguistic (Definition) not correct Mistake in technical data (values) Images
(set marker If applicable)
........................................................................................................................................................
Additional information ........................................................................................................................................................
(text, page number, etc.) ........................................................................................................................................................
.......................................................................................................................................................

VDL Bus & Coach will take your report seriously and, if necessary, we directly make an update in the document.

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