DRIVER'S MANUAL SB220GS - Training Registration System

DRIVER’S MANUAL
SB220GS
Date 9702 DW 050272

2
2

TABLE OF CONTENTS
INTRODUCTION ................................... 5
SAFETY REGULATIONS ...................... 6
IMPORTANT INSTRUCTIONS .............. 8
IDENTIFICATION ................................. 11
Chassis number ................................... 11
Engine number .................................... 11
Engine identification plate .................... 11
Identity card ......................................... 12
Vehicle identification plate ................... 12
Identification plate ................................ 13
Vehicle identification number ............... 14
INSTRUMENTS AND CONTROLS ..... 16
Instrument panel .................................. 16
Display panel ........................................ 18
Switches, gauges and warning lamps on
the instrument panel ............................ 20
Warning lamps on the display panel .... 31
Left multi-function switch ..................... 35
Adjustable steering column ................. 36
DRIVING .............................................. 37
Contact switch/starter switch/steering
lock ....................................................... 37
Operating panel in engine
compartment ....................................... 38
Preglowing system ............................... 38
Start procedure .................................... 39
Driving with the ZF HP/VOITH Diwa.3
automatic gearbox ............................... 40
Door-controlled brake .......................... 42
ZF/VOITH retarder ................................ 43
Differential lock* .................................. 44
Steering ............................................... 45
Brakes ................................................. 45
Stopping .............................................. 46
E-GAS (electronic throttle control)* ...... 47
ASR ...................................................... 48
Air suspension (ECAS)* ...................... 48
Engine protection system (EPS)* ....... 49
Rear service points ............................. 50
DAILY MAINTENANCE ........................ 51
Checking the engine oil level ............... 51
Checking the coolant level ................... 51
Tyres and rims ..................................... 52
Lighting and instruments ..................... 53
Driver's seat and mirrors .................... 53
WEEKLY MAINTENANCE ................... 54
Hydraulically assisted power steering 54
Hydraulic fan drive ............................... 54
VOITH automatic gearbox ................... 54
ZF automatic gearbox .......................... 55
Batteries ............................................... 55
Moisture serparator in fuel system ...... 55
Cheching the air drier of the brake
system ................................................. 56
Draining the air reservoir ..................... 56
Windscreen washer reservoir .............. 57
Automatic chassis lubrication .............. 57
Preventive maintenance before the winter
season ................................................. 57
Windscreen washer reservoir .............. 57
Check the antifreeze content ............... 58
Diesel fuel ............................................ 58
Preventive maintenance after the winter
season ................................................. 59
Cooling system .................................... 59
Windscreen washer reservoir .............. 59
EMERGENCY REPAIRS ..................... 59
Serious oil leakage .............................. 59
VOITH automatic gearbox ................... 59
ZF automatic gearbox .......................... 60
Differential 1339 axle ........................... 60
Rear wheel hubs 1339 axle ................. 60
V-belts .................................................. 61
Adjusting the brakes ............................ 62
Renewing the fuel filter ........................ 62
Bleeding the fuel system ..................... 63
Releasing the parking brake ................ 63
Wheels ................................................. 64
Inflating the tyres ................................. 65
TABLE OF CONTENTS
3

Leakage in air suspension system ...... 65
Towing .................................................. 65
Replacing bulbs ................................... 66
Fuses ................................................... 67
TECHNICAL SPECIFICATIONS .......... 74
LUBRICANTS, COOLANT AND FUEL
SPECIFICATIONS. .............................. 78
LUBRICATION CHART ........................ 82
INDEX .................................................. 84
4
TABLE OF CONTENTS

INTRODUCTION
This instruction manual contains all the
necessary information about using your
vehicle. Read it carefully before starting out
on your first trip. A thorough knowledge of
the operating instructions will make driving
more satisfactory and usually has a
favourable influence on the vehicle’s life.
We have tried to divide this manual into
practical, orderly parts. You will find an
explanation of the vehicle’s identification
data and operating instructions. The manual
also explains how to drive most efficiently.
Furthermore, the manual deals with daily,
weekly and periodic maintenance and it
gives descriptions of minor repairs which
may be carried out by
the driver himself.
The series dealt with in the instruction
manual, consist of different types and
models. Furthermore, each vehicle is
geared to meet the legal requirements of
the country in question and to the operating
conditions which are to be expected.
Therefore, this manual may contain text and
illustrations which do not correspond exactly
to what you find in your vehicle. This does
not influence operation and maintenance.
IMPORTANT
Make sure this instruction manual is in the
vehicle at all times and read it through
carefully before making your first trip. This
is the only way to benefit fully of all the possibilities
your DAF BUS vehicle has to offer.
WARNING SYMBOL
In order to enable the driver to use the
vehicle as safely as possible, the manual
contains warnings.
Each warning is preceded by the warning
symbol illustrated on the next page.
Text which is marked by an asterisk (*) in
this instruction book indicates an optional
extra.
Note:
This instruction manual is based on the
chassis and fittings as delivered by the DAF
BUS factory.
Depending on the desired superstructure
and fittings, the chassis builder may make
fundamental changes to e.g. the instrument
panel, lighting and electric wiring.
SAFETY INSTRUCTIONS
5

SAFETY REGULATIONS
Information preceded by the warning symbol
depicted above, is of great importance to
your health and safety.
Neglecting this information may result in
serious injury or possible death.
The following safety regulations should
be strictly adhered to in order to prevent
damage to the vehicle and not endanger
your own or other persons’ health and/
or safety.
WARNINGS AND SAFETY
REGULATIONS
Follow all warnings and safety regulations
which are contained in this manual.
Always read the instructions and
warnings mentioned on the labels and
stickers which you find on the various
components and make sure you follow
them! These instructions and warnings
have been put there for your own safety
and health, so do not neglect them!
ENGINE
Do not keep the engine running in a
closed, non-ventilated area.
COMPONENTS
Keep a safe distance from rotating and/
or moving components.
FILLER CAP COOLING SYSTEM
Do not remove the cooling system’s filler
cap when the engine has reached operating
temperature.
FIRE EXTINGUISHER
Make sure you always have a fire
extinguisher with you (obligatory in some
countries). The fire extinguisher should be
mounted correctly under the seat, within
reach of the driver and also within reach of
possible assistants. Have the fire extinguisher
tested each year. When you have
used the extinguisher, get it filled as soon
as possible.
FIRST AID KIT
Make sure you always have an adequate
first aid kit with you (obligatory in some
countries). Replace items which were used
with new ones as soon as possible.
6
SAFETY REGULATIONS

COLD-WEATHER CONDITIONS
Mount winter tyres or make sure you have
tyre chains with you when cold-weather
conditions (e.g., mountains), are to be expected.
(See also maintenance activities
before and after winter season).
OILS AND LUBRICANTS
When touched, several kinds of oils and
lubricants which are used may be harmful
to your health. This is also the case with
coolant, the cooling product R134a in the
air conditioning, battery acid, LPG and diesel
oil.
Therefore, avoid physical contact with these
substances.
MAINTENANCE ACTIVITIES
Always use blocks when working under a
vehicle which has been jacked-up.
- Always wear clean and well-fitting
clothes. When needed, apply protective
cream to your skin.
- Avoid inhaling dust from the brakes. Do
not touch these components unless you
are in a well-ventilated area with adequate
dust extraction.
In order to reduce fire risk, the engine and
its environment should be free of hot oil,
which may cause serious physical injury.
SAFETY REGULATIONS
7

IMPORTANT INSTRUCTIONS
In order to avoid damage to the vehicle,
follow the instructions mentioned
beneath.
RUNNING IN
During running in, do not overload the new
vehicle.
This also applies if a reconditioned motor,
gearbox or differential have been installed.
The following applies to the first 3000 km:
- Do not drive with full load
At cold start use a low gear and moderate
rotational speed until the coolant has
reached about 50°C.
While driving, check the instrument panel
regularly and act upon possible irregularities.
Do not let the engine idle unnecessarily.
This is harmful to the engine and also
causes unnecessary pollution of the environment.
Keep in mind that engine stalling while
driving influences servo steering. Steering
will require more strength.
Let the engine idle for a while before turning
if off after a long trip or high performance.
The engine cooling system is thermostatically
controlled. Therefore, never use a
muff on the radiator in cold weather.
When the coolant temperature is (too) high,
removing the thermostat will only cause
the engine temperature to rise to an even
higher level.
The turbocharger is a precision instrument.
Therefore, all abnormal noise that seems
to be coming from the turbocharger should
be reported immediately.
AIR LEAKAGE
If the pressure in the air reservoirs drops
rapidly, this indicates a leak. Since this
affects the safety of the brake system, the
leak should be traced and repaired as
quickly as possible.
VOLTAGE
The vehicle is equipped with a 24 Volts
electrical system.
When replacing or installing electric/
electronic components, check if these are
suited for this voltage.
BATTERIES
Never disconnect the battery
pole clamps while the engine
is running.
When charging the batteries, make sure you
are in a well-ventilated area and avoid
sparking or open fire. Do not use a battery
quick-charger unless absolutely necessary;
for this involves disconnection of the battery
cables.
8
IMPORTANT INSTRUCTIONS

Always disconnect the battery earth cable
when working on the electrics.
Never put tools on a battery. This may cause
short circuiting and may in the worst case
cause the battery to explode.
CHARGING
Always let frozen batteries thaw
before charging.
Remove all battery plugs before
charging.
First connect the battery charger’s + clamp
to the battery’s + pole and then connect the
- clamp to the - pole.
After charging, shut the battery charger off,
then first disconnect the - clamp before
disconnecting the + clamp.
During “normal charging”, the battery cables
do not have to be disconnected.
During “quick-charging”, both battery cables
must be disconnected.
WELDING
No welding is to be carried out on the chassis.
When welding, the battery cables must
first be disconnected. Disconnect all electric
connections between the Central E-panel
and the chassis and disconnect all
connections of the electronic units.
Make sure that the welder’s earth clamp is
set as closely as possible to the area on
the vehicle where the welding is to be
carried out and that contact is made with
the part to be welded. Do not attach the
earth clamp to springs or axles. Avoid
welding spatter on pneumatic wires, springs,
etc.
STARTING
Starting the vehicle using separate booster
batteries (about 24 Volts) or with the help of
another vehicle’s running engine (about 28
Volts) is permitted (the use of emergency
starting apparatus is not permitted). The
battery cables should not be disconnected.
If possible, place a peak-voltage cut-out
between the battery poles. First connect the
+ clamp, then the - clamp with the jumper
cables.
When ready, first disconnect the - clamp,
then the + clamp.
If the batteries are completely empty and
the engine to be started is running:
- Turn on as many power consumers as
possible.
- Then disconnect the jumper cables.
- Turn the power consumers off.
ENVIRONMENTAL CONCERNS
Pollution constitutes a serious threat to the
environment. In order to minimise pollution,
we recommend the following rules.
- Do not throw away used oil, hydraulic oil
or coolant in the drainage system,
sewers or just on the ground. This is also
illegal. These substances should be sent
back to the designated agency to be reused
or disposed of.
- Make sure the vehicle is regularly checked-up.
A well-maintained vehicle
contributes to maximum fuel economy
and a reduction in polluting emission
gases.
IMPORTANT INSTRUCTIONS
9

CLEANING
Cleaning the vehicle.
When using a high-pressure cleaning device
is used, note the following:
- Make sure all doors, windows and roof
hatchets are closed.
- Do not aim directly at the seals. They
may be blown open, causing the
lubricant behind them to be washed
away. This may happen to the swivel joint
of the steering house, for instance.
The swivel joint’s cross piece will then
get stuck, which results in “sticky” steering.
- Water may enter the steering oil reservoir
through the bleeder.
This damages the steering gear.
- When cleaning the radiator/intercooler,
make sure that the fins are not
damaged.
- Do not aim the beam at the air
conditioning system’s condenser for a
prolonged period of time. The rise in
temperature will cause the pressure in
the system to become too high. This has
a damaging effect.
- Make sure no water enters the
differential and gearbox through the
bleeders.
- Make sure no water enters the clutch,
brakes, etc. through the reservoir bleeder.
- The engine and engine compartment
may be cleaned with a high-pressure
cleaning device. Do not aim directly at
electric components such as starter
motor, alternator, etc.
- Carefully clean the engine encapsulation
and encapsulation parts. Make sure that
spoilt oil is removed (fire hazard).
- Do not aim the high-pressure cleaning
device’s beam at electric connections
like connectors, lighting wires, etc.
- Make sure no water enters the air inlet
system through the air inlet or its flexible
seals.
- Make sure no water enters via the oil
dipstick.
- After cleaning, the vehicle has to be
lubricated by means of a grease gun or
by means of the central lubrication
system. This helps to keep moisture and
dirt from entering the various pivots.
Note
Before cleaning the vehicle, check if there
are any leakages in the engine, axles,
gearbox, etc. It is not possible to do this after
cleaning the vehicle, during maintenance
activities.
10
IMPORTANT INSTRUCTIONS

-R05926-
01490B
01491B
IDENTIFICATION
CHASSIS NUMBER
The chassis number is stamped on the righthand
side member between the front axle
casing and the rear bracket of the front
spring.
The chassis number is stamped on the rear
crossbeam on the low-floor (LF) model.
ENGINE NUMBER
GS:
The engine number is stamped underneath
the engine on the distribution side of the
engine block.
ENGINE IDENTIFICATION PLATE
The engine identification plate is mounted
on the right-hand valve cover.
This plate also shows, besides the engine
specification number, the engine type and
engine number, as well as the adjustment
data.
IDENTIFICATION
11

IDENTITY CARD
Each vehicle has its own identity card which
can be used to identify the exact component
parts used in the construction of the
vehicle. Any subsequent modifications to the
vehicle should therefore be recorded on the
identity card.
The modifications should also be reported
to DAF BUS INTERNATIONAL.
It is important to have the identity card
available when calling ITS for assistance,
but also for finding the correct part numbers
in case of repairs.
VEHICLE IDENTIFICATION PLATE
The vehicle identification plate is fitted in the
first doorway by the body builder. This
identification plate is illustrated on the next
page together with an explanation of the
vehicle identification number as required by
law in all member states of the E.E.C. as of
October, 1982.
12
IDENTIFICATION

IDENTIFICATION PLATE
1. Gross combination weight (GCW)
2. Gross vehicle weight (GVW)
3. National approval number
4. Vehicle identification number
5. E.C. approval number
6. Technical gross vehicle weight (GVW)
7. Technical gross combination weight
(GCW)
8. Max. technically permissible weight on
fifth wheel
9. Max. technically permissible road weight
for each axle (listed from front to rear)
10. Max. legally permitted road weight for
each axle (listed from front to rear)
11. Max. legally permitted weight on fifth
wheel
Numbers 1-7-8-11 are normally not
applicable to buses. These will therefore not
be filled in.
IDENTIFICATION
13

VEHICLE IDENTIFICATION NUMBER
The Netherlands
-
X
M G D E 33 W S 0H000001
Chassis serial number
DAF BUS INTERNATIONAL
Overige voertuigen
B. TB bus (front engine)
C. MB bus (mid engine)
D. SB bus (rear engine)
02 MB 230, SB(G)220/225
SB 250, DB 250
03 SB 2300/2700
33 SB 3000/3015
23 TB 2175/SB 2750
21 SB 2100
40 SB(R) 4000
Engine
A Tuned inlet system
B Downrated and turbocharged
C Turbocharged
D Downrated and naturally
aspirated
S Turbocharged + intercooler
T Turbocharged
X Extra
G LPG
E 4 x 2
R 6 x 2 single
assembly on
trailing axle
A 6 x 2 MBG
P 6 x 2 SBG
Engine family
B 2,5 litre
C 5,85 litre
N 6,20 litre
H 8,25 litre
K 11,60 litre
L 11,60 litre (horizontal)
W 11,60 litre (cross-flow)
R 8,65 litre
G 8,65 litre (horizontal)
14
IDENTIFICATION

IDENTIFICATION
15

INSTRUMENTS AND CONTROLS
INSTRUMENT PANEL
16
INSTRUMENTS AND CONTROLS

The dashboard may differ in each vehicle.
1. Vehicle lighting switch
2. Dimmer switch
3. Front fog lights switch
4. Master switch instrument lamp
5. Retarder OFF warning lamp
6. Preglow warning lamp
7. Dipped beam warning lamp
8. Indicator warning lamp
9. Trailer’s indicator warning lamp
10. Main beam warning lamp
11. Yellow warning lamp (IWS)*
12 Red warning lamp (SWS)
13. Parking brake warning lamp
14. Door-controlled brake warning lamp*
15. Retarder in operation warning lamp
16. Vehicle not on driving level warning
lamp
17. ASR/Wabco speed limiter warning
lamp*
18. Central lubrication warning lamp
19. Rear fog light warning lamp
20. Starting switch*
21. Hazard warning lights switch
22. Cold start switch*
23. Preglow switch
24. Rear fog lights switch
25. Fuel gauge
26. Voltmeter/Retarder oil temperature
gauge
27. Air pressure gauge
28. Coolant temperature gauge
29. Rev. counter
30. Tachograph
31. Contact/engine stop switch*
32. Master switch operation switch
INSTRUMENTS AND CONTROLS
17

DISPLAY PANEL
18
INSTRUMENTS AND CONTROLS

33. Raise/lower vehicle switch*
34. Retarder on/off switch
35. ECAS driving level switch*
36. Reserve
37. Manually operated vehicle lowering
switch (ECAS 2)*
38. Differential lock switch*
39. Extra vehicle reverse operation switch*
40. Cigar lighter/inspection light
41. Central safety switch*
Display panel
Depending on the systems mounted on the
vehicle, the relevant lamps will light up in
the event of a fault.
Red warning lamps
A1 spare
A2 oil temperature retarder too high*
A3 engine compartment temperature too
high
A4 brake fluid level too low*
A5 engine oil level too low
A6 spare
B1 fault in gearbox (DIWA.3)
B2 fault in ABS*
B3 brake pressure too low
B4 battery charge warning lamp
B5 oil pressure too low
B6 gearbox oil level too low*
C1 fault in E-GAS*
C2 fault in steered trailing axle
C3 coolant temperature too high/level too
low
C4 generator voltage too high*
C5 steering pump oil level too low*
C6 fault in ECAS*
D5 engine compartment fan off*
Orange warning lamps
D1 brake lining worn down*
D2 door or hatch open
D3 fault in steering circuit 1*
D4 fault in steering circuit 2*
D5 (see red warning lamps)
D6 spare
E1 emergency door not locked
E2 limited speed exceeded*
E3 air filter clogged
E4 fuel down to minimum*
E5 fault in central timer*
E6 fault in central lubrication*
INSTRUMENTS AND CONTROLS
19

SWITCHES, GAUGES AND WARNING
LAMPS ON THE INSTRUMENT PANEL
1. LIGHT SWITCH
The vehicle lighting switch is a rotary type
switch with three positions:
- Position 0: vehicle lighting switched off.
- Position I: parking lamps and end/
outline marker lamps.
- Positin II: headlights, parking lamps
and end/outline marker
lamps.
When the vehicle lighting switch is in position
I or II, the warning lamps in the various
switches light up at half strength for easy
identification and location of the switches.
2. DIMMER SWITCH
When the vehicle lighting switch is in position
I or II, the instrument lighting also glows.
The intensity of this lighting can be adjusted
with this switch.
3. FRONT FOG SWITCH
The front fog lights can be switched on using
this switch when the vehicle lighting switch
is in position I or II. The warning lamp in the
switch lights up when the fog lights are
switched on.
Note:
The legal regulations for the use of fog lights
differ from country to country.
4. MASTER SWITCH INSTRUMENT
LAMP
This lamp lights up as soon as the master
switch is operated.
When the engine is running, this lamp
extinguishes again.
5. RETARDER OFF INSTRUMENT
LAMP
This lamp lights up as soon as the retarder
switch is switched in the off position.
6. PREGLOWING WARNING LAMP
This warning lamp lights up during the
glowing procedure. Also see the “DRIVING”
section of this handbook.
7. DIPPED BEAM WARNING LAMP
This lamp lights up when the headlight
dipped beams are switched on.
8. DIRECTION INDICATOR WARNING
LAMP
This lamp flashes together with the direction
indicators on the vehicle.
The light will flash approximately twice as
fast if one of the indicators does not work.
9. TRAILER’S DIRECTION
INDICATOR WARNING LAMP
This lamp flashes together with the direction
indicators on the vehicle (depending on the
constructor).
The light will flash approximately twice as
fast if one of the indicators does not work.
10. MAIN BEAM WARNING LAMP
This warning lamp lights up when the
headlamps are on main beam and when
the headlamps flash is operated.
20
INSTRUMENTS AND CONTROLS

11. YELLOW CENTRAL WARNING
LAMP*
The yellow central warning lamp works in
the same way as the red central warning
lamp. Direct action does not have to be
undertaken because the malfunction is less
serious. The
problem can again be seen on the display
panel (e.g. critical fuel level) and appropriate
action can be taken in time.
12. RED CENTRAL WARNING LAMP
This warning lamp lights up when the ignition
is turned on and the engine does not run.
The lamp must go out when the engine
starts.
The red central warning lamp lights up when
an important malfunction occurs in a vehicle
system. The information panel shows which
vehicle function has activated the warning.
In the event of too high coolant water
temperature, a high engine compartment
temperature, a low oil pressure, or a low
pressure in the pneumatic system, a buzzer
will also sound.
Stop without delay and switch off the engine
immediately when the red central warning
lamp lights up, unless otherwise stated.
13. PARKING BRAKE WARNING
LAMP
The warning lamp lights up when the parking
brake is activated or if the air pressure
in the parking brake circuit is too low to
release the parking brake. The warning light
remains lit until there is sufficient pressure.
Warning:
Never drive whilst the warning lamp is lit.
Stop immediately if the warning lamp comes
on whilst driving.
The parking brake may be used as an
emergency brake when there is a fault
with the foot brake system.
14. DOOR-CONTROLLED BRAKE
WARNING LAMP*
This lamp comes on when the doorcontrolled
brake is actuated.
15. RETARDER WARNING LAMP
This lamp lights up when the retarder is in
operation.
16. WARNING LAMP VEHICLE NOT
ON DRIVING LEVEL
The warning lamp lights up for a few
seconds when the ignition is switched on,
just as a routine check on the operation.
If the warning lamp starts to flash (whilst
driving), the air pressure for the electronic
chassis height adjustment is too low. Stop,
run the engine until the maximum system
pressure is reached, then turn the engine
and ignition off. Wait for five seconds before
switching on the ignition and starting the
engine.
If the warning lamp does not go out, the
vehicle should be driven to the nearest DAF
BUS dealer at a speed no greater than 15
km/h.
IF THE WARNING LAMP REMAINS LIT
(WHILST DRIVING), THE CHASSIS IS NOT
AT THE CORRECT DRIVING LEVEL. USE
THE SWITCH (35) TO BRING THE
VEHICLE TO THE CORRECT DRIVING
LEVEL.
INSTRUMENTS AND CONTROLS
21

17. ASR WARNING LAMP*
The anti-spin regulator (ASR) prevents the
wheels from spinning when pulling away and
on slippery road surfaces. When the wheels
spin, the driven wheels are slowed down
and/or the fuel supply is reduced depending
on the driving situation. ASR is a fully
automatic system integrated with the ABS
system and engine control unit. There is no
actuator or interrupter for the ASR system.
The instrument panel contains an ASR lamp
to check the ASR installation.
This lamp will light up when:
- Contact is switched on. If the installation
functions correctly, the lamp should go
off.
The lamp remains “off”, even if the
vehicle is stopped with the engine
running. The lamp will only come on
again and the switched on if contact is
switched off for at least 20 seconds.
- The ASR installation is started.
- Max. speed is exceeded (Wabco speed
limiter) or if there is a malfunction present
in the speed limiter system.
- ASR defect:
The ASR installation is defective when
the red warning lamp lights up while
vehicle speed is over 7 km/h and the
ASR installation is not working. In this
case, the fuses in the Central E-panel
should be checked.
If the defect cannot be resolved by
changing a fuse, you
can still drive on.
Have the defect repaired at a DAF BUS
Dealer.
18. CENTRAL LUBRICATION
WARNING LAMP
This lamp will light up when the central
lubrication system is started. In case of a
fault in the central lubrication system, the
lamp will remain on.
19. REAR FOG LIGHT WARNING
LAMP
This lamp will light up when the rear fog
lights are switched on.
20. START SWITCH*
The engine can be started using this switch.
Also see "DRIVING”.
21. HAZARD WARNING LIGHTS SWITCH
Pushing in this switch causes all the
direction indicators to flash simultaneously.
The hazard warning lights are switched off
by pushing in the switch again. The warning
lamp in the switch indicates that the hazard
warning lights are in operation.
23. PREGLOW SWITCH
With the contact switched on, this switch
will operate the preheating system. Also see
“DRIVING”.
24. REAR FOG LIGHT SWITCH
The rear fog lights can be switched on using
this switch when the vehicle lighting switch
is in position II or when the front fog lights
are already switched on.
The warning lamp in the switch and the
warning lamp (19) light up when the fog
lights are switched on.
Note:
The legal regulations for the use of fog lights
differ from country to country.
25. FUEL GAUGE
The fuel gauge only operates when the contact
is on.
22
INSTRUMENTS AND CONTROLS

26. VOLT METER/RETARDER
TEMPERATURE GAUGE
Depending on the type of vehicle, a volt
meter or a temperature gauge for the retarder
can be put here.
VOLT METER (BATTERY CONDITION
METER)
With the engine stationary, the battery voltage
should be approx. 24 V. When the
engine is running, the volt meter pointer
should be between 24 V and 29.5 V.
If the voltage is lower than 24 V, the batteries
will not be charged sufficiently and this
problem must be remedied during the next
service inspection. If the voltage rises above
approx. 29.5 V, immediately switch on as
many power consumers as possible and
drive to the nearest repair shop.
RETARDER TEMPERATURE GAUGE
The oil temperature must be in the green
zone (80 to 110°C). If the temperature
gauge indicates a temperature of more than
150°C when the retarder is in use (retarder
warning lamp (A2) will also flash), the retarder
must be switched off. Also see
“DRIVING”.
If the oil temperature remains too high,
proceed as follows:
- Stop the vehicle
- Put the selector switch into neutral
- Allow the engine to run with a slightly
increased stationary speed. If, after a
few seconds, the temperature is still not
in the acceptable area, check the oil level
and the cooling system for faults.
27. AIR PRESSURE GAUGE
Each pointer indicates the pressure in the
reservoir of the service brake circuits (circuit
1 and 2). If the pressure in one of the
circuits drops below 5 bar, a buzzer goes
off and bulb B3 of the information panel will
light up. To release the parking brake; circuit
3 (parking brake) shall only begin to fill
when circuits 1 and 2 are completely filled
(6.5 bar). The parking brake can only be
released once circuit 3 is completely filled.
The warning lamp (13) will then be extinguished.
The buzzer only works with the
contact switched on; the pressure gauge
works at all times.
It is not permitted to drive the vehicle if the
pressure in one of the circuits is below 6,5
bar.
28. COOLANT TEMPERATURE GAUGE
The coolant operating temperature should
be between 75°C and 93°C (black zone).
Never run the engine at full load when the
coolant temperature is below 50°C (orange
zone). If a sudden rise in coolant temperature
is observed and/or the gauge reading
enters the red zone, then the following
should be checked:
- The coolant level; unscrew the filler cap
with caution!
- The V-belts and water hoses.
- The hydraulic operation of the engine
cooling fan.
INSTRUMENTS AND CONTROLS
23

3
00800B
29. REV-COUNTER
Shaded green (*): very economical
Green:
economical
Yellow:
less economical
Shaded red: only permitted when
going downhill; use
exhaust brake
Red:
To be avoided
(*) Only for unladen vehicle.
30. TACHOGRAPH (COMPACT) (FOR
TWO DRIVERS)
Inserting tachograph discs
- Open the tachograph when the vehicle
is stationary, using the key.
- Lift the centre plate (3).
- Insert the co-driver’s disc with the green
side facing upwards.
- Lower the centre plate (3) and push it
home.
- Insert the driver’s disc with the green
side facing upwards and place it on top
of the centre plate.
- Close the tachograph and remove the
key.
Note
In this type of tachograph, there must
always be two discs present, even when
there is only one driver. A blank or blind disc
can be placed under the centre plate.
This can be used for an unlimited period.
Driver and co-driver have their own disc.
24
INSTRUMENTS AND CONTROLS

The tachograph disc has a maximum
registration time of one day (24 hours). It is
therefore necessary to replace the tachograph
disc (discs) with a new disc at least
every 24 hours.
The tachograph disc
The front of the tachograph disc is green
and the rear can either be red or blue.
The red rear side is used for manual time
group entries. The blue rear side is intended
for vehicles with an (extra) engine speed
(rpm) recording.
The following information is automatically
registered on the green front side of the
tachograph disc:
- Time scale (K).
- Speed in km/h (J).
- Time groups (L).
Driving time (small bar).
All other working times.
All other periods of time whilst pre
sent at the place of work.
Breaks and rest periods.
- Distance covered (M).
Completion of the middle part of the front
of the tachograph disc
Before inserting the disc:
19
No.
Name of driver/co-driver
Place where working time commenced
Date of commencement of working
time (top line)
Registration mark of vehicle
Odometer reading at start of working
time
INSTRUMENTS AND CONTROLS
25

Completion of the middle part of the
rear and of the tachograph disc
Here a maximum of three vehicle switches
can be recorded:
No.
k m
Time of switching
vehicles
Registration mark of new vehicle
Odometer reading at start
Odometer reading at end
Total number of kilometres driven
40
20
20
10
30
60
40
80
50
60
70
80
mph
v min 25 km /h
v max125 km/h
100
120
125 km/h
2
2 km 1
1
00797B
After removing the disc:
Place where working time ended
Date end of working time (bottom
19
line)
Odometer read. at end of working
time
k m Total number of kilometres driven
Completion of the outer edge of the rear
of the disc
This part of the disc can be used to fill in
the time groups by hand if necessary. This
may be the case if the driver/co-driver is
working away from the vehicle or if the
tachograph breaks down. In these cases a
line must always be drawn after the symbol.
Operating the time group recorder
The time group switches 1 (driver) and 2
(co-driver) operate the time groups recorder.
The following groups can be switched on.
Driving times
all other duties
Waiting time
Daily rest period
26
INSTRUMENTS AND CONTROLS

mph
v min 25 km /h
v max125 km/h
125 km/h
Operation with two drivers
- The drivers and the co-driver must first
fill in the tachograph disc’s centre field.
- Using the key, open the tachograph
whilst the vehicle is stationary and tilt
the separation plate (12) upwards.
- Check the time on the tachograph’s clock
and adjust if necessary using the
adjusting knob (9). The correct time on
the tachograph can be checked at the
red mark (10).
- The co-driver’s tachograph disc (13) is
first placed into the tachograph under
the upwardly tilting separation plate (12)
with the green side facing upwards.
Lower the separation plate (12) and
press it down firmly until locked.
- Next, place the driver’s tachograph disc
(14), also with the green side facing
upwards, onto the tachograph’s
separation plate (12).
- Close the tachograph using the key.
- The driver puts the time groups switch
(1) into the “Driving time and all other
work activities” position.
- The co-driver puts the time groups
switch (2) into the “waiting times” or “daily
rest times” position.
12
13
9
Operation with one driver
Operation with one driver is different to the
operation with two drivers.
- Using the key, open the tachograph
whilst the vehicle is stationary and tilt
the separation plate (12) upwards.
- Check the time on the tachograph’s clock
and adjust if necessary using the
adjusting knob (9). The correct time on
the tachograph can be checked at the
red mark (10).
- Now place a blank tachograph disc, or
a so-called “dummy” disc, into the
tachograph. The special “dummy” can be
2
10
40
20
20
10
30
60
40
2 km 1
0 0 001 6 5
80
50
60
70
80
100
120
1
14
01510B
reused indefinitely.
- Lower the separation plate (12) and
press it down firmly until locked.
- Next, place the driver’s completed
tachograph disc, with the green side
facing upwards, onto the tachograph’s
separation plate (12).
- Close the tachograph using the key.
- The driver places the time groups switch
(1) into the correct position (see time
groups recorder).
Operation whilst changing driver/codriver
- Co-driver becomes driver and vice
versa. The two tachograph discs in the
tachograph must be swapped over. The
new driver should now operate the time
groups switch (1) and the new co-driver
should operate the time groups switch
(2).
- The driver or co-driver leaves the vehicle
and is relieved.
The person who leaves the vehicle takes
his tachograph disc with him and completes
it. The new driver or co-driver places his
INSTRUMENTS AND CONTROLS
27

completed tachograph disc in the tachograph
as described in the operation for two
drivers.
- Driver and co-driver leave the vehicle.
Both take their tachograph discs with
them and complete them as necessary.
The new drivers place their tachograph
discs in the tachograph as required.
Warning lamps
Warning lamp (2) comes on when the
tachograph is not ready for use, i.e.:
- tachograph discs not inserted;
- cover not properly closed;
- the time groups switch is not switched
to rest time for the 1+2 driver tachograph
model without co-driver
- recording pen faulty.
Warning lamp (2) flashes if the working time
is not being recorded correctly.
Warning lamp (3) comes on if a certain
speed is exceeded. This speed can be set
with screw (4). The value set is shown in
display (5).
1
40
20
20
10
30
60
Setting the time
Adjust the timepiece with the knob (9); note
the difference between for instance 06.00
hrs and 18.00 hrs. The line on the second
disc (1) shows whether the clock is working.
The exact time on the tachograph disc can
be checked at the red point (10).
40
80
50
60
70
100
120
80
mph 125 km/h
v min 25 km /h
v max125 km/h
2 3
2 km 1
0 0 001 6 5
00796B
4
5
6
9
11
10
0367793
OI
V D O Kleinste GmbH D-78052
Typ 1318 . 27
No. 2277471
Setting the warning device for the vehicle
speed/engine speed
- The vehicle speed warning value is set
by turning the adjustment screw (4) to
the left or to the right.
The window (5) shows the new warning
value. The minimum value obtainable: 40
% of the full scale value.
- When the vehicle speed warning value
is exceeded, the vehicle speed warning
lamp (3) lights up.
- The engine speed warning value is set
by turning the adjustment screw (8) to
the left or to the right. The window (7)
shows the new warning value.
jahr E97
Villingen
00218B
6
7
8
28
INSTRUMENTS AND CONTROLS

The minimum value obtainable: 25% of
the full scale value.
- Exceeding the engine speed warning
value can only be observed optically or
audibly.
In the case of faults in the input signal line,
the speedometer will sweep over every 8
seconds. This will also be recorded on the
disc.
Self-test
The electronic circuits in the tachograph
continuously check the equipment for:
- interruption of the power supply
- faults in the input signal from the
gearbox.
The tachograph will not work without power
supply.
When the voltage returns, the speedometer
will briefly sweep over to max. and a line will
be drawn on the disc. If the cover has been
opened while the power supply was
interrupted, the following must be carried
out:
- set the time
- insert the tachograph discs
- close the cover
- briefly move the vehicle
The speedometer should now return to zero.
INSTRUMENTS AND CONTROLS
29

31. CONTACT/ENGINE STOP
SWITCH*
The vehicle’s contact is turned on using this
switch. If the engine is running, it can be
turned off using this switch.
32. MASTER SWITCH OPERATION
When the master switch is turned off, the
electrical system is de-energized with the
exception of the hazard warning lights and
the tachograph.
33. RAISE/LOWER VEHICLE SWITCH*
The vehicle can be raised or lowered whilst
this switch is depressed.
The vehicle will be raised by depressing the
top part of the switch. This position is used
when a large ground clearance is
temporarily required, as for example when
driving onto a ferry boat.
The vehicle will be lowered by depressing
the bottom part of the switch (up to the rubber
axle bumper).
The height adjustment may only be used
temporarily.
The vehicle will automatically return to the
driving level at a speed greater than
15 km/h. Also see “DRIVING”.
Note that the vehicle may be raised or
lowered without the risk of trapping somebody
between the vehicle and the edge of
the pavement.
Clamping risk
The ECAS system only operates whilst the
engine is running. If the engine is switched
off whilst the vehicle is in a raised position,
the vehicle will return to the neutral position
when the engine is restarted.
Note
Depending on the constructor, there could
possibly be a kerb sensor which will stop
the lowering when an obstacle is detected.
34. RETARDER ON/OFF SWITCH
The retarder can be switched on or off using
this switch.
35. ECAS DRIVING LEVEL SWITCH*
This switch can be used to bring the vehicle
back to its normal driving level after it has
been raised, lowered or knelt.
Also see “DRIVING”.
37. MANUALLY OPERATED VEHICLE
KNEELING SWITCH (ECAS 2)*
This switch can be used to allow the vehicle
to be knelt at the front whilst stationary.
Whilst the switch is depressed, the vehicle
will kneel at a certain set height.
Depending on the design of the vehicle, the
following will occur if the switch is released
before the kneeling height is reached.
- the kneeling is stopped;
- the kneeling is interrupted and the chassis
returns to the DRIVING LEVEL.
The vehicle can only be returned to the
“NORMAL DRIVING LEVEL” after kneeling,
or when the kneeling is stopped, using the
switch (35).
Note
Kneeling is not possible with insufficient air
pressure.
Attention
Kneeling the vehicle reduces the ground
clearance.
30
INSTRUMENTS AND CONTROLS

38. DIFFERENTIAL LOCK SWITCH*
The rear axle’s differential lock is switched
on and off using this switch. Also see
“DRIVING”.
The warning lamp is lit when the differential
lock is switched on.
39. EXTRA VEHICLE REVERSE
CONTROL SWITCH
This switch must be operated
simultaneously with the preselector switch
“R” in order to engage reverse gear.
40. CIGAR LIGHTER/INSPECTION LAMP
SOCKET
- Push in the cigar lighter and wait: it will
spring back automatically when ready
for use.
- Withdraw the lighter from the socket.
When the vehicle lighting is switched on,
the cigar lighter is also illuminated.
The cigar lighter socket can also be used to
connect up an inspection lamp.
41. CENTRAL SAFETY SWITCH*
When the central safety switch is pushed
in:
- the engine is automatically switched off,
- the delivery of fuel is shut off by
interrupting the electric circuit,
- the hazard warning lights start to flash
and the electrical system is de-energized
with the exception of the tachograph.
WARNING LAMPS ON THE DISPLAY
PANEL
The function of various lights on the display
panel are explained below.
RETARDER TEMPERATURE WARNING
LAMP (A2)*
This lamp flashes when the retarder’s oil
temperature goes above 150°C. If this happens,
turn off the retarder. Also see
“DRIVING”.
ENGINE COMPARTMENT
TEMPERATURE WARNING LIGHT (A3)
If the temperature in the engine com-partment
reaches higher than 110°C then this
lamp will be lit continuously. A buzzer will
also sound whilst the lamp is lit.
- If the warning lamp remains lit, the
buzzer sounds and the cooling water
gives an indication of cooling difficulties,
then;
Stop the vehicle, allow the engine to idle
for a couple of minutes and then turn
the engine off.
- If the warning lamp is lit without further
indication of cooling difficulties;
INSTRUMENTS AND CONTROLS
31

Fire risk !!
Stop the vehicle and stop the power
using the main switch. In the case of
danger, bring the passengers to safety.
ENGINE OIL LEVEL WARNING LAMP (A5)
This warning lamp lights up when the
ignition is switched on and the engine does
not run. The lamp must go out when the
engine starts.
If the lamp does not go out after starting
the engine, or comes on whilst driving, then
the vehicle must be stopped as quickly as
possible and the engine turned off.
Check the engine’s oil level and check
whether there are any leakages visible on
the engine. If necessary, top up with oil. Also
see “DRIVING”.
Check whether the lamp goes out after topping
up.
GEARBOX WARNING LIGHT (B1)
This lamp flashes, together with the DNR
switch, when there is a serious fault with
the DIWA 3 gearbox.
The vehicle must be brought to an
immediate stop and must not be driven any
further so as to prevent causing any serious
damage.
WARNING LAMP ABS (B2)*
This lamp lights up if:
- the contact is turned on. A correctly
functioning installation should turn off the
light at approx. 7 km/h.
* The lamp will then remain “off”, even if
the vehicle is stopped while the engine
is still running. Only if the contact is
turned off for at least 20 seconds and
then turned back on, the light will come
on again.
ABS installation malfunctions
If the red warning light is on at speeds higher
than 7 km/h, the ABS installation is
malfunctioning. In this case, the fuses in the
ABS electric box must be checked.
Even if the fault cannot be resolved by
replacing a fuse, driving can be continued
because it is only the ABS system that has
gone down, leaving the regular braking
system intact. Malfunctions should be
repaired by a DAF dealer.
WARNING LAMP AIR PRESSURE (B3)
This lamp lights up when the air pressure
in one of the service brake circuits (circuit 1
and 2) is too low. A buzzer also sounds.
Never drive whilst this lamp is lit.
If this lamp is lit whilst driving, stop
immediately and look for the cause.
BATTERY CHARGE WARNING LAMP
(B4)
The warning lamp lights up if the ignition is
switched on and the engine does not run.
The lamp must go out when the engine
starts.
If the warning lamp does not go out after
starting the engine, or comes on whilst
driving, stop and turn the engine off.
Check whether the V-belts are faulty or slipping.
If this is not the case, a repair shop must be
found as quickly as possible. Since the
batteries are constantly being run down, all
the unnecessary electric devices should be
switched off.
32
INSTRUMENTS AND CONTROLS

OIL PRESSURE WARNING LAMP (B5)
The warning lamp lights up when the
ignition is switched on and the engine does
not turn. The lamp go out when the engine
starts.
If the warning lamp does not go out after
starting the engine, or comes on whilst
driving (a buzzer will also sound), stop and
turn the engine off. Check the oil level and
top up if necessary.
If the lamp remains lit even though the oil
level is correct, do not drive any further. The
engine must also not be allowed to idle.
E-GAS WARNING LAMP (C1)*
In the case of a fault with the electronic fuel
system, the warning lamp (C1) flashes or
is lit continuously, depending on the fault. If
the lamp remains continuously lit then the
fault is less serious.
The fault is serious if the lamp flashes and
a service outlet should be warned
immediately.
WARNING LAMP COOLANT
TEMPERATURE/COOLANT LEVEL (C3)
The warning lamp is lit for a couple of
seconds when the ignition is switched on,
just as a routine check on the operation.
If the warning lamp is not extinguished
afterwards, or comes on whilst driving (a
buzzer will also sound), the temperature of
the liquid coolant could be too high or the
liquid coolant level could be too low.
Stop, turn the engine off and check the
liquid coolant level/fan operation. If
necessary, top up the liquid coolant.
If the warning lamp is not extinguished even
when the liquid coolant level and fan
operation are correct, do not drive any
further.
HIGH GENERATOR VOLTAGE WARNING
LAMP (C4)*
The charging voltage is limited by an overvoltage
security device in the dynamo. If,
due to a fault, a voltage greater than 30 V
exists, this warning lamp lights up.
Turn on as many electronic devices as
possible and drive to the nearest repair
workshop. If the lamp still does not go out,
the vehicle must not be driven any further.
CHASSIS HEIGHT ADJUSTMENT
WARNING LAMP (C6)*
The warning lamp is lit for a couple of
seconds when the ignition is switched on,
just as a routine check on the operation.
If the warning lamp lights up whilst driving,
this implies that there is a slight fault. A
number of devices will be switched off. Get
in contact with a DAF BUS workshop as
quickly as possible.
If the warning lamp starts flashing whilst
driving, this implies that there is a serious
fault in the electronic part of the system.
The electronic system switches itself off
completely. The suspension and damping
will no longer be regulated and controlled.
In emergencies, the chassis height can be
adjusted manually using the control
switches. Drive carefully to the nearest DAF
BUS repair workshop at a speed no greater
than 15 km/h.
When a kerb sensor has been fitted by the
constructor, the CHASSIS HEIGHT
ADJUSTMENT warning lamp (C6) and the
VEHICLE NOT ON DRIVING LEVEL/AIR
PRESSURE TOO LOW warning lamp (16)
will flash alternately for 2 seconds, indicating
that the kerb sensor has been activated.
INSTRUMENTS AND CONTROLS
33

DOOR OR HATCH OPEN WARNING LAMP
(D2)
This lamp lights up if a door or hatch is open.
Dependant on customer specifications.
EMERGENCY DOOR NOT LOCKED
WARNING LAMP (E1)
This lamp lights up if the emergency door is
not locked and a buzzer will also sound.
Dependant on customer specifications.
OPERATION INSTRUMENTS
1. Brake pedal.
2. Accelerator.
3. Steering adjustment handle.
4. Column switch (multi-function).
5. Pneumatic steering adjustment control
knob.
SPEED LIMITER WARNING LAMP (E2)*
The warning lamp lights up when the ignition
is switched on and the engine does not turn.
The lamp go out when the engine starts.
This light will come on as soon as the set
speed is exceeded (e.g. when driving
downhill).
4
40
20
60
80
100
120
AIR CLEANER WARNING LAMP (E3)
This warning lamp lights up if the air cleaner
is blocked or unduly fouled. The filter
element should in that case be cleaned or
renewed at the first opportunity.
5
3
01509B
1 2
34
INSTRUMENTS AND CONTROLS

LEFT MULTI-FUNCTION SWITCH
Dipped beam/main beam/headlamp flash
A. Dipped beam
B. Main beam
Only if the light switch is switched in position
II.
Against the spring pressure: light flash
Direction indicators
To operate the direction indicators briefly,
press the stalk lightly against the spring
pressure and hold it in this position. The
direction indicators only operate when the
contact is switched on.
C. Direction indicators, left turn
D. Direction indicators, right turn
Horn
The horn is operated by depressing button
E against the spring pressure.
INSTRUMENTS AND CONTROLS
35

Windscreen wipers
The windscreen wipers are operated by
turning the switch F,
Position O : wipers switched off
Position I : low wiper speed
Position II:
Position J:
high wiper speed
intermittent wipe, in this
position the windscreen
wipers make a stroke every
8 seconds.
The windscreen wipers will only operate
when the contact is switched on.
Windscreen washers
Press the ring G to operate the windscreen
washers.
Release ring G and the windscreen washers
stop and the windscreen wipers make two
strokes.
The windscreen washers only work when
the ignition is switched on.
DIM/DIP UNIT (UK VERSION)
This unit ensures that the headlight dipped
beams also light up at reduced intensity
when the side lamps are switched on.
ADJUSTABLE STEERING COLUMN
01476B
The adjustable steering column
may only be adjusted
when the vehicle has come
to a standstill.
Mechanical steering adjustment
The position of the steering column and the
height of steering wheel are adjustable. To
adjust these, turn the side handle up. The
two adjustments (position and height) can
be made at the same time. To lock the steering
column, turn down the handle.
Pneumatic steering adjustment
The position and height of the steering
wheel are adjustable.
To adjust these, the control knob on the floor
of the bus must be depressed by foot. Both
adjustments (position and height) can be
adjusted at the same time. The steering
column can be relocked by releasing the
knob. The steering adjustment can only be
made when the doors are open.
36
INSTRUMENTS AND CONTROLS

DRIVING
CONTACT SWITCH/STARTER SWITCH/
STEERING LOCK
Never remove the key from
the contact while driving. The
steering gear may be
blocked.
Position St: rest position
The key can be removed. When the key is
taken out, the steering wheel is locked.
Position M: contact on
The electrical equipment can be switched
on.
Position D: starting position
When the key is released it automatically
springs back to position M.
Note:
If the battery voltage is too low then the key
cannot removed from the ignition.
The key can be turned from the St position
to the M position but can then not be turned
any further or back again.
For vehicles without a contact key, the contact
may be switched on using the master
switch. The engine can be started using the
starting switch.
DRIVING
37

FRONT/
REAR
1 2
OPERATING PANEL IN ENGINE
COMPARTMENT
The engine can be started from the engine
compartment for safety reasons and to help
with certain service work.
If the engine is started from the engine
compartment then it is not possible to start
via the contact - starting switch and vice
versa.
The conditions for starting the engine from
the engine compartment are :
- main switch in the “on” position;
- contact - starting switch in the “on”
position, “M”;
- gearbox in neutral, “N”.
1187168
3 4
01478B
To guard against further accidents during
work in the engine compartment, the engine
operating compartment is equipped to allow
for interruptors to be connected which make
it impossible to start the engine from the
driver’s compartment when there is an
engine hatch open. The interruptors are
fitted by the bodywork constructors.
Starting the engine from the engine
compartment.
Place the option switch in the position (2)
“rear”.
If necessary, pre-glow using the pre-glow
knob (4).
Start the engine using the engine start knob
(1).
The engine can be turned off using the
engine stop knob (3).
1. Engine start knob.
2. Front/Rear Operation selector switch.
3. Engine stop knob.
4. Pre-glow knob.
PREGLOWING SYSTEM
With the ignition switched on, the preglowing
system is brought into operation by using
the tumbler switch in the instrument panel,
or the push-button on the operating panel
in the engine compartment. The warning
lamp 6 lights up as soon as the switch is
pressed in.
- The preglowing system will work for 45
seconds when the switch is pushed to
the right. By pushing the switch to the
left, the preglowing system will work for
as long as the switch is depressed (max.
90 seconds). (See also “start procedure”).
38
DRIVING

START PROCEDURE
When starting the engine in
a building, open the doors.
The exhaust gases contain
carbon monoxide, an invisible
and odourless gas
which is highly poisonous. If
breathed in, these gases may
cause unconsciousness and
death.
Apply the parking brake.
A. Switch on the master switch and the
contact
Check if the warning lamps light up for
oil pressure, oil temperature, battery
charge and the parking brake (see
INSTRUMENTS AND CONTROLS).
Also check that the fuel gauge, retarder
oil temperature gauge, air pressure
gauge and coolant temperature gauge
give a reading.
B. Put the gearbox into ‘neutral’.
C. At low temperatures the air in the inlet
manifold can be preheated using the
preglowing system.
Outside temperature above 0°C:
Vehicles with a contact slot:
Depress the accelerator pedal and turn the
contact key to position D. Pre-glowing starts
automatically for 3 seconds.
If the engine fails to start, the key must be
released after 10 seconds. Wait several
seconds and repeat the procedure.
Vehicles with a starting switch:
Depress the accelerator pedal completely
and operate the starting switch.
Pre-glowing starts automatically for 3
seconds.
If the engine fails to start, the switch must
be released after 10 seconds. Wait 10
seconds and repeat the procedure.
When the engine starts, do
not increase the engine
speed until the oil pressure
warning lamp has gone out
and the oil pressure gauge
indicates sufficient pressure.
Outside temperature below 0°C:
- It must be preglowed according to the
table.
- Start as described above.
Preglowing times advice
surrounding temperature
from 0°C to -5°C
from -5°C to -10°C
from -10 to -18°C
preglow time
0-30 sec
30 sec
30-90 sec
When a minimum amount of smoke production
is required, it may also be preglowed
and after-glowed as much as necessary
above 0°C.
When the engine starts, do
not increase the engine
speed until the oil pressure
warning lamp has gone out
and the oil pressure gauge
indicates sufficient pressure.
Before driving away, check if
the red central warning lamp
is off (see “Instruments and
Controls”). If an ABS system
is fitted on the vehicle the red
central warning lamp goes of
when the vehicle speed is
over 7 km/h.
DRIVING
39

DRIVING WITH THE ZF HP/VOITH
DIWA.3 AUTOMATIC GEARBOX
The ZF automatic gearbox has 4 or 5
forward speeds and 1 reverse gear. The
Voith automatic gearbox has 3 or 4 forward
speeds and 1 reverse speed.
These gearboxes also have a built-in retarder.
The automatic gearbox is electrically
operated by selecting the required gear from
a row of gear selector buttons on the instrument
panel.
Depending upon the specific application of
the vehicle, the automatic gearbox offers the
following gear selector positions:
- 3 positions: DNR
- 6 positions: 123 DNR
Gear selector positions:
R - Reverse:
Reverse gear may only be engaged whilst
the vehicle is stationary and the engine is
idling. To engage position “R” from position
“D”, “1,2,3”, the brake pedal must be
depressed.
Never engage reverse gear whilst driving
forward.
The reversing lamps light up whilst in the
“R” position with the contact switched on.
N - neutral (stationary) position:
Only engage the neutral position when the
speed of the vehicle is less than 5 km/h or
when the vehicle is stationary.
D - normal position whilst driving
forwards.
In this position the gearbox automatically
changes UP and DOWN through all the
forward speeds (depending upon the road
speed and the position of the accelerator
pedal).
Under certain circumstances during driving
it is better to temporarily engage one of the
options described below.
1 - position for steep mountainous routes:
This option is recommended for extreme
height differences and steep inclines.
The vehicle only drives in 1st gear. 2nd and
3rd gear remain blocked. The maximum
engine operation is reached due to this.
The speed regulating system cannot be
used whilst in position 1.
2 - position for mountainous routes:
This option is intended for long inclines and
routes with steep hills.
1st and 2nd gears are changed up and down
depending on the engine load and the
driving speed. 3rd and 4th gears remain
blocked. The engine brake operation is
further increased due to this.
40
DRIVING

3 - position for hilly routes:
1st, 2nd and 3rd gears are changed up and
down depending on the engine load and the
driving speed.
Kick-down
A kick-down switch is fitted under the
accelerator pedal. When fast acceleration
is required, the accelerator pedal should be
pushed down to its full extent. Depending
upon the road speed, this will cause the
gearbox to change down automatically to a
lower forward speed.
Changing up to the next gear will only occur
once the maximum engine speed allowed
has been reached.
Starting
The engine can only be started when
position N is engaged.
Operate the parking brake before starting.
ZF Automatic gearbox:
At temperatures below - 15°C start the
engine and run the engine warm in position
N for about 10 minutes at 1000 rpm before
driving away.
Driving away from rest
With the vehicle stationary, the brakes
applied and the engine idling, select the
desired position (D = forward speed, or R =
reverse), then wait for 1-2 seconds, release
the brakes, depress the accelerator pedal
and drive away.
Do not accelerate whilst switching on and
stationary.
Note
To prevent the bus from rolling backwards
whilst on a slope, the accelerator should be
depressed before the brake pedal/parking
brake is released.
Special note!
If the vehicle does not drive away or the
wrong option is selected:
- Remove the foot from the accelerator;
- Press the “N” key and then the desired
option key.
Should you unintentionally engage position
N whilst the vehicle is in motion, you must
again select position D in order to prevent
damage to the drive line. The electronically
controlled gear selector unit will then
automatically select the forward speed that
matches the road speed.
Stopping
The vehicle can always be brought to a stop
regardless of the chosen gear.
The electronic automatic gear always changes
to 1st gear after stopping (depending
on any fitted options such as Neutral at
Stationary (NBS, EK-ab) etc.). Whilst stopping
for a short period of time, for example
at a traffic light, the gearbox can remain in
option “D” or in the chosen gear. The engine
may then only idle.
Driving in reverse
Change from “D” to “R” or vice versa:
- Bring the vehicle to a stop and keep the
brake pedal depressed;
- Idle the engine;
- Push in the neutral switch “N”.
If the vehicle is equipped with a switch
(39), then this switch should also be
operated.
- Select the required option.
DRIVING
41

Parking
The option “N” must be selected and the
parking brake activated if the vehicle is going
to be stopped for a long period of time or
when it is parked.
Driving in mountainous country
Driving uphill
If for example, an incline is too steep for the
second speed when driving uphill with
position D engaged but not steep enough
for the first forward speed, the gearbox will
continuously change UP and DOWN when
full throttle is given. Naturally, this has a
negative influence on the life expectancy of
the gearbox. The gearbox can, however, be
prevented from changing UP by giving less
throttle or, if fitted on the gearbox, by
engaging position 1. After position 1 has
been selected, the first forward speed is
locked and the gearbox can no longer
change gear automatically. In principle, this
also applies to gear selector positions 2 and
3 (if fitted on the gearbox). The gearbox will
never change UP past the selected position.
The kick-down can also be used in these
positions.
Driving downhill
When driving downhill in a vehicle equipped
with a fully automatic gearbox, the gearbox
quite often changes UP automatically to a
higher speed, which is precisely what we
do not want. Having the possibility to select
a lower lock-up speed (by engaging position
3, 2 or 1) prevents the gearbox from changing
UP. In this case the engine braking effect
is retained and there is less wear on
the wheel brakes.
Before commencing to drive downhill be
sure to engage the correct gear selector
position: this is dependent upon the safe
speed of descent.
In order to avoid overrevving the engine, the
gearbox will change UP under extreme
circumstances, even though the 1st, 2nd or
3rd gear has been preselected.
Malfunctioning:
When the automatic gearbox malfunctions,
the DNR switch will start to blink.
If the DNR switch is blinking, change down
to a low gear and drive to the nearest DAF
BUS Dealer under partial load.
In the event of a serious failure of the Voith
automatic gearbox a warning lamp (B1) on
the SWS panel will flash simultaneously with
the DNR switch. The vehicle must be
stopped without delay to prevent consequential
damage to its driveline.
DOOR-CONTROLLED BRAKE
The door-controlled brake can be used with
a speed lower than 3 km/h. For the doorcontrolled
brake to operate, the switch only
needs to be operated for a short time. If the
door-controlled brake is turned on, the
vehicle will slow down and come to a
standstill and the brake will remain on. The
door-controlled brake can be turned off by
using the accelerator pedal. Therefore, the
handbrake should be used when stopping
at a bus stop, where passengers get on or
off, before the doors are opened (depending
on fitted options such as NBS etc.).
The door-controlled brake can also be used
for short stops, for example at a traffic light.
The foot brake does not need to be used
and the vehicle is prevented from “creeping”.
Depending on the type of construction, the
door-controlled brake can be operated via
one or more doors.
If one or more doors are open, then it is not
possible to accelerate and the gearbox will
come to the NBS position (depending on
fitted options).
42
DRIVING

If the door-controlled brake is in use, the
warning lamp on the instrument panel lights
up.
If the door-controlled brake is in use, the
driver must never leave the driver’s seat.
ZF/VOITH RETARDER
The retarder is a hydrodynamic brake which
is integrated in the gearbox.
The retarder consists essentially of an oil
pump which is driven by the vehicle.
Braking force is subsequently applied to the
circulating oil. This braking force generates
heat which is dissipated to atmosphere via
the heat exchanger. In this way a wear-free
transmission brake is created, which
enables driving the vehicle downhill at
relatively high speeds, without having to use
the service brakes.
Use of the retarder saves wear and tear on
the service brakes which are therefore fully
at the driver’s disposal.
Retarder ZF/VOITH
The retarder is a wear-free, hydraulic,
continuous brake and is therefore ideal for
downhill braking or additional braking.
The retarder is operated by the service
brake foot pedal.
When the retarder is used for continuous
braking (e.g. during extended downhill
braking), a close watch should be kept on
the SWS panel and the instrument panel.
If the pointer of the temperature gauge
reaches 150°C, a warning lamp will light up.
If the warning lamp lights up, further use of
the retarder must be avoided until the oil
temperature is reduced again.
If the oil temperature remains too high,
proceed as follows:
- Stop the vehicle
- Put the selector switch into neutral
- Allow the engine to run with a slightly
increased stationary speed. If after a few
seconds, the temperature is still not in
the acceptable area, check the oil level
and the cooling system for faults.
DRIVING
43

ASR
5 15
P
01798B
Retarder warning lamp
There are two options depending on the
design.
- The orange warning lamp (5) lights up
when the retarder is not in operation.
- The green warning lamp (15) lights up
when the retarder is in use.
Voith DIWA.3/ZF HP automatic gearbox
When there is a fault in the retarder, the
DNR switch starts to flash.
Retarder fault indicating lamp (A2)
Voith DIWA.3/ZF HP
- Lamp flashes:
A. Temperature higher than 150°C
DIFFERENTIAL LOCK*
General
Differential lock is possible on the rear axle.
Directions for use
The differential lock may only be used when
driving on soft ground or on a slippery
road surface, and never on firm ground with
good grip.
The differential lock should always be
engaged as follows:
- Before driving on soft ground or on a
slippery road surface.
44
DRIVING

- With the vehicle stationary or moving
very slowly.
- With the automatic gearbox is in neutral.
The differential lock may never be engaged
while there is wheel spin on one of the axles,
so wait until the wheel has stopped before
you engage the differential lock.
Disengage the differential lock as soon as
you reach firm ground. If the warning lamp
in the switch stays on, drive forwards a short
distance and then reverse in order to release
the locking mechanism.
STEERING
The steering gear is of the hydraulically
assisted type. As excessive pressure can
cause damage to the hydraulic pump, you
should stop turning the steering wheel when
the road wheels are at full lock; you should
likewise stop turning the wheel if the road
wheels are blocked by an obstacle.
The vehicle can of course also be steered
without hydraulic assistance, but this
requires considerable effort.
BRAKES
ABS (ANTI-LOCK BRAKING SYSTEM)
The ABS unit prevents the wheels from
locking during emergency braking or when
braking on a slippery surface. Furthermore,
vehicles equipped with ABS retain their good
steering properties and directional stability
in these conditions.
DO NOT ADJUST YOUR DRIVING STYLE
OR BRAKING TO THE ABS!
In particular, do not brake later and harder
than you would normally do. This will only
cause accelerated wear of the tyres and the
brake system, and you may endanger other
road users who are driving behind you and
who do not have ABS on their vehicles.
Note:
ABS will never shorten the braking distance.
01480B
Do not disengage the parking
brake before the steering
wheel is unlocked.
Otherwise, it will be impossible
to steer the vehicle.
Service brake and parking brake/
emergency brake
The service brake is operated by means of
the brake pedal. If the service brake does
not work because of insufficient air
pressure, the parking brake can be used
as an emergency brake. By moving the parking
brake lever slowly backwards the
vehicle is gradually braked. With the lever in
the back position, the rear wheels of the
vehicle are braked as much as possible.
DRIVING
45

Only use the parking brake in
an emergency when the
vehicle is moving! Since the
parking brake only affects the
driven wheels, this will produce
a restricted braking
ability and can cause the
wheels to skid.
The warming lamp (13) in the instrument
panel lights up when the parking lever is
operated.
To release the parking brake, pull the parking
brake lever backwards slightly and then
move it forwards.
When leaving the driver’s seat, always
engage the parking brake.
Ensure that the parking brake is in the
blocked position.
STOPPING
Parking
Apply the parking brake with the parking
brake lever. Move the gear lever into neutral.
Switch off the contact and remove the contact/starter
key (if applicable). Place the
main switch in the “OFF” position. Check that
all roof hatches, windows and luggage
lockers are closed and then lock all the doors
of the vehicle.
Special note
When the vehicle is parked on a gradient,
one or more of the following precautions
must also be taken:
- Place chocks behind or in front of the
wheels.
- Angle the front wheels so that the vehicle
will not move into the traffic stream if it
is accidentally set in motion.
Switching off the engine
Bring the vehicle to a halt. Put the gear lever
in ‘neutral’ and run the engine at idle for
a few minutes to let it cool down and -equally
important - to ensure adequate lubrication
of the turbocharger.
Switch off the engine by turning the starter
key to the position “St”, or by using the contact/stop
switch.
Note:
The engine can also be switched off with
the stop push-button in the engine
compartment.
46
DRIVING

E-GAS (ELECTRONIC THROTTLE
CONTROL)*
General
Under the accelerator pedal there is a
sensor which transmits signals to the
electronic control unit indicating the position
of the accelerator pedal. On the governor
of the fuel injection pump there is an
electrical actuator which responds to the
signals from the electronic control unit which
makes it possible to vary the engine speed.
The engine speed can be adjusted from
between stationary and 1200 rpm using the
E-gas system whilst the speed is less than
7 km/h. The idle engine speed control keeps
the idle engine speed constant to the set
value. Use can also be made of the speed
control, “cruise control”, for speeds above
25 or 50 km/h (depending on the programming).
Vehicle speed control
The EGAS vehicle speed control works as
of 25 or 50 km/h.
Drive at the required speed and move the
tumbler set switch (G) on the instrument
panel briefly to left or right. This speed is
now entered into the EGAS memory.
Operating the brake pedal, the parking
brake, the engine brake or the memory/stop
button for whatever reason will immediately
disengage the speed control.
To resume the set speed, simply press the
memory/stop button (F). The memory
retains the last set speed until the contact
is switched off.
If a different speed (different to the set
speed) is required, this can be obtained by
sliding tumbler set switch G on the steering
column stalk to reduce speed (to the left)
or to increase speed (to the right) without
having to use the accelerator pedal. The last
set speed is retained in the memory.
Note:
The vehicle speed control should only be
used when the traffic situation allows a constant
speed to be maintained.
Warning!
Do not use the vehicle speed
control in heavy traffic or on
winding or slippery roads.
Engine speed control
The engine speed control works up to 7.5
km/h.
With setswitch G on the steering column
stalk the engine speed can be varied from
idling to 1,200 rpm. The engine speed remains
constant at varying loads. The vehicle
speed is limited to 7.5 km/h. The set speed
can be overruled by using the accelerator
pedal. When the accelerator pedal is
released, the set engine speed is
automatically restored.
DRIVING
47

When driving over 25 or 50 km/h, the
electronic control system will disengage the
throttle operation. The engine speed control
can be switched of with memory/stop button
(F).
EGAS WARNING LAMP (C1)
If a fault occurs in the electronic accelerator
pedal, the warning lamp (C1, red) will either
flash or remain on, depending upon the type
of fault. If the lamp remains on, this indicates
a fault of a less serious nature. A flashing
lamp, however, indicates a serious fault and
a DAF BUS dealer should be notified without
delay.
ASR
In combination with ABS, the vehicle can
also be equipped with an ASR installation.
The ASR installation prevents slipping of the
wheels when driving on slippery roads.
Depending on the situation, the ASR system
reduces engine speed or slows down the
slipping wheel.
If the ASR system is activated, a warning
lamp will light up at the display panel.
DO NOT ADJUST YOUR DRIVING
BEHAVIOUR TO THE ASR SYSTEM.
AIR SUSPENSION (ECAS)*
The vehicle can be optionally equipped with
an electronically controlled suspension and
height control system, ECAS (Electronically
Controlled Air Suspension).
The vehicle’s chassis height is recorded in
the microprocessor’s memory. If the chassis
height changes then it is automatically
adjusted.
- The vehicle can be raised or lowered by
depressing the RAISE/LOWER
VEHICLE switch (33) (see
CONTROLS). The vehicle will be raised
by depressing the top part of the switch.
This position is used when a large
ground clearance is temporarily
required, as for example when driving
onto a ferry boat.
The vehicle will be lowered by depressing
the bottom part of the switch (up to
the bump stop).
The height adjustment may only be
used temporarily.
The vehicle will automatically return to
the driving level at a speed greater than
15 km/h.
Note that the vehicle can be raised or
lowered without the risk of trapping
somebody between the vehicle and the
edge of the pavement.
Note:
Depending on the constructor, there
could possibly be a kerb sensor which
will stop the vehicle being lowered when
an obstacle is detected.
- The vehicle can be brought back to its
normal driving level after being raised,
lowered or knelt using the “DRIVING
LEVEL” switch (35) (see CONTROLS).
- The vehicle can be knelt at the front
whilst stationary using the “MANUALLY
OPERATED VEHICLE KNEELING”
switch (37) (see CONTROLS). The
vehicle will kneel at a certain set height
whilst the switch is depressed.
If the switch is released before the
kneeling height is reached then, depending
on the design, the following will
happen:
- the kneeling is stopped;
- the kneeling is interrupted and the
vehicle returns to the DRIVING
LEVEL.
48
DRIVING

The vehicle can only be returned to the
“NORMAL DRIVING LEVEL” after
kneeling, or when the kneeling is
stopped, using the switch (35).
Note:
Kneeling is not possible with insufficient
air pressure.
Attention:
Kneeling the vehicle reduces the ground
clearance.
ECAS WARNING LAMP
If the CHASSIS HEIGHT warning lamp (C6)
(see Controls) lights up whilst driving, this
implies that there is a slight fault. A number
of functions will be switched off. Get in contact
with a DAF BUS workshop as quickly
as possible.
If the warning lamp starts flashing whilst
driving, this implies that there is a serious
fault in the electronic part of the system.
The electronic system will switch itself off
completely. The suspension and damping
will no longer be regulated and controlled.
In emergencies, the chassis height can be
adjusted manually using the control switch.
Drive carefully to the nearest DAF BUS repair
workshop at a speed no greater than 15
km/h.
ENGINE PROTECTION SYSTEM (EPS)*
The vehicle can be equipped with an engine
protection system. The position of the
engine protection system’s warning lamp
depends on the constructor. If the oil
pressure is lower than 0.42 bar, or the water
temperature is higher than 96°C, the
engine protection system’s warning lamp
lights up.
If the oil pressure falls below 0.21 bar, or
the water temperature reaches higher than
99°C, the fuel supply to the engine will be
cut off and the engine will turn itself off.
The engine protection system makes sure
that the engine can still turn for a maximum
of 30 seconds from the time that the starting
switch is operated. The vehicle must be
driven as quickly as possible to a safe place
and a DAF BUS service outlet must be
consulted.
DRIVING
49

REAR SERVICE POINTS
1. Liquid coolant reservoir.
2. Hydraulic power steering reservoir.
3. Moisture separator.
4. Engine compartment instrument panel.
5. Hydraulic fan drive reservoir.
6. Engine oil filler port.
7. Engine oil dip stick.
8. Automatic sump refill unit reservoir.
50
MAINTENANCE

2
Max.
3
DAF
4
Max.
Min.
-18
c
Min.
MAX
01481B
1
MIN
01501B
01482B
DAILY MAINTENANCE
CHECKING THE ENGINE OIL LEVEL
1. Make sure the vehicle is standing on
level ground.
2. Remove oil dipstick (1) from the holder.
3. Clean the dipstick with a non-fluff cloth.
4. Replace the dipstick in the holder and
wait a few seconds.
5. Again remove the dipstick and take the
oil level reading.
The oil level should always be between
the two marks.
6. If necessary, top up oil through filler hole
(2). Always use oil of the same brand
and quality grade. Never over-fill!
Note:
Difference between maximum and minimum
for the engine: approx 4 litres.
For vehicles equipped with an automatic
sump refill unit, the oil level in the tank must
be between the maximum and minimum
marks. Top up as necessary via the filler
opening (3).
The automatic sump refill
unit does not work when the
oil level is below the minimum
level.
CHECKING THE COOLANT LEVEL
Important!
- Check the coolant level while the engine
is cold.
When the coolant is hot,
there is overpressure in the
cooling system. Carefully
unscrew the filler cap (e.g. by
putting a cloth over the cap
first) to the stop to release
the overpressure.
Then push the filler cap down
and unscrew it.
MAINTENANCE
51

Coolant is a harmful liquid.
In order to avoid poisoning,
avoid skin contact.
In order to avoid damage
when pouring cold liquid into
a hot engine, let the engine
run and pour slowly.
1. Set the heater’s temperature turning
knob to “warm”.
2. Remove the filler cap (4) from the
expansion tank.
3. Let the engine run for a few minutes.
4. Switch off the engine and check the
coolant level.
5. The coolant level should be between the
MAX and MIN marks. Top-up with
coolant if necessary.
Filling procedure cooling system
1. Close all heater valves and open the filler
cap on the expansion tank.
2. Fill the expansion tank to the maximum
level (engine not running).
3. Close the filler cap on expansion tank.
4. Start the engine and allow it to idle for
several minutes.
5. Open the filler cap on the expansion tank
and top up the expansion tank to the
maximum level.
6. Gradually open the heater’s supply valve
and simultaneously top-up the
expansion tank to the maximum level.
7. Open the heater breathers for a few
seconds and top up the expansion tank
to the maximum level. Repeat this step
until no more air is released from the
breather.
8. Open the return valve of the heater and
wait until no air is coming up through
the expansion tank.
9. Operate the engine at 1500 rpm until
no air comes up through the expansion
tank. Top up the expansion tank to the
max.level.
10. Make a test drive to check for leakage.
TYRES AND RIMS
- Check the tyres for wear, any foreign
matter embedded in the tread and other
damage.
- Remove any foreign matter from the
tread and from between twin tyres.
- Check the wheel attachment.
- Check the tyre pressure (do not forget
the spare). Checking and adjusting the
pressure must be done when the tyres
are cold.
- Do not fit tyres of different sizes
otherwise the ABS system will not work
correctly. The difference in the depth of
tread must also not be greater than 7,5%
(also see Replacing Tyres).
52
MAINTENANCE

LIGHTING AND INSTRUMENTS
- Check the vehicle lighting, brake lights
and instruments for correct operation.
- Also check the horn, windscreen wipers
and washers for correct operation.
DRIVER’S SEAT AND MIRRORS
- Adjust the seat and mirrors to the correct
position.
MAINTENANCE
53

2
DAF
-18
c
MAX
MIN
1
Max.
Min.
01477B
01483B
WEEKLY MAINTENANCE
HYDRAULICALLY ASSISTED POWER
STEERING
- Check the fluid level.
1. Thoroughly clean the area around the
dipstick.
2. Check the fluid level in the reservoir with
the dipstick.
3. With the engine running, the fluid level
should be up to the upper mark (Max.)
on the dipstick. With the engine switched
off the fluid level is 2 cm higher.
HYDRAULIC FAN DRIVE
- Check the fluid level.
1. Check the fluid level through the gauge
glass (1) with the engine idling.
2. The liquid level should lie between the
maximum and minimum marks. Top up
with oil as necessary via the filler port
(2).
VOITH AUTOMATIC GEARBOX
- Check the oil level.
1. Make sure the vehicle is standing on level
ground.
2. Move the gear lever into neutral.
3. Let the engine idle.
4. Check the oil level with the dipstick. At a
minimum temperature of 60°C the oil
level should be between the minimum
and maximum mark.
54
MAINTENANCE

FRONT/
REAR
1
A
1187168
00736B
01484B
2
01485B
ZF AUTOMATIC GEARBOX
- Check the oil level.
1. Make sure the vehicle is standing on level
ground.
2. Move the gear lever into neutral
3. Let the engine idle.
4. Check the oil level with the dipstick. At
operating temperature (± 85°C) the oil
level should be between the two marks
(A).
BATTERIES
Sulphuric acid is an aggressive
liquid. When it has come
in contact with clothes, skin or
eyes, rinse off immediately with
an ample amount of water
- Check the electrolyte level; this should
reach up to approx. 10 mm above the
cell plates or, if fitted, up to the level
indicator. If required, top up with distilled
water.
- Check to ensure that the battery terminal
posts and clamps are clean and
greased. Coat the battery posts as
required with petroleum jelly (vaseline).
MOISTURE SEPARATOR IN FUEL
SYSTEM
Diesel fuel is combustible
and may not be exposed to
open fire or other heat
sources such as a hot engine.
Catch leaking fuel in a
suitable can.
- Check the moisture separator for the
presence of water or dirt and drain if
necessary.
MAINTENANCE
55

FRONT/
REAR
1
1187168
01486 B
2
01485B
LF version
1. Place a tray under the moisture
separator.
2. Unscrew the bleed nipple (1) on top of
the moisture separator for the benefit of
ventilation.
3. Unscrew the serrated nut (2) a couple
of turns.
4. Allow as much liquid to flow out of the
moisture separator until clean diesel
comes out.
5. Tighten the serrated nut (2) and the
bleed nipple (1).
CHECKING THE AIR DRIER OF THE
BRAKE SYSTEM
Operation of the air drier can be checked
by inspecting whether the air reservoirs
contain condensation.
DRAINING THE AIR RESERVOIR
1. Check all the air reservoirs for the
presence of condensation and oil by
pulling the draining valve’s ring.
2. Feel the air flow using your hand. The
air flow must feel dry and free from oil.
3. If the air flow contains moisture or oil
vapour, then the air dryer’s cartridge
must be replaced.
Oil vapour in the air flow could indicate
that there is a fault with the air
compressor.
56
MAINTENANCE

Damp air in the air-operated
brake system implies that
there is severe danger of a
total loss of brake pressure
due to the brake valves
freezing during cold weather.
WINDSCREEN WASHER RESERVOIR
- Check the fluid level and top up as
necessary.
mIn
SC
min. 25 mm
PREVENTIVE MAINTENANCE BEFORE
THE WINTER SEASON
- The cooling system should preferably be
filled with a ready-mixed coolant
containing antifreeze and corrosion
inhibiting additives. When pure (demineralised)
water is used, an ethyleneglycol
based antifreeze must always be
added if there is a possibility of the
ambient temperature falling below +5°C.
Summer season:
Add a windscreen cleaner to the water in
the reservoir (DAF Part No. 0610764).
Winter season:
Add a special screenwash antifreeze to the
water in the reservoir. (DAF Part No.
0610763).
01523B
AUTOMATIC CHASSIS LUBRICATION
If automatic chassis lubrication is used,
check the pump’s grease level. If necessary,
top up.
WINDSCREEN WASHER RESERVOIR
- Add screenwash antifreeze to the water
in the reservoir (DAF Part No.
0610763)
MAINTENANCE
57

CHECK THE ANTIFREEZE CONTENT
Coolant is a harmful liquid. In
order to avoid poisoning,
avoid skin contact.
1. Turn the rotary temperature control knob
in the vehicle to maximum.
2. Remove the filler cap of the cooling
system.
When the coolant is hot,
there is overpressure in the
cooling system. Carefully
unscrew the filler cap (e.g. by
putting a cloth over the cap
first) to the stop to release
the overpressure.
3. Check the antifreeze level of the coolant.
4. Fill the cooling system with antifreeze if
this has not been done yet.
In order to avoid damage
when pouring cold liquid into
a hot engine, let the engine
run and pour slowly.
5. Preferably use coolant, or if not
available antifreeze, which meets the
specifications set by DAF according to
ASTM D-3306, BS 6580 and SAE J 1034.
In case an aluminium radiator is used,
you should always be extra careful that
these specifications are met.
See the manufacturer’s instructions for
the correct mixing ratio when adding
antifreeze.
DIESEL FUEL
- During the winter months the oil
companies often use additives, such as
flow improvers, to prevent blockages
caused by the precipitation of paraffin
crystals (wax deposits).
- At extremely low temperatures - and if
permitted by law - a maximum of 20%
kerosene may be added. However, if this
is prohibited by law, a maximum of
20% lead-free petrol may be added.
Notes:
Additives which are used to improve the flow
properties of diesel fuel have a purely
preventive effect. They cannot re-dissolve
the paraffin crystals once they have been
precipitated.
Always carry a spare element for the main
fuel filter on the vehicle so that you can
replace it in the event of a clogged filter (also
due to paraffin crystals).
58
MAINTENANCE

PREVENTIVE MAINTENANCE AFTER
THE WINTER SEASON
COOLING SYSTEM
- The antifreeze mixture may be left in the
cooling system during the summer.
- In climates where the temperature never
falls below O°C, a corrosion-inhibiting
agent should be added to the coolant.
The coolant must at all times comply with
specification ASTM D 3306, BS 6580 or
SAE-J-1034.
WINDSCREEN WASHER RESERVOIR
- It is advisable to add windscreen cleaner
(DAF Part No. 0610764) to the water
in the screenwash reservoir.
EMERGENCY REPAIRS
SERIOUS OIL LEAKAGE
In the case of a (serious) oil leakage from
any of the driveline components, drive the
vehicle (if this is still possible) to the nearest
workshop.
The levels of oil should
always be kept above the minimum
level.
If the oil level threatens to
drop below the minimum
mark then the vehicle should
be stopped and the engine
turned off.
VOITH AUTOMATIC GEARBOX
Checking the oil level:
1. Make sure the vehicle is standing on level
ground.
2. Move the gear lever into neutral.
3. Let the engine idle.
4. Check the oil level with the dipstick. At
the minimum the temperature of 60°C
the oil level should be between the minimum
and maximum mark.
MAINTENANCE
59

A
A
DAF
00736B
B
01487B
ZF AUTOMATIC GEARBOX
Checking the oil level:
1. Make sure the vehicle is standing on level
ground.
2. Move the gear lever into neutral.
3. Let the engine idle.
4. Check the oil level with the dipstick. At
operating temperature (± 85°C) the oil
level should be between the marks (A).
DIFFERENTIAL 1339 AXLE
Note:
Do not check the oil level immediately after
a trip, but let the oil settle and cool down for
about half an hour.
Checking the oil level:
1. Place the vehicle on level ground.
2. Remove the spill plug (A). The oil level
should be up to the edge of the filler/
level hole (A). If necessary, top up.
3. After checking, replace the spill plug.
REAR WHEEL HUBS 1339 AXLE
Checking the oil level:
1. Place the vehicle on level ground.
2. Position the wheels so that the arrow
on the hub points upwards (vertically).
3. Remove the filler/spill plug (A). At the
hubs, the oil level should be up to the
edge of the filler/level hole (A).
4. After checking, replace the spill plug.
60
MAINTENANCE

V-BELTS
Renewing V-Belts
- Always fit the same type of V-belt.
- If two V-belts are used, always renew
the V-belts as a set.
1. Slacken the central bolt (1) on the tensioning
pulley.
2. Slacken the fastening bolt on the spindle
(2).
3. Slacken the fastening bolts on the front
and rear of the alternator (3).
4. Slacken the lock nut (4) on the sleeved
nut (5). Turn the sleeved nut so that the
alternator is turned over to the engine
bed.
5. Remove the V-belt(s).
6. Inspect the pulleys for damage, rust and
grease deposits.
7. Fit the new V-belt(s).
8. Adjust the V-belt tension.
Adjusting the V-belt tension
1. Slacken the bolt (1) on the tensioning
pulley.
2. Slacken the fastening bolt on the stud
(2).
3. Slacken the fastening bolts on the front
and rear of the alternator (3).
4. Slacken the lock nut (4) on the sleeved
nut (5).
5. Move the alternator by turning the sleeved
nut (5) until the correct V-belt tension
has been reached.
MAINTENANCE
61

2
1
01498B
6. When correctly tensed, it should be possible
to deflect the V-belt 10 to 12 mm
between the alternator and the crankshaft
pulley when light pressure is exerted.
7. Tighten the fastening bolts on the alternator,
spindle and tensioning pulley.
Note:
- Check the V-belt tension adjustment
again after the first 50 km.
- Have the V-belt tension checked by a
DAF BUS Dealer as soon as possible.
ADJUSTING THE BRAKES
The vehicle is fitted with automatic brake
shoe adjusters. A clicking noise will be heard
when the adjuster cam is backed off. Consult
a DAF BUS dealer in case a vehicle
with automatic brake shoe adjusters needs
to be adjusted.
RENEWING THE FUEL FILTER
Diesel fuel is combustible
and may not be exposed to
open fire or heat sources
such as a hot engine. Catch
leaking fuel in a suitable can.
1. Remove the fuel filter.
2. Tighten the new filter with hand pressure
only.
3. Bleed the fuel system.
4. Check for possible leakage with the
engine running.
62
MAINTENANCE

01499B
BLEEDING THE FUEL SYSTEM
Diesel fuel is combustible
and may not be exposed to
open fire or heat sources
such as a hot engine. Catch
leaking fuel in a suitable can.
1. Open the bleed screw (3) on the filter
body.
2. Pump fuel out of the bleed screw with
the manual pump (4) until no more air
bubbles are visible in the fuel.
3. Close the bleed screw.
RELEASING THE PARKING BRAKE
a. With compressed air
1. Place chocks behind and in front of the
wheels.
2. Move the parking brake lever forwards.
3. The spring brake actuators can be
released by connecting a tyre inflating
hose to the tyre inflating connection.
4. If necessary, air can be obtained from
one of the tyres.
5. Note the correct line pressure when
doing this (max. 10 bar).
b. Mechanically
1. Place chocks behind and in front of the
wheels.
2. Use a ring spanner to turn the bolt counter-clockwise
as far as the stop.
3. Repeat this procedure for the other
spring brake actuators.
Important!
Restore the parking brake to its normal
operating condition as soon as possible by
turning the bolts clockwise and tightening
to a torque of 40-50 Nm.
MAINTENANCE
63

WHEELS
Wheel hub centring
DAF BUS uses wheel hub centring on its
vehicles.
Typical of wheel hub centring:
- wheels with cylindrical bolt holes;
- wheel nuts with a loose (captive) flat
thrust washer;
- wheel hub with cast-on letter “C”.
Caution!
Always use wheels and wheel nuts designed
specifically for wheel hub centring.
Changing disc wheels
1. Place chocks behind and in front of the
wheels.
2. Clean the wheel nuts and apply a drop
of oil to the screw thread.
3. Place the jack under the axle, as close
as possible to the wheel that is being
changed.
4. Before fitting the wheel, carefully clean
the mating edge of the wheel hub and
the inner edge of the spare wheel and
remove any burrs and remnants of paint.
Apply a thin coating of grease to the
mating edge.
5. Clean the wheel studs and lightly
lubricate the screw thread with oil.
The use of Copaslip or Molykote is
not permitted.
6. Apply a drop of oil between the thrust
washer and the wheel nut.
7. Fit the wheel and gradually tighten the
wheel nuts in a crosswise sequence to
the specified torque (see the Specifications).
8. Retorque the wheel nuts after 100 km
and 500 km.
64
MAINTENANCE

After changing a tyre, the difference in diameter
between the fitted tyres may have
become too large (e.g. because of a
difference in tread depth and/or tyre
pressure). The ABS system cannot handle
too large a difference and will therefore be
switched off. This will cause the orange ABS
warning lamp to come on.
Depending upon the type of tyres on the
front and rear axle, this may already happen
with a worn tyre which is 2 bar below
the required pressure. Check the tyre
pressure first if the fault lamp lights up after
changing tyres.
Under extreme circumstances, no ABS
will occur!
This is why the difference in tyre diameter
of new tyres may not surpass 7.5%. (This
may occur when fitting non-regular types of
tyres on front or rear axle).
INFLATING THE TYRES
01488B
1. Remove the tyre inflating nipple’s cap,
the test connection at the passenger
entrance at main switch housing (LF)
or the test connection on the air dryer.
2. Connect the tyre inflating hose.
3. Inflate the tyres while the engine is running
and with maximum pressure in the
air reservoirs.
Note:
The entire air pressure system can be filled
externally with air via the test connection at
the passenger entrance or the test connection
on the air dryer. Note the correct line
pressure when doing so (see the Specifications).
LF version
01773B
LEAKAGE IN AIR SUSPENSION SYSTEM
If one of the air suspension bellows becomes
defective, the air delivery line leading
to both bellows on the same axle should be
disconnected. The delivery line must also
be plugged to prevent the loss of a substantial
amount of compressed air in the
reservoirs, which is also needed to operate
the brakes.
MAINTENANCE
65

TOWING
- Move the steering lock/contact-starter
key of the towed vehicle to the position
in which the steering wheel is unlocked
(unless the vehicle is being towed with
its wheels hoisted clear of the road; also
see below).
- Always use a towing bar. Departure from
this rule is only allowed in emergency
situations; in that case the maximum
permissible towing speed in 40 km/h.
- To prevent possible damage to the
gearbox, the propeller shaft should be
disconnected at the differential.
- To prevent possible damage to the
chassis, the angle at which the vehicle
is towed may not exceed 30° in relation
to the road surface.
- Release the parking brake if the air reservoir
pressure is insufficient (see also
“Releasing the parking brake”).
If the differential is damaged:
- Hoist the vehicle at the rear end and
engage the steering wheel lock.
Tow-starts
It is not possible to start the engine of a
vehicle equipped with an automatic
gearbox by using the tow-start method.
REPLACING BULBS
- Before attempting to replace any bulbs
on the vehicle, refer to the chassis builder’s
instructions (if supplied). This
applies to the interior and exterior lights
of the vehicle as well as to adjustment
of the headlights.
- When fitting a new bulb, make sure that
the ridges on the bulb holder fit in the
recesses in the reflector.
- Never touch the glass of a halogen bulb
with your bare fingers.
1
00799B
Tachograph
- Rotate lamp holder (1) a quarter turn,
remove, and replace the bulb.
1
66
MAINTENANCE

FUSES
- The central panel of the electric
installation contains all the usual fuses.
For the location of the central electrics
panel, see the chassis builder’s
specifications (if supplied).
- Never replace a burnt out fuse with
one of a higher rating!
- Always place the main switch in the
“OFF” position when removing a
fuse.
MAINTENANCE
67

68
MAINTENANCE

FUSES AND RELAYS
E000 Fuse 7.5A, LH side-marker/corner-marker/tail light
E001 Fuse 7.5A, RH side-marker/corner-marker/tail light
E004 Fuse 7.5A, dipped beam, left
E005 Fuse 7.5A, dipped beam/dipped beam warning lamp,
right
E006 Fuse 7.5A main beam, left
E007 Fuse 7.5A, main beam/main beam warning lamp, right
E009 Fuse 7.5A, fog lights
E010 Fuse 7.5A, rear fog lights
E013 Fuse 7.5A, stop lights
E016 Fuse 7.5A, reversing lights
E017 Fuse 7.5A, hazard warning system/tachograph
measuring system (A3)
E019 Fuse 7.5A, operation, glowing
E022 Fuse 7.5A, hazard warning system
E023 Fuse 7.5A, cold-starting switch, tachograph clock, cab
heater timer
E024 Fuse 7.5A, wipe/wash/intermittent wipe
E025 Fuse 15A, windscreen wiper motor/headlamp
washer motor
E026 Fuse 7.5A, cigar lighter
E029 Fuse 7.5A, retarder/exhaust brake
E035 Fuse 7.5A, instruments and warning lamps
E040 Fuse 7.5A, ABS
E041 Fuse 7.5A, ABS
E042 Fuse 7.5A, ABS
E049 Fuse 7.5A, central lubrication
E050 Fuse 7.5A, chassis lubrication
E051 Fuse 7.5A, ECAS-1
E053 Fuse 7.5A, ECAS (16-pole diagnostic connector)
E055 Fuse 7.5A, EGAS (6/2)
E056 Fuse 7.5A, EGAS
E061 Fuse 7.5A, ECAS bus
E065 Fuse 7.5A, start locking relay/additional operation
E084 Fuse 7.5A, lighting
E089 Fuse 7.5A, compact tachograph, VLG A1
E091 Fuse 7.5A, heating element, air drier, fuel sedimenter
E101 Fuse 7.5A, neutral position, Easyshift
E107 Fuse 15A, central safety switch
E109 Fuse 7.5A, oil sump filling system/engine fuel valve
E119 Fuse 7.5A, control relay engine oil temperature
E131 Fuse 7.5A, main beam
E132 Fuse 7.5A, dipped beam
E201 Fuse 15A, engine compartment fan
E226 Fuse 7.5A, battery charge D+
E227 Fuse 7.5A, stop brake
E228 Fuse 7.5A, engine protection system
E231 Fuse 1.5A, oil sump filling system
E232 Fuse 15A, start relay
E247 Fuse 7.5A, main switch steering signal
E249 Fuse 7.5A, tail light (tractors)
G000 Relay width indicator/side-marker/tail lights
G001 Relay dipped beam
G002 Relay main beam
G004 Relay fog light
G005 Relay fog light, rear
G007 Relay reversing lamps
MAINTENANCE
69

70
MAINTENANCE

RELAYS
G008 Relay windscreen wipers (speed I, II)
G009 Relay windscreen wipers (automatic parked position)
G015 Relay ignition
G021 Relay ABS power supply
G022 Relay ABS power supply
G023 Relay ABS, 3rd brake/retarder
G025 Relay ABS warning lamp
G036 Relay stop light, 1st
G038 Relay start
G039 Relay start inhibitor
G079 Relay start inhibitor
G085 Relay main switch, transfer
G099 Relay engine stop, D+
G119 Relay engine stop, EGAS
G125 Relay engine oil temperature control
G134 Relay door release
G135 Relay gearshift prevention
G138 Relay throttle blocking
G139 Relay 3 km/h
G140 Relay accelerator pedal position
G141 Relay stop brake transfer
G147 Relay charging current
G149 Relay throttle blocking released if gearbox is in neutral
G169 Relay stop brake
G215 Relay oil sump filling system (off)
G216 Relay oil sump filling system (on)
MAINTENANCE
71

KONNEKTION TO:
CW
IP
CH
PO
CF
FH
CENTRAL WARNING SYSTEM
INSTRUMENT PANEL
CHASSIS
MAIN SWITCH (POWER)
CHASSIS FRONT
FUSEHOLDER
01507B
72
MAINTENANCE

RELAYS
G059 Relay retarder operation
G062 Relay ngine compartment fan, auxiliary fan
G081 Relay alarm, engine compartment temperature
G082 Relay central safety circuit/switching off engine
compartment fan/ ESU control
G083 Relay main switch, drop-out/CVS
G093 Relay central safety circuit, switching on hazard warning
lights
G106 Relay control, automatic gearbox, Voith
G118 Relay reversing gear, automatic gearbox
G143 Relay engine oil pressure EPS
G155 Relay warning lamp lifting/lowering front axle
G168 Relay safety, lowering prevented
G200 Relay retarder reduction
G233 Relay central safety switch transfer function
G251 Relay central safety switch hazard lights supply
G254 Relay speed limiter anti-throttle
MAINTENANCE
73

TECHNICAL SPECIFICATIONS
Unless stated otherwise, these specifications apply to all models
of the SB 220GS.
Fuel additives and lubricants of any kind may not be used
unless approved of by DAF.
COMPONENT OVERVIEW SB 220 GS
Engine
GS
Gearbox
ZF 4HP500
ZF 5HP500
Voith D851.3
Voith D854.3
Rear axle 1339
Front axle:
130 N
- LF-version 154 N
Steering gear:
ZF8043
- LF-version TRW TAS 75
ENGINE
General
Manufacturer
Type
Construction
Number of cylinders
Bore & stroke
DAF
GS 160 M - GS 200 M
Water-cooled four stroke diesel
engine with direct fuel injection
and piston cooling, turbocharger
and inlet-air cooling.
6 horizontal in line
118 x 132 mm
Total capacity
8.65 litres
Compression ration 16.1:1
Idling speed
625 rpm, depending on the
gearbox type/E-gas
Max. engine speed, unloaded
- GS 160 M 2555 ± 30 rpm
- GS 200 M 2540 ± 30 rpm
Max. engine speed, loaded
Threads used in engine
Valve clearances (hot or
cold engine
Lubricating system
capacity, incl. filters and
oil cooler
oil sump capacity, max. level
oil sump capacity, min. level
Oil pressure
Engine at operating temp.
at idling speed
max. loaded engine speed
2300 rpm
metric, to ISO standards
inlet 0.5 mm
exhaust 0.5 mm
approx. 28 litres
approx. 22 litres
approx. 18 litres
min. 0.55 bar
3.35 - 4.35 bar
Cooling system
Cooling system capacity approx. 40 litres
Cooling system capacity
(with integrated retarder) approx. 50 litres
Operating temperature max. 95°C
Coolant
see coolant specifications
74
TECHNICAL INFORMATION

Fuel system
Injection order 1-5-3-6-2-4
Injection pressure
230 - 240 bar
Fuel
see fuel specs
Fuel tank(s) contents:
2 x 172 litres
2 x 130 litres
2 x 160 litres
- LF-version 1 x 250 litres
max. power
P (kW at rpm)
max. torque
M (Nm at rpm)
engine speed at max. power np (rpm)
engine speed at max. torque nm (rpm)
P(kW) n p (rpm) M(Nm) n m
injection timing
GS 160M 160 2300 850 1250 8°
GS 220M 200 2300 1010 1500 9°
Automatic gearbox ZF HP500 ZF 5HP500
Number of gears 4 5
Reductions 1st gear 3.43:1 3.43:1
2nd gear 2.01:1 2.01:1
3rd gear 1.42:1 1.42:1
4th gear 1.00:1 1.00:1
5th gear - 0.83
reverse 4.84 4.84
Capacity
approx. 30 litres when
changing oil, approx. 15 litres
Automatic gearbox Voith D851.3 D854.3
Number of forwards gears 3 4
Reductions 1st gear 5.20:1 5.20:1
2nd gear 1.36:1 1.36:1
3rd gear 1.00:1 1.00:1
4th gear - 0.73
reverse 3.8:1 3.8:1
Capacity
approx. 23-26 litres
Retarder
Type:
Oil:
Type:
Oil:
ZF integrated retarder
See oil specifications
Voith integrated retarder
See oil specifications
Rear axle
Type: 1339
Reduction: 3.31, 3.73, 4.10, 4.56, 5.13
Capacity
approx. 20 litres
Capacity per hub
(bearing):
approx. 0.9 litres
Front axle
Type:
N 130 / 154 N
Camber angle 1°
King pin inclination
7°30'
Castor 3°
Toe-in
0-1 mm
Max. turning angle,
- inner wheel 56°
TECHNICAL INFORMATION
75

- outer wheel 47°
Per hub bearing:
wheel bearing grease
Lubrication:
see specifications
Air suspension
Front axle:
Rear axle:
Variable height setting (ECAS):
front and rear:
front:
Two air bellows with two heightcontrol
valves and ECAS
Four air bellows with two
height-control valves and
ECAS
adjustable ±60 mm (LF-version
±90 mm) above normal running
height.
adjustable ±100 mm (LFversion
±75 mm) below normal
running height (kneeling
device)
Steering gear
Type:
hydraulically assisted
Type number: ZF 8043 / TRW TAS 75
Fluid:
see hydraulic fluid specifications
Capacity
approx. 8 litres
Brake system
Service brake:
Front axle:
Rear axle:
Parking brake:
Air cylinders,
operating pressure:
Brake lining:
Brake adjusters :
Compressor:
Electrical system
Starter motor
Type:
Output:
Alternator
Type:
Output:
Option:
pneumatic-mechanic, dual circuit
system, fully separated
drum brakes
drum brakes
spring brake actuators
8.6 - 9.8 bar
Jurid 570 asbestosfree
Haldex, self-adjusting
2 cylinders, water-cooled top,
swept volume 440 cc
Bosch
JD
5.2 kW
alternating current
28 V - 140 A
2nd alternator 28 V 140 A
Battery
Number: 2
Voltage:
12 V
Capacity:
200 Ah/180 Ah
76
TECHNICAL INFORMATION

Wheels
Wheel bolts
tightening torque:
700 Nm
Tyre pressure
Tyre pressures vary, depending upon the size and make of the
tyre. Refer to the tyre pressure table of the relevant tyre
manufacturer for the correct pressures.
TECHNICAL INFORMATION
77

LUBRICANTS, COOLANT AND FUEL SPECIFICATIONS.
TO MEET GUARANTEE REQUIREMENTS AND TO INCREASE
DAF BUS INTERNATIONAL PRODUCTS’ LIFETIME, IT IS OF THE
UTMOST IMPORTANCE THAT THE CORRECT LUBRICANTS,
COOLANT AND FUEL ARE USED AND THAT REPLACEMENT
INTERVALS ARE BEING OBEYED.
Ask your fuel and lubricants supplier(s) if their products meet the
DAF BUS INTERNATIONAL specifications.
Warning:
Upon repair or reconditioning of engines involving the renewal
of piston rings and/or cylinder liners, the engine must be filled
with a “single grade (SAE 30)” ACEA-A1 (or CCMC-D4) oil.
Change this for the specified oil after 2,500 km.
Temperature limits
should be used as
guidelines only.
VISCOSITY
Avoid contact of skin with:
- fuel
- lubricants
- coolants
On skin contact, remove fluid immediately with water and soap.
OIL SPECIFICATIONS:
engine oil:
All engines
Oil quality
ACEA-E3 (or CCMC-D5)
**
When using SAE-10W oil, constant high number of revolutions
and heavy loads must be avoided if the temperature rises above
the indicated value.
Note:
If ACEA-E1 or E2 (or CCMC-D4) oil is used instead of the specified
ACEA E3 (or CCMC-D5) quality, the maximum period of time between
oil changes is 5000 km, regardless of the sulphur contents of
the fuel.
78
TECHNICAL INFORMATION

Specification gearbox and intermediate gear oil
Viscosity
Type Multi grade Single grade oil Oil quality
oil
< 0°C > 0°C
ZF SAE 80W90 SAE-80W SAE-80W API-GL4
SAE-30 SAE-30 CCMC-D4
SAE-40/*
ZF gearbox with SAE-30 SAE-30 CCMC-D4
ZF retarder/intarder
ALLISON (GM)
Voith D851,D854,Diwa2-3
ZF HP 500,590,600
Automatic transmission
ATF suffix A or Dexron II D or E
ATF types Dexron II D or E,or Dexron III or Mercon M
Specification lubricants for driven axles
Type Viscosity class Oil quality
Multigrade oil
< 0°C > 0°C
All types SAE85W140 API-GL5
Specifications for hydraulic fluids, greases and oils.
Hydraulic fluids
Hydraulic power steering
Hydraulic fan drive
Bevel box steering gear
}
ATF type A suffix A or ATF type
Dexron II D with valid approval
number
*
When SAE-80W90 or SAE-40 oil is used, there may be an
increase in the gear-changing forces.
Specification retarder oil:
Type Viscosity Oil quality
Voith Single grade SAE-20W20 or 10W or SAE 30 CCMC-D4
Multigrade all types API-CC/SF or better
TECHNICAL INFORMATION
79

Greases and oils
Automatic greasing system:
Lubricating grease:
Oil lubricated front wheel hubs:
Grease-lubricated front wheel hubs:
NLGI O EP grade
Lithium-base grease with
EP additive, NLGI class 2
SAE-80W90 or SAE-80W
according to API-GL4 or
GL5
Lithium-base grease with
EP additive,
NLGI class 2, or a better
grease, such as:
Castrol LMX,
BP ENERGREASE LC2,
ELF GRX 500,
MOBILGREASE HP2,
Q8 RUBENS,
SHELL RETINAX LX,
TEXACO HYTEX EP2,
or an equivalent
Specifications of diesel fuel
The minimum requirement for fuel is to EN 590. At extremely low
temperatures - AND IF PERMITTED BY LAW - a maximum of 20%
kerosine my be added. However, if this is PROHIBITED BY LAW, a
maximum of 20% lead-free petrol may be added.
If high speed fuel systems are used make sure to use fuel with
non-foaming diesel only.
Note
When using diesel fuel with a sulphur content HIGHER than 0,5%,
the oil change intervals should be adapted as follows:
Sulphur content Oil change interval
0.5% - 1,0 % 10.000 km
1.0% - 1.5% 5.000 km
Lubricity standard
Requirement: test method HFRR according to CEC-F-06-A96
standard
Test value ≤ 400 µm
NO ADDITIVE OF ANY KIND MAY BE MIXED WITH THE FUEL
OR LUBRICANTS EXCEPT IN THOSE CASES SPECIFIED BY
DAF BUS INTERNATIONAL.
80
TECHNICAL INFORMATION

Specification of coolants
Coolant is a noxious fluid.
Protect skin and eyes.
Coolant is harmful for the environment; after use,
it should be processed as industrial waste.
The cooling system should preferably be filled with a ready-mixed
coolant containing antifreeze and corrosion-inhibiting additives.
When tap water is used, an ethylene-glycol based antifreeze must
always be added as well as corrosion-inhibiting additives if there is
a possibility of the ambient temperature falling below +5°C.
- For protection down to - 18°C, a solution containing 33%
antifreeze can be used.
- For protection down to - 37°C, a solution containing 50%
antifreeze can be used.
Both ANTIFREEZE and ANTI-CORROSION coolants must
satisfy the following specifications:
ethylene-glycerol: ASTM D-3306, BS 6580 and SAE-J-1034;
propylene-glycerol: ASTM D-5216 and BS 6580.
Ethylene-glycerol and propylene-glycerol must never be mixed
because the agents cannot tolerate each other. It is also better not
to mix one type of glycol coming from different manufacturers.
In the summer, coolant containing antifreeze can remain in the
cooling system.
The antifreeze concentration, and the protection taken, for example,
against corrosion, should then also be kept topped up.
In climates where temperatures never fall below + 5°C, it is sufficient
to add a corrosion-inhibiting agent to the coolant according to ASTM
D-3306.
Follow the manufacturer’s instructions when using coolants.
Coolant quality requirements:
- pH 5.5-9.0
- total solid matter ≤ 340 ppm
- Hardness ≤ 170 ppm (calcium and/or
magnesium carbonate).
- Chloride ≤ 40 ppm (sodium chloride)
- Sulphate ≤ 100 ppm (magnesium
and/or sodiumsulphate)
In regard to the use of additives, the cooling system should be
flushed out and filled with the new coolant every two years.
The information and data given above are based on normal
operating conditions. As the specified substances are marketed
under various brand names, consult your lubricant supplier for the
correct interpretation of these specifications.
TECHNICAL INFORMATION
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LUBRICATION CHART SB 220 GS
Multi purpose grease
Engine oil
Transmission fluid
Hypoid oil
Brake fluid
Automatic transmission fluid
1. Not applicable 9. Automatic transmission C = CHECK
2. Brake camshafts 10. Hydraulic fluid reservoir, power steering S = SYMMETRICAL
3. Front wheel bearings 11. Hydraulic fan drive V = CHANGE/RENEW
4. King pins (top and bottom) 12. Engine oil
5. Differential
6. Brake camshafts
7. Rear wheel bearings
8. Universal joint
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LUBRICATION CHART

LUBRICATION CHART 83

Index
A
ABS (Anti-lock Braking System) ............................................ 45
Adjustable steering column ................................................... 36
Air cleaner warning lamp ....................................................... 34
Air leakage ............................................................................... 8
Air pressure gauge ................................................................ 23
Air suspension (ECAS) .......................................................... 49
ASR warning lamp ................................................................. 22
Automatic chassis lubrication ................................................ 57
B
Batteries ............................................................................ 8, 55
Battery charge warning lamp ................................................ 32
Brakes .................................................................................... 45
C
Central lubrication warning lamp ........................................... 22
Central safety switch .............................................................. 31
Charging .................................................................................. 9
Chassis height adjustment warning lamp .............................. 33
Chassis number ..................................................................... 11
Check the antifreeze content ................................................. 58
Checking the coolant level ..................................................... 51
Checking the oil level ............................................................. 51
Cheking the air drier of the brake system ............................. 56
Cigar lighter/inspection lamp socket ...................................... 31
Cleaning ................................................................................. 10
Cold-weather conditions .......................................................... 7
Components ............................................................................ 6
Contact switch/starter switch/steering lock ........................... 37
Contact/engine stop switch .................................................... 30
Coolant temperature gauge ................................................... 23
D
Daily maintenance ................................................................. 51
Diesel fuel .............................................................................. 58
Differential lock ...................................................................... 44
Differential lock switch ........................................................... 31
Dimmer switch ....................................................................... 20
Dipped beam warning lamp ................................................... 20
Direction indicator lamp ......................................................... 20
Display panel.......................................................................... 18
Door controlled brake warning lamp ...................................... 21
Door or hatch open warning lamp ......................................... 34
Door-controlled brake ............................................................ 42
Draining the air reservoirs ..................................................... 56
Driver's seat and mirrors ....................................................... 53
Driving .................................................................................... 37
Driving with the ZF HP/Voith Diwa.3 automatic gear ............ 40
E
E-gas (electronic throttle control) .......................................... 47
E-gas warning lamp ............................................................... 33
Ecas driving level switch ........................................................ 30
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INDEX

ECAS warning lamp ............................................................... 51
EGAS warning lamp .............................................................. 48
Emergency door not locked warning lamp ............................ 34
Emergency repairs ................................................................ 59
Adjusting brakes ............................................................... 82
Bleeding the fuel system .................................................. 59
Releasing the parkign brake ............................................ 59
Serious oil leakage ........................................................... 59
V-belts .............................................................................. 59
Voith automatic gearbox .................................................. 59
Engine ...................................................................................... 6
Engine compartment temperature warning light ................... 31
Engine identification plate ...................................................... 11
Engine number ...................................................................... 11
Engine oil level warning lamp ................................................ 32
Engine protection system (EPS)* .......................................... 51
Environmental concerns .......................................................... 9
Extra vehicle reverse control switch ...................................... 31
F
Filler cap cooling system ......................................................... 6
Fire extinguisher ...................................................................... 6
First aid kit ............................................................................... 6
Front fog switch ...................................................................... 20
Fuel gauge ............................................................................. 22
Fuses ..................................................................................... 67
G
Gearbox warning light ............................................................ 32
H
Hazard warning lights switch ................................................. 22
High generator voltage warning lamp .................................... 33
Hydraulic fan drive ................................................................. 54
Hydraulically assisted power steering ................................... 54
I
Identification ........................................................................... 11
Identification plate .................................................................. 13
Identity card ........................................................................... 12
Important instructions .............................................................. 8
Inflating the tyres ................................................................... 65
L
Leakage in air suspension system ........................................ 65
Left multi-function switch ....................................................... 35
Light switch ............................................................................ 20
Lighting and instruments ....................................................... 53
Lubricants. coolant and fuel specifications
Specifications of coolants ................................................ 78
Lubrication chart SB 220 GS ................................................. 82
INDEX
85

M
Main beam warning lamp ...................................................... 20
Maintenance activities ............................................................. 7
Manually operated vehicle kneeling switch (Ecas 2) ............. 30
Master switch instrument lamp .............................................. 20
Master switch operation ......................................................... 30
Moisture separator in fuel system ......................................... 55
O
Oil pressure warning lamp ..................................................... 33
Oils and lubricants ................................................................... 7
Operating panel in engine compartment ............................... 38
Operations instruments ......................................................... 34
P
Parking brake warning lamp .................................................. 21
Preglow switch ....................................................................... 22
Preglowing system ................................................................. 38
Preglowing warning lamp ....................................................... 20
Preventive maintenance after the winter season .................. 59
Cooling system ................................................................. 59
Windscreen washer reservoir .......................................... 59
Preventive maintenance before the winder season .............. 57
R
Raise/lower vehicle switch ..................................................... 30
Rear fog light switch .............................................................. 22
Rear fog light warning lamp ................................................... 22
Rear service points ................................................................ 50
Red central warning lamp ...................................................... 21
Replacing bulbs ..................................................................... 66
Retarder off instrument lamp ................................................. 20
Retarder on/off switch ............................................................ 30
Retarder temperature gauge ................................................. 23
Retarder temperature warning lamp ..................................... 31
Retarder warning lamp .......................................................... 21
Rev-counter ........................................................................... 24
Running in ................................................................................ 8
S
Safety regulations .................................................................... 6
Speed limiter warning lamp .................................................. 34
Start procedure ...................................................................... 39
Start switch ............................................................................ 22
Starting .................................................................................... 9
Steering ................................................................................. 45
Stopping ................................................................................ 46
Switches, gauges and warning lamps on the instrume ...... 20
T
Tachograph............................................................................ 24
Technical specifications ........................................................ 74
Component overview SB 220 GS .................................... 74
Towing ................................................................................... 66
Trailer's direction indicator warning lamp ............................ 20
86
INDEX

Tyres and rims ....................................................................... 52
V
Vehicle identification number ................................................. 14
Vehicle identification plate ..................................................... 12
Voith automatic gearbox ........................................................ 54
Voltage ..................................................................................... 8
Voltmeter (battery condition meter) ....................................... 23
Voltmeter/retarder temperature gauge .................................. 23
W
Warning lamp ABS ................................................................ 32
Warning lamp air pressure .................................................... 32
Warning lamp coolant temperature/coolant level .................. 33
Warning lamp vehicle not on driving level ............................. 21
Warning lamps on the display panel ...................................... 31
Warning symbol ....................................................................... 5
Warnings and safety regulations ............................................. 6
Weekly maintenance ............................................................. 54
Welding .................................................................................... 9
Wheels ................................................................................... 64
Windscreen washer reservoir ................................................ 57
Z
ZF automatic gearbox ............................................................ 55
ZF/Voith retarder .................................................................... 43
Y
Yellow central warning lamp .................................................. 21
INDEX
87

DAF BUS INTERNATIONAL B.V.
is part of the VDL-group.
A powerful combination of specialised companies
in the metal and plastics industries.
The VDL Group’s activities vary from surface treatment,
plastics processing and metal working in particular,
to the development, assembly and sale
of semi-manufactured and end products.
DAF BUS INTERNATIONAL B.V.
In the interest of ongoing product development,
DAF BUS INTERNATIONAL B.V. reserves the right at all times,
to alter specifications or products without prior notice.
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