5 - Training Registration System - VDL Bus & Coach

MAINTENANCE MANUAL 

SB(R)4000+ PF/XF SB(R)230 PF Euro3 

0616 DW05073102


Introduction 

This maintenance manual contains all the relevant maintenance 

work. It also contains safety regulations, which 

must be strictly observed. 

Work which is not described in this maintenance manual, 

such as revision, fault finding, etc., is described in the 

VDL Bus & Coach Workshop Instruction Manual or the 

Workshop Instructions for the component concerned. 

Experienced mechanic 

The technical information and the explanation of the 

maintenance work given in this maintenance manual 

have been compiled with the utmost care. 

Whilst compiling this maintenance manual, it has been 

assumed that the mechanic has the necessary experience 

and has had the required education or training to be 

able to carry out the maintenance work in a responsible 

and safe manner. 

Vehicle type 

The information in this maintenance manual has been 

updated until the time of printing and only relates to the 

vehicle series: 

SB(R) 4000+ PF/XF Euro3 

SB(R) 230 PF Euro3 

0616


� Technical information 

0616 

PE/XE engine................................................. 1-1 

General information ........................................ 1-1 

Tightening torques .......................................... 1-3 

Filling quantities .............................................. 1-4 

Gearbox ......................................................... 2-1 

General ........................................................... 2-1 



Retarder ......................................................... 3-1 



Rear axle ........................................................ 4-1 




Brakes ............................................................ 5-1 



Steering mechanism/fan drive..................... 6-1 




Front axle/trailing axle.................................. 7-1 



General information...................................... 8-1 

Specifications.................................................. 8-1 

� Special tools 

Special tools.................................................. 1-1 

� Threaded connections 

Threaded connections.................................. 1-1 


� Liquids, oils and lubricants 

Specifications................................................ 1-1 


Engine............................................................. 1-2 

Gearbox and retarder...................................... 1-4 

Axles and hubs ............................................... 1-7 

Hydraulic fluids and greases........................... 1-9 

Fuel system................................................... 1-10 

Coolant specification..................................... 1-12 

� maintenance schedule 

CONTENTS 

Maintenance intervals ...................................1-1 

The Maintenance schedule .............................1-1 

Explanation of the maintenance schedule.......1-2 

Influence of diesel on the maintenance 

intervals ...........................................................1-5 

Service intervals for difficult conditions............1-6 

First service .....................................................1-6 

Maintenance activities .................................2-1 

First service .....................................................2-1 

Intermediate service ........................................2-3 

Mileage dependent service..............................2-4 

Annual service .................................................2-6 

� Explanation of the 

maintenance work 

Safety regulations .........................................1-1 

General information ......................................2-1 

Introduction......................................................2-1 

Technical information ......................................2-1 

Warning symbol...............................................2-2 

Environment ....................................................2-2 

Spare Parts and Components .........................2-3 

Maintenance guidelines...................................2-3 

Inspection and adjustment ...........................3-1 

Inspecting the pedal rubbers ...........................3-1 

Inspecting the adjustability of the 

steering column ...............................................3-1 

Inspecting the battery ......................................3-2 

Inspecting the battery connections ..................3-4 

Checking the battery box attachment ..............3-5 

Checking the earth and positive 

feed-through on the chassis ............................3-6 

Inspecting the anti-chip coating .......................3-8 

Anti-corrosion treatment ..................................3-9 

Fault analysis.................................................3-10 

Inspecting the engine oil level .......................3-12 

Checking for fuel leaks ..................................3-14 

Inspecting the fuel tank 

clamping straps .............................................3-15 

Inspecting and adjusting the valve clearance 3-16 

Inspecting the compressor line......................3-18 

Inspecting the v-belts.....................................3-19 

Inspecting the poly v-belt...............................3-21 

Checking the automatic poly v-belt 

tensioner........................................................3-21 

Checking the air conditioning v-belt...............3-22 

Inspecting the air filter blockage indicator .....3-23 

Checking the air inlet 

dust trapping valve ........................................3-24 

Inspecting the air intake system for 

leaks, damage and attachment .....................3-25 

Inspecting the exhaust system ......................3-26 

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CONTENTS 

Inspecting the Eminox ESI............................ 3-27 

Checking the exhaust back pressure............ 3-29 

Inspecting the catalyser ................................ 3-31 

Inspecting the hydraulic fan drive fluid level . 3-32 

Checking the hydraulic fan lines/hoses......... 3-33 

Checking the cooling system’s antifreeze 

concentration ................................................ 3-34 

Inspecting/topping up the coolant level......... 3-35 

Checking the cooling system for leaks and 

damage ......................................................... 3-36 

Checking the radiator and intercooler for 

contamination................................................ 3-39 

Checking the steering oil level ...................... 3-40 

Inspecting the steering mechanism’s 

lines/hoses/connections................................ 3-41 

Inspecting the steering 

mechanism’s bevel box................................. 3-42 

Inspecting the pivot points of the steering 

mechanism.................................................... 3-43 

Inspecting the swivel axle play...................... 3-46 

Inspecting the blocking cylinders of the 

3rd axle ......................................................... 3-47 

Inspecting the maximum wheel turning angle3-49 

Inspecting the brake components and 

brake lines..................................................... 3-50 

Inspecting the brake calliper play.................. 3-51 

Checking the thickness of the brake pads .... 3-54 

Checking the automatic slack adjuster ......... 3-55 

Inspecting the brake discs ............................ 3-57 

Greasing guide bushes and bearing bushes 3-58 

Inspecting the brake 

deceleration .................................................. 3-59 

Inspecting the oil separator........................... 3-60 

Checking the attachment of the shock 

absorbers and checking them for damage.... 3-61 

Inspecting the U-bolts ................................... 3-61 

Checking the pivot points of the axle 

suspension and the pneumatic suspension .. 3-61 

Inspecting the pneumatic suspension’s 

air bellows ..................................................... 3-62 

Inspecting the chassis’ pneumatic 

suspension.................................................... 3-63 

Checking the driving height........................... 3-64 

Checking the differential ............................... 3-65 

Inspecting the drive shafts, 

sliding joints and universal joints for wear..... 3-67 

Inspecting the grease lubricated wheel hubs 3-68 

Inspecting and adjusting the wheel 

bearing play (ZF hubs).................................. 3-69 

Inspecting the tyres and wheel rims.............. 3-70 

Checking the attachment of the wheels 

(retightening)................................................. 3-72 

Changing wheels .......................................... 3-73 

Checking the tyre pressure (including the 

spare tyre)..................................................... 3-76 

Checking the gearbox oil level ...................... 3-77 

Checking the SGS setting............................. 3-79 

Checking the clutch system for leaks............ 3-81 

DW05073102 


Inspecting/topping up the hydraulic 

clutch fluid......................................................3-82 

Checking the clutch plate for wear ................3-83 

Checking the oil level of the R115E retarder .3-84 

Checking the operation of all the driving and 

braking functions ...........................................3-85 

Checking the operation of the retarder ..........3-85 

Checking the instruments and inspection 

lights ..............................................................3-86 

Inspecting the gearbox and the gear 

changing pattern............................................3-86 

Removal and installation ..............................4-1 

Removing and installing the main fuse(s)........4-1 

Removing and installing the engine oil filter ....4-2 

Removing and installing the 

centrifugal filter rotor........................................4-3 

Removing and installing the fuel filter..............4-4 

Removing and installing the cylinder head 

cover................................................................4-5 

Removing and installing the air filter element..4-6 

Removing and installing the CRT 

filter/catalyser ..................................................4-7 

Removing and installing the hydraulic fan 

filter................................................................4-10 

Removing and installing the steering 

mechanism’s filter..........................................4-11 

Removing and installing the air dryer 

filter element ..................................................4-12 

Removing and installing the brake pads........4-13 

Removing and installing the (Spring) 

brake cylinder ................................................4-17 

Removing and installing the brake calliper ....4-19 

Removing and installing the brake 

calliper bracket ..............................................4-22 

Removing and installing the wheel hub .........4-23 

Removing and installing the 

v-belts ............................................................4-26 

Removal and installation gearbox oil filter 

element .........................................................4-29 

Draining and filling ........................................5-1 

Topping up the battery fluid .............................5-1 

Draining and filling the engine oil.....................5-2 

Draining the water separator ...........................5-3 

Draining and filling the hydraulic fan drive.......5-4 

Draining and filling the coolant ........................5-5 

Draining and filling the steering oil...................5-7 

Draining the condensation from the 

air reservoirs....................................................5-9 

Draining and filling the differential oil.............5-10 

Draining and filling the gearbox oil and 

replacing the filter ..........................................5-11 

Draining and filling the hydraulic clutch fluid..5-15 

Bleeding the clutch system............................5-16 

Draining and filling the retarder OIl................5-18 

Bleeding the fuel system ...............................5-20 

0616


0616 

Cleaning......................................................... 6-1 

Cleaning the battery terminals ........................ 6-1 

Cleaning the water separator.......................... 6-2 

Cleaning the coarse fuel filter element ........... 6-3 

Cleaning the CRT filter.................................... 6-4 

Cleaning the catalyser .................................... 6-5 

Cleaning the radiator and the intercooler 

element .......................................................... 6-6 

Cleaning the rear axle breather ...................... 6-9 

Cleaning the gearbox breather(s) ................. 6-10 

Cleaning the vehicle...................................... 6-11 

Lubrication .................................................... 7-1 

Lubricating according to the lubrication 

schedule.......................................................... 7-1 

Lubrication diagram ........................................ 7-3 

Jacking and lifting instructions................... 8-1 

Jacking instructions......................................... 8-1 

Lifting instructions ........................................... 8-3 

supporting the vehicle ..................................... 8-6 

CONTENTS 

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Maindisclaimer 

© 0616 VDL Bus & Coach bv, Eindhoven, 

The Netherlands. 

In the interest of continuous product development VDL 

Bus & Coach reserves the right to change specifications 

or products at any time without prior notice. 

No part of this publication may be reproduced and/or 

published by printing, by photocopying, in digital format 

or in any way whatsoever without the prior consent in 

writing of VDL Bus & Coach. 

This manual shall be governed by and applied in accordance 

with the laws of the Netherlands. 

Any dispute here under shall be referred to the decision 

of the District Court of ‘s-Gravenhage in the Netherlands 

0616


TECHNICAL INFORMATION 

0616 


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1. PE/XE ENGINE 

1.1 GENERAL INFORMATION 

1.1.1 VALVE CLEARANCE 

Cold valve clearance adjustment inspection 

Inlet 0.45 mm 

Outlet 0.45 mm 

1.1.2 V-BELT TENSION 

AVX open flank V-belt tension (N) 

New V-belt 

Adjustment tension 650 ± 10% 

Inspection tension ≤ 400 

Run-in V-belt 

Lowest tension ≤ 300 

Correction tension 350 

Explanation: 

1. V-belts with an open flank can be recognized by the fact 

that there is no fabric in the rubber on the flanks and the 

inside of the V-belt, with the exception of the top of the 

belt flank (ground belt flank). 

Type: with or without teeth. 

2. After fitting the new V-belt, adjust the pre-tension to the 

adjustment tension and, after taking a test drive, check 

the pre-tension against the inspection tension. 

If the measured inspection tension is less than the value 

given in the table, adjust the V-belt to the minimum 

inspection tension. 

3. If the belt tension is less than the lowest tension, then it 

should be adjusted to the correction tension. 

0616 


PE/XE engine 

00842b 

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PE/XE engine 

1.1.3 AUTOMATIC POLY V-BELT TENSIONER 

Torque from (0) to close to 17 mm rotation (A): 19 - 37 Nm 

1.1.4 EXPANSION TANK PRESSURE CAP 

Opening pressure of pressure relief 

valve 

1 - 1.2 bar 

Opening pressure of vacuum valve 0.1 - 0.02 bar 

Pressure-testing the cooling system 

Pressurization pressure 0.7 - 0.9 bar 


1 - 2 0616


1.2 TIGHTENING TORQUES 

Lubrication system 

Drain plug 60 Nm 

Oil filter screw cap 40 Nm 

Centrifugal oil filter central bolt 20 Nm 

Fuel system 

Fuel filter screw cap 25 Nm 

Fuel tank clamping strap attachment nuts 20 Nm 

Cylinder head cover 

Cylinder head cover attachment bolts 25 Nm 

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PE/XE engine 

1 - 3 

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PE/XE engine 

1.3 FILLING QUANTITIES 

PE engine lubrication system 

Engine contents (including filter 

and oil cooler) 

Approx. 33 litres 

Sump, minimum level Approx. 18 litres 

Sump, maximum level Approx. 26 litres 

XE engine lubrication system 

Engine contents (including filter 

and oil cooler) 

Approx. 39.5 litres 

Sump, minimum level Approx. 25 litres 

Sump, maximum level Approx. 33 litres 

Cooling system 

Engine cooling system Approx. 25 litres 

Total cooling system (excluding Approx. 70 litres 

heating) 

Total cooling system (including Approx. 100 - 140 litres 

heating) 


1 - 4 0616


2. GEARBOX 

2.1 GENERAL 

ZF gearbox type 

Each gearbox has a type-plate attached to it, indicating the 

type of gearbox. This data is also stated on the identity card 

of the relevant vehicle. 

0616 


Gearbox 

ZF gearbox type-plate 

1. Type of gearbox 

2. Series no. (ZF) 

3. Parts list (ZF) 

4. Specification no. 

5. Pulse generator ratio 

6. Gearbox ratio 

7. Engine speed using PTO 

8. PTO speed 

9. Gearbox oil capacity 

10. Oil specification 

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Gearbox 


ZF Ecomat 2 

Oil filter cover (A) 25 Nm 

Oil drain plug (B) 50 Nm 

ZF AS Tronic with integrated retarder 

Oil spill plug/Oil filler plug (A) 60 Nm 

Oil drain plug gear box (B) 60 Nm 

Oil drain plug retarder (C) 60 Nm 

Oil filter attachment bolt (1) 23 Nm 


2 - 2 0616 

03902B


GO170/190/210 

Oil spill plug/Oil filler plug (A) 47 Nm 

Oil sieve plug (B) 60 Nm 

Oil drain plug (C and D) 47 Nm 

GO170/190/210 gearbox bleed unit 

Bleed bolt (A) 20 Nm 

0616 


Gearbox 

03900B 

03901B 

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Gearbox 


ZF Ecomat 2 (6HP592C/6HP602C) 

Volume: When changing the oil 

1st filling Approx. 10 litres 

2nd filling whilst idlingthe Approx. 4 litres 

engine 

ZF AS Tronic 

Volume: When changing the oil Approx. 12.0 litres 

GO 170/190/210 

Volume: When changing the oil Approx. 12.5 litres 

Comment 

If the oil volume is indicated on the type plate, then this is 

decisive. 


2 - 4 0616


3. RETARDER 


R115E 

Oil filler plug (A) 100 Nm 

Oil spill plug (B) 65 Nm 

Oil drain plug (C and D) 65 Nm 

Oil sieve plug (E) 100 Nm 

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Retarder 

03903B 

3 - 1 

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Retarder 


R115E 

Volume: When changing the oil Approx. 7 litres 

1st filling Approx. 7.8 litres 

Comment 

If the oil volume is indicated on the type plate, then this is 

decisive. 


3 - 2 0616


4. REAR AXLE 


Driving height 

Front axle 435 ± 5 mm (with calibration blocks) 

Rear axle 510 ± 5 mm (with calibration blocks) 


1347 HAS 

0616 

03898B 

A. Axle shaft attachment bolts 260 Nm 

B. Wheel nuts 700 Nm (retighten after 100 km) 

C. Differential oil drain plug 85 Nm 

D. Differential oil spill plug/oil filler plug 85 Nm 

E. Brake calliper bracket attachment bolts 300 - 330 Nm 

F. Differential attachment bolts 260 Nm a 

G. Drive flange attachment nut 1,250 Nm b 

a. Secure with Loctite 572 

b. Secure with Loctite 262 

ABS sensor ring 

Axial oscillation Max. 0.25 mm 


Rear axle 

4 - 1 

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Rear axle 

Rear axle suspension 


Differential 

Volume when changing the oil Approx. 21 litres 

03899B 

Wheel hub 

The wheel bearings of the wheel hub unit are grease-lubricated 

and maintenance-free. 


A. Shock absorber nut M16 X 1.5 100 Nm 

B. Air bellows attachment bolt M16 8.8 Max. 170 Nm 

C. Air bellows nut M10 Max. 45 Nm 

D. Torque rod nut M20 8.8 395 ± 30 Nm 

E. Torque rod nut M20 8.8 395 ± 30 Nm 

F. Stabiliser shackle nut M12 8.8 79 ± 6 Nm 

G. Stabiliser nut M18 8.8 235 ± 35 Nm 

H. Torque rod nut M20 8.8 395 ± 30 Nm 

I. Stabiliser nut M16 10.9 260 ± 20 Nm 

J. Rubber axle bumper bolt M12 10.9 110 ± 8 Nm 

K. Leaf-spring clip nut M24 10.9 615 ± 50 Nm a 

a. Tighten both leaf-spring clip nuts evenly in turn in 3 or 4 steps 

4 - 2 0616


5. BRAKES 


Brake pads 

Max. brake pad thickness (C). 30 mm 

Minimum lining thickness (E). 2 mm (at the thinnest 

place) 

Minimum brake pad thickness 11 mm (at the thinnest 

(F) 

place) for a 9 mm rear 

plate thickness (D) 

Replacement Replace all the brake pads 

on the same axle at the 

same time and only use 

brake pads of the specified 

lining quality 

Brake pad/brake disc play 0.6 - 1.1 mm 

Brake disc 

Max. brake disc thickness (A). 45 mm 

Minimum brake disc thickness 37 mm (wear limit, disc 

(B). 

must be replaced) 

Minimum thickness, turning 40 mm 

size 

Comment 

If the brake disc thickness is £39 mm at the time the brake 

pads are replaced, then the brake disc must also be 

replaced. 

Wear patterns below are permissible: 

A1 Network of heat cracks. 

B1 Cracks which run to the middle and which are less than 

1.5 mm wide and 1.5 mm deep. 

Max. 0.75 x width of the friction surface (a). 

C1 Irregularities in the disc surface up to 1.5 mm. 

D1 Not permitted: Through-cracks. 

0616 


Brakes 

5 - 1 

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Brakes 

Axial brake calliper play in direction (A)0.6 - 1.1 mm 

Sliding over the guide pins minimum 25 mm 

Brake calliper play on the guide maximum 2.0 mm 

bushes (Y - X) 



Brake calliper 

Brake calliper attachment bolts 180 Nm +90° extra angular rotation 

Brake calliper bracket on the wheel hub unit (VDL axle) 440 Nm 

Brake calliper bracket on the wheel hub unit (ZF axle) 275 Nm (guide bolt) 

300 Nm (hexagonal bolt M16 x 1.5 10.9) 

Brake disc 

Locking plate attachment bolts (VDL axle) 30 Nm 

5 - 2 0616


6. STEERING MECHANISM/FAN DRIVE 


0616 


Steering mechanism/fan drive 

Maximum axial track rod/steering rod ball play 2.0 mm (for an axial force of approx. 1,800 N) 

Maximum pitman arm play 0 - 0.02 mm 


Steering mechanism 

03905B 

A Steering rod coupling lock nut M10 10.9 52 ± 4 Nm 

B Steering box bolt M20 10.9 600 ± 30 Nm 

C Pitman arm nut 850 ± 42 Nm 

D Auxiliary pitman arm bracket bolt M20 10.9 520 ± 20 Nm 

E Track rod/steering rod lock nut M18 10.9 250 ± 10 

F Track rod/steering rod castellated nut M24 10.9 290 ± 10 Nm a 

G Track rod arm bolt M24 10.9 1,100 Nm 

H Steering wheel nut 65 ± 5 Nm 

a. Continue to tighten until the split pin fits (max. 30°) 

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Steering mechanism/fan drive 

04117B 

Fan drive 

Fan driver filter element attachment bolt 21.2 Nm 



A Steering cylinder bracket bolt M14 10.9 170 ± 15 Nm 

B Steering arm bolt M24 10.9 1,100 Nm 

C Track rod arm bolt M24 10.9 1,100 Nm 

D Steering shock absorber castellated nut M14 80* Nm 

E Track rod castellated nut M24 10.9 265 ± 15 Nm a 

F Steering shock absorber bracket bolt M20 10.9 620 Nm 

G Steering shock absorber bolt M14 12.9 90 ± 13 Nm 

H Wheel nut M22 10.9 600 Nm 

I Steering cylinder fork lock nut M22 100 ± 10 Nm 

J Steering rod clamping bow lock nut 170 ± 10 Nm 

a. Continue to tighten until the split pin fits (max. 60°). 

Fan drive oil reservoir Approx. 10 litres 

Steering mechanism oil reservoir Approx. 7.5 litres 

6 - 2 0616


7. FRONT AXLE/TRAILING AXLE 


Wheel bearings 

Play 0.02 - 0.04 mm 

Swivel axle play 

Axial 0.01 - 0.15 mm 

Wheel speed sensor ring 

Axial oscillation Max. 0.25 mm 

Driving height 

Front axle 435 ± 5 mm (with adjustment 

gauge) 

Rear axle 510 ± 5 mm (with adjustment 

gauge) 

0616 


Front axle/trailing axle 

Wheel turning angle 

Front axle Inner wheel Outer wheel 

56° 46° For tyre size 275/70R22,5 

52° 43.7° For tyre size 295/80R22.5 

52° 43.7° For tyre size 315/70R22.5 

51° 41.5° For tyre size 315/80R22.5 

Trailing axle Inner wheel Outer wheel 

15° 13.2° 

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The tightening torques only apply to wax-dipped threaded 

connections. 

7.2.1 WHEEL HUB UNIT 

A Hub cap attachment bolt 25 Nm 

B Hub nut 240 Nm 

C Hub nut lock bolt 65 Nm 


7 - 2 0616 

03906B


7.2.2 FRONT WHEEL SUSPENSION 

0616 

1151577 

A Air bellows nut M10 8.8 Max. 45 Nm 

B Air bellows bolt M16 10.9 Max. 170 Nm 

C Shock absorber nut M16 10.9 100 ± 10 Nm 

D Brake calliper guide bolt 275 Nm 

Brake calliper bolt M16 10.9 300 Nm 

E Stop bolt 300 Nm 

F Wheel nut M22 10.9 600 Nm (1) 

G Supporting arm attachment bolt 1,000 Nm 

H Supporting arm attachment bolt 1,000 Nm 

I Upper supporting arm bolt M18 10.9 360 ± 30 Nm 

J Lower supporting arm bolt M24 10.9 880 ± 60 Nm 

Spacer disc Allen screw M8 8.8 23 ± 2 Nm (2) 



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7.2.3 TRAILING AXLE SUSPENSION 

04117B 

Comments 

1. Retighten after 100 km. If new wheel bolts are fitted, retighten again after 500 km. 

2. Secure bolt with Loctite 2701 or a similar product. 

3. Continue to tighten until the split pin fits (max. 30°). 

4. Continue to tighten until the split pin fits (max. 60°). 


A Steering cylinder bracket bolt M14 10.9 170 ± 15 Nm 

B Steering arm bolt M24 10.9 1,100 Nm 

C Track rod arm bolt M24 10.9 1,100 Nm 

D Steering shock absorber castellated nut M14 80 Nm(3) 

E Track rod castellated nut M24 10.9 265 ± 15 Nm (4) 

F Steering shock absorber bracket bolt M20 10.9 620 Nm 

G Steering shock absorber bolt M14 12.9 90 ± 13 Nm 

H Wheel nut M22 10.9 600 Nm (1) 

I Steering cylinder fork lock nut M22 100 ± 10 Nm 

J Steering rod clamping bow lock nut 170 ± 10 Nm 

7 - 4 0616


8. GENERAL INFORMATION 

8.1 SPECIFICATIONS 

8.1.1 FUEL SYSTEM 

Fuel tank clamping strap attachment nuts 20 Nm 

8.1.2 AIR INTAKE SYSTEM 

PE engine intake vacuum pressure 

Clean air filter (at maximum loaded engine speed) 25 - 35 mbar 

Contaminated air filter (at maximum loaded engine speed) 54 - 64 mbar 

XE engine intake vacuum pressure 

Clean air filter (at maximum loaded engine speed) 50 mbar 

Contaminated air filter (at maximum loaded engine speed) 75 mbar 

Maximum intake vacuum pressure 

Air filter blockage indicator RX00-2275 75 mbar 

Air filter blockage indicator AE-36501-00332 80 mbar 

8.1.3 CRT EXHAUST SYSTEM 

Exhaust gas back pressure 

For maximum loaded engine speed 105 mbar 

Tightening torques 

V-clamp 14 Nm* 

Shock absorber clamping brace 14 Nm* 

Exhaust pipe clamping brace 11 Nm* 

TorcTite clamping brace 80 Nm* 

* Fit using heat-resistant grease. Silicon-free heat-resistant grease must be used on vehicles 

with a CRT filter. 

8.1.4 BRAKE SYSTEM 

0616 


General information 

Air compressor 

Cut-out pressure 9.6 - 10.0 bar 

Cut-in pressure 0.6 - 1.2 bar below the cut-out pressure 

8.1.5 DRIVE SHAFT 

Play must not be felt on the universal joints or the sliding joint. 

Radial universal joint play 0.01 - 0.05 mm 

Maximum permitted axial universal joint play 0.3 mm 

Maximum permitted axial sliding joint play 0.2 mm 

8 - 1 

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Drive flange attachment bolt tightening torque 

M14 10.9 170 Nm 


8 - 2 0616


SPECIAL TOOLS 

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SPECIAL TOOLS 

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SPECIAL TOOLS 


0616


1. SPECIAL TOOLS 

Boost pressure pressurization cap, DAF part 

no. 0694831 

V-belt tension gauge, DAF part no. 1240443 

Oil filter key, DAF part no. 1240115 

0616 

SPECIAL TOOLS 

Special tools 

Boost pressure pressurization cap, DAF part 

no. 1329310 

Hose and two hoses clips for the pressurization cap, 

DAF part no. 1329310 and 1329311 

Hydraulic fluid pressure gauge for measuring TRW and 

ZF steering box control pressures, DAF part no 

0535653 

1 - 1 

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SPECIAL TOOLS 

Special tools 

Crankshaft cranking tool, DAF part no. 1310477 

Pitcat, VDL Bus & Coach part no. 1194535 

SGS system adjusting plate, VDL Bus & Coach part no. 

1152234 


DCI diagnosis tool, VDL Bus & Coach part no. 1149133 

1 - 2 0616


Wheel hub assembly and removal tool, ZF 

no. 5870 000 090 

Break Out Box, VDL Bus & Coach part no. 1152266 

0616 

03969B 

Adjustment gauge (VDL Bus & Coach part no. 1152749) for 

adjusting the driving height of the pneumatically suspended 

front wheel suspension. 

This special tool must be used to calibrate the height of the 

chassis and can be easily made using the diagram opposite. 

The tool, therefore, cannot be ordered from VDL Bus & 

Coach. 

SPECIAL TOOLS 

Special tools 

Dial gauge and dial gauge holder, 

ZF no. 5870 200 057 and 5870 200 055 

Adjustment gauge 1152749 

03970B 

1 - 3 

1

1 

SPECIAL TOOLS 

Special tools 

Gauge (VDL Bus & Coach part no. 1198824) for adjusting 

the driving height of the pneumatically suspended rear axle. 

This special tool must be used to calibrate the height of the 

chassis and can be easily made using the diagram below. 

The tool, therefore, cannot be ordered from VDL Bus & 

Coach. 

1198824 


1 - 4 0616


THREADED CONNECTIONS 

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1. THREADED CONNECTIONS 


The components may have threaded connections that have 

been treated with lubricant (dipped threaded connection). 

Galvanised bolts and nuts are wax dipped in the factory. 

Black annealed and phosphatised bolts and nuts are oil 

dipped. 

The advantage of using dipped nuts and bolts is that friction 

during tightening is reduced, so that the specified pre-tension 

force can be accurately obtained. The tightening torque can 

be reduced while the pre-tension force remains the same. 

To achieve a small spread in the pre-tension force, the 

dipped threaded connection must be tightened accurately. 

Therefore, always use a reliable torque wrench that provides 

a high degree of accuracy. 

Note: 

Have torque wrenches regularly inspected and calibrated. 

Re-use of fasteners (bolt/nut/threaded end) 

1. Clean the thread (take particular care to remove locking 

compound residues) and the clamping faces. 

2. Check the thread for damage. 

To do so, manually screw a new nut/bolt onto the thread 

to be checked. 

If the new nut/bolt cannot be fully hand-screwed onto the 

entire thread of the fastener to be checked, the fastener 

is not allowed to be re-used. 

3. Apply one drop of engine oil to the upper turn of the bolt 

(threaded end)/lower turn of the nut and one drop to the 

clamping faces (other lubricants are not allowed). 

4. If a locking compound has been specified, oil should not 

be applied to the thread. 

The following applies to all threaded connections (for 

both new and used vehicles): 

– in case of standard connections, apply the lubricant before 

fitting, and (re)tighten in accordance with the standard for 

dipped bolts; 

– in the case of special connections, apply the lubricant 

before fitting, and (re)tighten in accordance with the values 

specified in the instructions. 

The instructions for using lubricants also apply to new bolts 

from the warehouse. Dry threaded connections may not be 

used because of their highly variable friction coefficients. 

See the workshop instructions for the standard tightening torques. 

If one of these threaded connections must be tightened 

to a different tightening torque, then this will be stated in the 

“Technical information”. 

0616 


Threaded connections 

1 - 1 

2

2 


Threaded connections 

Applying locking compounds 

– Clean both the internal and external screw thread. 

– Remove any grease from the screw thread using a suitable 

degreasing agent which leaves no residue that could 

reduce the effectiveness of the locking compound. 

– Depending on the diameter, apply one or more drops of 

locking compound to the screw thread. Never dip the bolt 

or stud into the locking compound. 

– Apply a drop of oil under the bolt head. Locking compounds 

also reduce the frictional resistance, so that no oil has to be 

applied to the screw thread. 

– Tighten the connection to the specified torque. 


1 - 2 0616


LIQUIDS, OILS AND LUBRICANTS 

0616 


3

3 



0616


1. SPECIFICATIONS 


Comment 

See the corresponding technical information for an up-todate 

summary of the specified liquid, oil and lubricant specifications. 

In order to comply with the warranty terms and to guarantee 

the durability of VDL Bus & Coach products, it is 

essential that the correct lubricants, coolant and fuel are 

used and that they are changed in accordance with the 

intervals specified. 

Lubricant, fuel and coolant additives of any type whatsoever 

are not permitted, except in the cases specified by 

VDL Bus & Coach. 

Always follow the safety information issued by VDL Bus 

& Coach or by the supplier. 

Ask your lubricant and fuel supplier(s) whether the products 

they supply comply with VDL Bus & Coach specifications. 

VDL Bus & Coach is not responsible for any damage resulting 

from the following: 

1. Using oil of a lower quality than specified. 

2. Using oil of a lower/higher viscosity than specified. 

3. Exceeding the changing interval. 

4. Using a lubricant, fuel, coolant or brake fluid which does 

not meet the requirements set by VDL Bus & Coach. 

0616 

Avoid skin contact with: 

- Fuel 

- Lubricants 

- Coolant 

- Battery acid 

In the event of skin contact: Remove with a paper towel or a cloth, wash with water 

and soap. Contact a doctor if irritation continues. 

In the event of contact: with 

the eye 

Remove substance with a soft cloth and rinse with 

plenty of water. Contact a doctor in the event of persistent 

irritation. 

If any is swallowed: Do NOT induce vomiting. Rinse mouth, drink two 

glasses of water and contact a doctor. 

In the event of inhalation: Get some fresh air and take a rest. 


Specifications 

1 - 1 

3

3 



1.2 ENGINE 

Never mix oil of different specifications. 

This has a negative effect on the quality 

of the oil. 

DAF Engines 

The engine oil specification overview is related to the maintenance 

schedules as stated in the maintenance manuals. 

DAF specification list refer to international standards such as 

ACEA and API. 

In addition, requirements are made as to viscosity. 

If necessary, the engine oil can be subjected to additional 

requirements. These are listed in the DAF HP (High Performance) 

specification. 

If the engine oil must meet the DAF HP specification, it is 

listed as such in the overview. 

On the oil specification sheet pertaining to the specific oil 

company and on the packaging, there is an indication as to 

whether the DAF HP specifications are met. This means that 

the oil may be used for the relevant application. 

DAF HP (High Performance) specification for diesel 

engines 

– HP1: low-viscosity oil ..W30 E4/E5 

– HP2: low-viscosity oil ..W40 E4/E5 

Additional information: 

ACEA E2 and E3: mineral oil 

Explanation of overview 

V = may be used 

HP... = may be used if listed specifications have been met. 


ACEA E5: further developed ACEA E3 oil, geared to possible higher requirements on Euro 

3 engines. 

ACEA E4: partially or entirely synthetic oil, specially developed for extended oil-change 

intervals and/or highly loaded engines. 

Engine type ACEA E3 

..W-40 

PE 

Standard changing 

interval 

PE 

Extended changing 

interval 

ACEA E4 

..W-40 

ACEA E4 

..W-30 

ACEA E5 

..W-40 

ACEA E5 

..W-30 

V HP1 V HP1 

V HP2 HP2 HP2 

1 - 2 0616


Engine type ACEA E3 

..W-40 

XE 


interval 

XE 


interval 

Prescribed oil grade after an engine repair/overhaul 

For engine repair/overhaul during which short block, piston 

rings and/or cylinder linings are replaced, the engine must be 

filled with SAE 30 or 15W-30 grade oil. 

Replace this oil after 7,500-10,000 km with the specified oil. 

0616 

ACEA E4 

..W-40 

ACEA E4 

..W-30 



ACEA E5 

..W-40 

ACEA E5 

..W-30 

V V HP1 V HP1 

V HP2 HP2 HP2 

1 - 3 

3

3 



1.3 GEARBOX AND RETARDER 

1.3.1 GEARBOX OIL FOR GO GEARBOXES 

The oil specification overview is related to the maintenance 

schedule as stated in the maintenance manual. 

Type of gearbox Type of oil 

GO170/190/210 

1.3.2 GEARBOX OIL FOR ZF GEARBOXES 



For a summary of all the oil products that can be used in the 

ZF AS Tronic and ZF automatic gearbox, please refer to the 

up-to-date ZF lubricant list TE-ML-02 and TE-ML14 which is 

available from ZF on request, or consult the ZF-website 

www.ZF.com. 



1. Lubricant class 02D can only be used after a total transmission 

mileage of: 

540 000 km/3 years (long-haul/coach operation) or 

360 000 km/3 years (local/distribution/service route operation, 

heavy-duty operation). 

2. Use of class 02D or 02H oil is advised against as there 

may be an increase in the required gear-changing forces 

at low temperatures. 

Low temperatures limits 

Veedol Synmesh-AT 

Castrol Syntrans-AT 

BP Energear SHX 30 

Deagear Synth 

Shell Transmission MA 

Type of gearbox Lubricant classification 

02D (1)(2) 02E 02H (2) 02L 

ZF AS Tronic V V V V 


Lubricant class Oil type/SAE viscosity grade Use at oil sump temperatures 

02D/02E/02L 75W/75W-80/75W-85 75W-90/ATF above -40°C 

02H 80W/80W-85/80W-90 above -25°C 

1 - 4 0616


1.3.3 GEARBOX OIL FOR VOITH GEARBOXES 




Voith Diwa automatic gearbox, please refer to the up-to-date 

Voith lubricant list which can be requested from Voith, or consult 

the Voith website www.voithturbo.com. 

0616 



Type of gearbox Oil type Viscosity Lubricant class 

ZF AS Tronic 

Shell Transmission ZFLD 

Total Transmission TI 

Mobiltrans SHC 30 

75W-80 02D 

Castrol Syntrans Z MAX 

ZF-Ecofluid M 

75W-80 02E 

TUTELA TRUCK ZC 90 

BP Energear SHX 30 

80W-90 02H 

Castrol Syntrans 

Veedol Synmesh 

75W-80/75W-85 02L 

Type of gearbox Lubricant classification 

14A 14B 14C 14E 

ZF Ecomat2 V V V 

Type of gearbox Oil type Lubricant class 

ZF Ecomat2 

Shell donax TX 

Shell ATF XS 

Shell donax TZ 

14B 

14C 

14E a 

a. ZF Ecomat II plus transmissions with oil sump temperatures above 100°C may only 

be operated with fluids from the 14E lubricants category. Always use fluids according 

to 14E in borderline cases or in the case of uncertainty with reference to transmission 

operation temperature 

Service interval 60,000km/every 2 years: lubricant list 55.6335.xx 

Service interval 120,000km/every 2 years: lubricant list 55.6336.xx 

1 - 5 

3

3 



1.3.4 RETARDEROIL VOITH RETARDERS 


Type Viscosity Oil grade / Supplier 

Voith 

R115E 

mineral oil: 

(semi-) synthetic oil 

SAE-20W20 or 10W or SAE- 

30W 

SAE 0W40 

SAE 5W30 

SAE 5W40 

SAE 5W50 

SAE 10W30 

SAE 10W40 

API-CC/SF or higher 

API-CC/SF or higher 

synthetic oil SAE 75W/80W Emgard MTF Henkel 

1 - 6 0616


1.4 AXLES AND HUBS 

Rear axles 

DAF 



ZF 





ZF A132 rear axle, please refer to the up-to-date ZF lubricant 

list TE-ML-12 which is available from ZF on request, or consult 

the ZF-website www.ZF.com. 

0616 



Type of axle Type of oil Viscosity Ambient 

temperature 

Oil grade 

1347 


Mineral 

see graphic see graphic API-GL5 

interval 

1347 

Synthetic see graphic see graphic API-GL5 or GL4/GL5 


interval 

Synthetic see graphic see graphic API-GL5 or GL4/GL5 


Type of axle Lubricant classification 

A132 

12B 12C 12D 12E 

V(2) V V V 

Type of axle Type of oil Viscosity Lubricant class 

A132 

Shell spirax ASX 75W-90 12B 

Mobilube LS 80W-90 12C 

Castrol SAF-XLS 75W90 12D 

Castrol EPX 80W-90 12E 

1 - 7 

3

3 



Hubs 

Rear wheel hubs 

Grease-lubricated ZF hubs 

Grease-lubricated DAF hubs 

Front wheel hubs 

Grease-lubricated ZF hubs 


Fuchs Renolit LX-PEP2 

Fuchs Renolit LX-N EP2, 

please refer to the up-to-date ZF lubricant list 

TE-ML12 which is available from ZF on request, 

or consult the ZF-website www.ZF.com. 

Lithium-base grease with EP additive, NLGI 

class 2 

(or better), such as: 

Castrol LMX 

ELF MULTIPLEX EP2 

BP ENERGREASE LC2 

MOBILGREASE HP2 

Q8 RUBENS 

SHELL RETINAX LX 

TEXACO STARPLEX EP2 

FUCHS RENOLIT LX PEP 2B 

TOTAL MULTIS COMPLEX EP2 

or equivalent 

Saponified lithium mineral oil-based multi grade 

grease, NLGI class 2 (grease code KP2K-30 in 

according to DIN 51825), please refer to the upto-date 

ZF lubricant list TE-ML12 which is available 

from ZF on request, or consult the ZF-website 

www.ZF.com. 

1 - 8 0616


1.5 HYDRAULIC FLUIDS AND GREASES 

HYDRAULIC fluids 

Hydraulic power steering DEXRON III with valid approval number 

Hydraulic cooling fan drive DEXRON III with valid approval number 

Hydraulically-operated clutch Brake fluid DOT 4 

Greases 

Automatic greasing system: NLGI class 2 EP quality 

0616 



Lubricating grease general: Lithiumbase grease with EP additive, NLGI class 2 

Dry plate clutch: 

- Clutch plate - prise-as connection: 

- Thrust bearings without plastic coating: 

- Thrust bearings with plastic coating: 

- Clutch lever with bearing bush (manual 

gearbox) 

- Clutch lever without bearing bush (AS- 

Tronic gearbox) 

Grease on lithium base NLGI 3 

Grease on lithium base NLGI 3 

No grease permitted, dry mounting 

No grease permitted, dry mounting 

Lithium-based grease, NLGI 3 

Brake claw guide sleeves Fuchs Renolit HLT2 (white), Syntheso GL EP1 (green) 

Auxiliary pitman arm Fuchs Renolit LX-OS3, FAG Arcanol L260 

Swivel king pin and control arms ZF RL-75 A/ 

EC 

Steering box 

-Space behind the output shaft dirt and water 

seal 

Saponified lithium mineral oil-based multi grade grease, 

NLGI class 2, grease code KP2K-30 in accordance with 

DIN51825). Please refer to the up-to-date ZF lubricant list 

TE-ML12 which is available from ZF on request, or consult 

the ZF-website www.ZF.com. 

Lithium-based grease with EP additive, NLGI class 2 

(or better), such as: 

Exxon Unirex EP2 

Drive shaft Shell Retinax LX2, Fuchs Renolit LX PEP 2B 

Aluminium rims Freylube Prema or equivalent 

1 - 9 

3

3 



1.6 FUEL SYSTEM 

Diesel fuel must comply with the requirements stipulated in 

EN 590. Only non-foaming diesel may be used for highspeed 

fuelling systems. 

DAF Trucks engines 

1.6.1 SULPHUR CONTENT OF DIESEL FUEL 

Vehicles equipped with a CRT filter 

• The sulphur content of fuels used for vehicles equipped 

with a CRT filter may not exceed 50 ppm (0.005%). 

• Lubricant oils may not be added to diesel fuel for vehicles 

equipped with a CRT filter. The use of diesel fuel containing 

lubricant oil will cause damage to the catalyser, in turn 

resulting in non-compliance with the stipulated emission 

requirements. 

Vehicles equipped without a CRT filter 

• The sulphur content of fuels used for vehicles that are not 

equipped with a CRT filter may not exceed 0.2%. If the content 

is higher act according to table below. 

Sulphur content Engine oil changing interval 

> 0.2% 

At extremely low temperatures, exclusively in an emergency 

(for example, breakdown), may a quantity (depending on the 

outside temperature) of petroleum (maximum 20%) or a flow 

improver (follow product instructions) be added. 

However should THE STATUTORY REGULATIONS NOT 

PERMIT the use of the above then a maximum of 20% 

unleaded petrol may be added. 

The fuel should possess a lubricative effect in accordance 

with the following requirement (lubricity standard): 

1.6.2 BIODIESEL APPLICATION 

Half the interval with a maximum of 

25,000 km. 

Test method: HFRR, in accordance with CEC-F- 

06-A96 standard 

Test value: < 460 mm 

• There may be no negative (destructive) chemical reaction 

of the fuel on any of the engine or fuel system components. 

• Biodiesel is only permitted for the DAF PE and XE engines 

with a biodiesel modification-kit. 

• All EN590 fuel standard requirements must be met (for 

100% Biodiesel EN14214). 

• Only official produced diesel or blends with alternative fuel 

up to 5% Biodiesel is allowed for PE engines up to engine 

number S-09839 and for XE engines up to engine number 

T-78817. 

• Only official produced diesel or blends of standard diesel 

fuel with up to 100% Bio-diesel/FAME is allowed for PE 


1 - 10 0616


engines from engine number S-09839 and XE engines 

from engine number T-78817 onwards. 

• Blends of standard diesel fuel with up to 100% Bio-diesel/ 

FAME is allowed if following additional conditions are met: 

– the oil- and fuel filter change interval period must be 

diminished by half. 

– extended oil service intervals are not allowed. 

Comment 

Biodiesel has dissolving characteristics so that the change 

from diesel to biodiesel may cause deposits in the fuel system 

to dissolve and thereby clogging the filter. When changing 

from diesel to biodiesel it is wise to check the filters after 

1 or 2 tank fillings and to replace any clogged filters. At low 

temperatures biodiesel may cause problems such as clogging 

of filters. 

0616 



1 - 11 

3

3 



1.7 COOLANT SPECIFICATION 

Coolant is a toxic liquid. Protect the skin 

and eyes. 

Coolant is harmful for the environment, and 

must be processed as industrial waste. 

Use solely TEXACO HAVOLINE Extended Life Antifreeze 

Coolant (XLC). 

Follow the coolant manufacturer's directions for use. 

These VDL Bus & Coach vehicles are filled during their manufacture 

with: 

– TEXACO HAVOLINE XLC, this has a bright orange colour . 

Texaco Havoline XLC satisfies the VAG specification TL 774 

D. 

– The standard mixing ratio of Texaco Havoline xlc is 1 op 1, 

or 50% Texaco Havoline xlc and 50% water which satisfies 

the specifications opposite. This offers protection against 

corrosion and frost up to -40° C. 

– When using Texaco Havoline xlc coolant or equivalent, 

only mineralised water or water which satisfies the specifications 

opposite may be used. 

– No other coolant, additive or antifreeze may be added to 

the mixture. This may affect the corrosion protection, silt up 

lines and cause blockages. 

– The anti-freeze mixture may be left in the cooling system 

during the summer months. The concentration of antifreeze 

should be maintained in order to protect against 

damage such as corrosion, for example. 

When due regard is taken of all the 

requirements applicable to Texaco 

Havoline xlc the coolant may be used for 

up to 5 years and a maximum of 650,000 

km before being replaced 

Coolant water quality requirements 


- pH 7.0 - 9.0 

- Total fixed content ≤ 340 ppm (< 340 mg/litre) 

- Hardness* ≤ 140 ppm (calcium and/or magnesium carbonate) 

- Chloride ≤ 40 ppm (< 40 mg/litre) (sodium chloride) 

- Sulphate ≤ 100 ppm (< 100 mg/litre) (magnesium and/or sodium sulphate) 

*Hardness: 140 ppm = 8.0° German hardness /14° French hardness /10° British hardness. 

1 - 12 0616


MAINTENANCE SCHEDULE 

0616 


4

4 



0616


1. MAINTENANCE INTERVALS 

1.1 THE MAINTENANCE SCHEDULE 

The maintenance intervals stated in the maintenance schedule 

are based on the oil specifications specified by 

VDL Bus &Coach. 

1. Only applicable to the XE engine. For the PE engine, a 

maximum of 75,000 km with an intermediate inspection 

after 37,500 km. 

2. Only applicable to the XE engine. For the PE engine, a 

maximum of 100,000 km with an intermediate inspection 

after 50,000 km. 

3. Deviating oil changing intervals apply to the VOITH 

R115E retarder, ZF AS Tronic and the ZF automatic 

gearbox (see the service schedule for further information). 

0616 


Maintenance intervals 

1 - 1 

4

4 



1.2 EXPLANATION OF THE MAINTENANCE 

SCHEDULE 

Vehicle use 

The use of the vehicle will determine whether it is classified 

as being in service group I, II or III. 

Service group I 

Local traffic 

– Airport transportation 

– Transport up to a maximum of 30,000 km per year 

Service group II 

Urban and regional traffic 

– Regional bus services 

– Transportation between villages and towns located close 

to each other 

Service group III 

National/International traffic 

– Transportation over long to very long distances 

STANDARD OIL-CHANGE INTERVAL 

This is the symbol for the standard oil-change interval. 

Please refer to the latest VDL Bus “Fluids and Lubricants 

specifications” information sheet for the stipulated specifications 

of the oil. 

EXTENDED OIL-CHANGE INTERVAL 

This is the symbol for the extended oil-change interval. If the 

prescribed oil specification and any additional conditions 

(please refer to the latest VDL Bus “Fluids and Lubricants 

specifications”) have to be complied with, an extended 

changing interval may be applied. 

Note: 

An extended changing interval for engine oil may be subject 

to additional conditions. The additional conditions are 

included in the VDL Bus “Fluids and Lubricants” specifications. 

INTERMEDIATE INSPECTION 

This is the symbol for an intermediate inspection. Intermediate 

inspections are based on several visual inspections. 

When an extended changing interval is applicable to the 

engine oil (X-service) an intermediate inspection should be 

carried out. 


G000230 

G000229 

G000088 

1 - 2 0616


X SERVICE 

This is the symbol to indicate an X service. An X-service is a 

service which depends on the number of kilometres driven 

and consists of changing the engine oil and a number of 

inspections. 

Notes: 

– If the prescribed oil specification and any additional conditions 


specifications”) have to be complied with, an 

extended changing interval (X-service) may be applied. 

– An X service must be carried out at least once a year. 

Y SERVICE 

This is the symbol for a Y service. 

A Y service is an annual service comprised of specific maintenance 

work and, where applicable, supplemented with an 

oil-change for the gearbox and the rear axle. 

Notes: 

– If the prescribed oil specification and any additional conditions 


specifications”) have to be complied with, an 

extended changing interval (X-service) may be applied. 

– The Voith retarder R115E, ZF AS Tronic and the automatic 

gearboxes are subjected to alternative changing intervals. 

ZF AUTOMATIC GEARBOX MAINTENANCE INTERVALS 

Maintenance groups I - II 

Maintenance groups III 

Note: 

In case of initial oil change transition from an ATF of the lubricants 

category 14A or 14B to an ATF featuring extended oil 

change intervals, an interim oil change interval after < 60.000 

km/max. 2 years is required. 

0616 

Oils according to ZF lubrication 

list TE-ML14 class 14B 


list TE-ML14 class 14C 


list TE-ML14 class 14E 


list TE-ML14 class 14B 


list TE-ML14 class 14C 


list TE-ML14 class 14E 



2 years/maximum of 45,000 km 






G000086 

G000087 

1 - 3 

4

4 



ZF AS TRONIC GEARBOX WITH INTARDER MAINTENANCE INTERVALS 

Maintenance groups I - II 

Maintenance groups III 

Heavy use 

Heavy use means: 

– Use in areas with a high outside temperature (for example, 

Saudi Arabia). 

– Frequent mountainous routes. 

– Extremely short routes with a large number of inclines. 


The oil changing interval must be reduced if frequent use is 

made of the retarder (more than 10% of the duration of the 

daily use of the vehicle). 

If in doubt, contact VDL Bus & Coach. 

Oils according to ZF lubrication list 

TE-ML 02 class 02H 


TE-ML 02 class 02D/02L 


TE-ML 02 class 02E 


TE-ML 02 class 02H 


TE-ML 02 class 02D/02L 


TE-ML 02 class 02E 

VOITH R115E RETARDER MAINTENANCE INTERVALS 

Normal use 

Service groups I,II,III 

Heavy use 


1 year/maximum of 120,000 km 



1 year/maximum of 160,000 km 



Mineral oil 1 year/maximum of 135,000 km 

Semi-synthetic oil 2 years/maximum of 180,000 km 

Synthetic oil 2 years/maximum of 300,000 km 

Mineral oil 1 year/maximum of 60,000 km 

Semi-synthetic oil 1 year/maximum of 60,000 km 

Synthetic oil 2 years/maximum of 300,000 km 

1 - 4 0616


1.3 INFLUENCE OF DIESEL ON THE 

MAINTENANCE INTERVALS 

1.3.1 DIESEL FUELS 

Sulphur content Engine oil changing interval 

> 0.2% Half the interval with a maximum of 

25,000 km. 

1.3.2 BIODIESEL APPLICATION 

• There may be no negative (destructive) chemical reaction 

of the fuel on any of the engine or fuel system components. 

• All EN590 fuel standard requirements must be met (for 

100% Biodiesel EN14214). 

• Only official produced diesel or blends of standard diesel 

fuel with up to 100% Bio-diesel/FAME is allowed for PE 

engines from engine number S-09839 and XE engines 

from engine number T-78817 onwards. 

• Blends of standard diesel fuel with up to 100% Bio-diesel/ 

FAME is allowed if following additional conditions are met: 

– the oil- and fuel filter change interval period must be 

diminished by half. 

– extended oil service intervals are not allowed. 

0616 



1 - 5 

4

4 



1.4 SERVICE INTERVALS FOR DIFFICULT 

CONDITIONS 

If the vehicle is used under very specific, difficult conditions, 

the dealer or importer must be contacted and, if necessary, 

the maintenance intervals and the maintenance work to be 

carried out during the service must be changed. 

1.5 FIRST SERVICE 

The first service should be carried out between the first 

7,500 km and 10,000 km or a maximum of 8 weeks after 

delivery of the vehicle, which ever comes first. 


1 - 6 0616


2. MAINTENANCE ACTIVITIES 

2.1 FIRST SERVICE 

First Service to be carried out between the first 7.500 and 

10.000 km. For registration apply the latest version of the 

First Service forms with document number DW050719. 

2.1.1 SB(R)4000+ PF/XF AND SB(R)230 PF EURO_3 

First Service 

BODY-WORK, ELECTRICAL SYSTEM 

O Check/top up the battery liquid level 

O Inspect/clean battery connections and cables 

O Read out and erase the error messages of the diagnostic tools 

LUBRICATION SYSTEM 

O Change the engine oil 

O Replace the engine-oil filter(s) 

O Inspect the oil lubrication system for leaks 

FUEL SYSTEM 

O Drain/clean fuel-system water separator 

O Replace fuel filter 

O Inspect the fuel system for leaks 

ENGINE 

O Inspect V-belt(s) and tension/replace, if necessary 

AIR INTAKE SYSTEM 

O Inspect the air-intake system mountings, inspect for leaks and damage 

COOLING SYSTEM 

O Hydraulic fan: replace filter 

O Hydraulic fan: inspect pipes/hoses for damage and leaks 

O Inspect the entire cooling system for leaks and damage 

STEERING-MECHANISM 

O Hydraulic steering-mechanism: replace filter 

O Hydraulic steering-mechanism: check/top up fluid level 

O Hydraulic steering-mechanism: check hoses/tubes for damage and leaks 

O Grease kingpin bearing (without load) 

BRAKE SYSTEM AND PNEUMATIC SYSTEM 

O Inspect the mountings of the brake pipes and components, inspect for leaks and wear 

WHEEL SUSPENSION 

O Tighten spring U-bolt nuts 

TRANSMISSION AND CHASSIS 

O Check all accessible chassis bolts and nuts 

O Change the differential oil 

O Grease driveshaft, tighten the bolts 

O Grease spare-wheel winch cable and pivoting points 

O Inspect the wheelnuts (tighten) 

GEARBOX 

O Inspect the gearbox for leaks 

0616 


Maintenance activities 

2 - 1 

4

4 



First Service 

O Check/top up the hydraulic-clutch fluid level 

RETARDER 

O Check the retarder oil level, top up as necessary 

TEST DRIVE 

O Test drive 


2 - 2 0616


2.2 INTERMEDIATE SERVICE 

Within the maintenance activities the intermediate service is 

represented by the T-Service symbol. 


The intermediate maintenance activities are listed in the table. 

For registration apply the latest version of the Maintenance 

Forms with document number DW050725. 

T-Service = Intermediate Maintenance Activities 


O Check the engine-oil level 

FUEL SYSTEM 


O Replace fuel filter (see note 29) 


ENGINE 


O Inspect poly V-belt and replace if necessary 



EXHAUST SYSTEM 

O Inspect the exhaust system mountings, inspect for leaks 

O CRT filter: check exhaust gas back-pressure (see note 25) 




O Inspect all steering-mechanism pivoting points for wear and leakage 


O Inspect the thickness of the brake linings/brake pads 


O Inspect the rear axle for leaks 

O Check oil/grease-lubricated hubs for leaks 

GEARBOX 

O Check/top up the gearbox oil level 


O Inspect the wear of the clutch disc 

RETARDER 


NOTES 

25 Every 1-2 months 

29 Every T-maintenance if year kilometrage exceeds 100,000 km. 

0616 



2 - 3 

4

4 



2.3 MILEAGE DEPENDENT SERVICE 

Within the maintenance activities the mileage dependent 

service is represented by the X-Service symbol. 


The mileage dependent maintenance activities are listed in 

the table. For registration apply the latest version of the Maintenance 



X-Service = Mileage Dependent Maintenance Activities 


O Check/top up the battery liquid level 

O Inspect/clean battery connections and cables 

O Inspect the ground terminals and the positive feed-throughs 

O Replace the main fuses (see note 20) 

O Read out and erase the error messages of the diagnostic tools 


O Change the engine oil (see note 04) 

O Replace the engine-oil filter(s) 

O Replace the rotor of the centrifugal oil filter 

O Inspect the oil lubrication system for leaks 

O Grease all grease nipples in accordance with the lubrication chart 

O Check the engine-oil level 

FUEL SYSTEM 


O Replace fuel filter 


ENGINE 


O Inspect poly V-belt and replace if necessary 


O Inspect the air-filter blockage indicator, and replace the air-filter element if necessary 



O Inspect the exhaust system mountings, inspect for leaks 


O Hydraulic fan: check/top up fluid level 

O Hydraulic fan: inspect pipes/hoses for damage and leaks 

O Check/top up the level of the coolant in the cooling system 


O Inspect the radiator/intercooler element for fouling, clean if necessary 


O Hydraulic steering-mechanism: check/top up fluid level 

O Hydraulic steering-mechanism: check hoses/tubes for damage and leaks 

O Inspect the steering-mechanism's angular transmission for wear and leaks 

O Inspect all steering-mechanism pivoting points for wear and leakage 


O Drain the condensation in the air tanks 

2 - 4 0616


X-Service = Mileage Dependent Maintenance Activities 

O Inspect the mountings of the brake pipes and components, inspect for leaks and wear 

O Inspect the thickness of the brake linings/brake pads 

O Inspect the brake discs for wear, inspect the thickness 


O Inspect the mountings of the shock-absorbers, inspect for leaks 

O Inspect the mountings and the condition of the U-bolts 

O Inspect the axle mounting points (and pneumatic suspension) 

O Inspect the bellows of the pneumatic suspension 

O Inspect the operation of the chassis-pneumatic suspension 

O Check driving height 


O Inspect the rear axle for leaks 

O Check/top up differential oil level 

O Clean the differential's bleeder 

O Grease driveshaft (see note 21) 

O Visually inspect the nuts of the driveshaft and the rear axle 

O Check oil/grease-lubricated hubs for leaks 

O Inspect the tyres and wheel rims for wear and damage 

O Inspect the wheelnuts (tighten) 

O Check the tyre pressures (including the spare wheel) 

GEARBOX 

O Check/top up the gearbox oil level 

O Clean gearbox breather 

O ZF Astronic gearbox: change gearbox oil and replace oil filter ( see note 04) 

O Automatic gearbox: change gearbox oil and replace oil filter (see note 01) 

O Inspect the hydraulic clutch mechanism for leaks 


O Inspect the wear of the clutch disc 

RETARDER 


NOTES 

4 For changing interval see maintenance schedule in Maintenance Manual 

20 Every 300,000 km 

21 Grease drive shaft every 50,000 km or every 6 months 

0616 



2 - 5 

4

4 



2.4 ANNUAL SERVICE 

Within the maintenance activities the annual service is represented 

by the Y-Service symbol. 


The annual maintenance activities are listed in the table. For 

registration apply the latest version of the Maintenance 



Y-Service = Annual Maintenance Activities 


O Check pedal rubbers for wear 

O Check the adjustability of the steering-column 

O Check battery compartment locking 

O Inspect the coating on the body work, repair if necessary, repeat treatment every 5 years. 

O Repeat the anti-corrosion treatment every 3 years 

FUEL SYSTEM 

O Clean feed pump coarse fuel filter 

O Tighten fuel tank tension straps 

O Check fuel tank bleed valve 

ENGINE 

O Inspect/adjust the valve clearance (see note 12) 

O Inspect compressor tubes 

O Inspect the condition of the alternator (see note 07) 

O Inspect the condition of the starter motor (see note 07) 


O Check air inlet dust trapping valve 


O Clean and inspect Catalyst 


O Hydraulic fan: replace filter (see note 08) 

O Hydraulic fan: change oil (see note 08) 

O Check the concentration of the antifreeze in the cooling system (for the winter) 

O Replace coolant in the cooling system (see note 24) 


O Hydraulic steering-mechanism: replace filter (see note 08) 

O Hydraulic steering-mechanism: change oil (see note 08) 

O Inspect the play in the steering-knuckle 

O Check steering damper on 3rd axle for leakage 

O Check steering collar and function of blocking cylinder on 3rd axle 

O Check maximum wheel deflection on 3rd axle 

O Grease auxiliary pitmanarms 


O Replace air-dryer filter element 

O Inspect the automatic-adjusters of the brake callipers 

O Lubricate the bushes and sleeves of the brake callipers 

O Inspect brake deceleration 

O Check (Haldex) oil separator (see note 26) 

2 - 6 0616


0616 



Y-Service = Annual Maintenance Activities 


O Inspect the condition of the axle and wheel suspensions and inspect its mountings 

O Grease all swivel king pins and control arms (see note 26) 


O Change the differential oil (see note 04) 

O Inspect the differential lock 

O Inspect the driveshafts, sleeve yokes and universal joints for wear 

O Change the grease of grease-lubricated hubs (see note 02) 

O Check the wheel bearing clearance 

GEARBOX 

O Manual gearbox: change gear box oil / clean oil strainer (see note 17) 

O Check SGS system 

O Change hydraulic fluid of the hydraulic-clutch system (see note 08) 

RETARDER 

O Change retarder oil / clean oil strainer (see note 04) 

NOTES 

2 Every 2 years with maximum mileage of 500,000 km (ZF RL75) 

4 For changing interval see maintenance schedule in Maintenance Manual 

7 Every 250,000 km. 

8 Every 2 years. 

12 Check the valve clearance on the 1st and 2nd Y-service, and subsequently check and adjust, where necessary, 

every second year 

17 Every two years, maximum interval of 300,000 km when using the following synthetic oil 

- Veedol Synmesh AT; Castrol Syntrans AT; - Deagear Synth;- Shell Transmission MA; BP Energear SHX30 

24 Every 4 years, maximum interval of 400,000 km 

26 Every year, with a maximum kilometrage of 90,000 km 

2 - 7 

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2 - 8 0616

EXPLANATION OF THE MAINTENANCE WORK 



0616 

5

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0616



Safety regulations 

1. SAFETY REGULATIONS 

The work described in this maintenance manual must 

only be carried out by trained and competent personnel. 

Always observe the locally applicable legal safety and 

environmental regulations. 

Comply with all warnings and safety regulations given in 

this maintenance manual. Always read and observe the 

instructions and warnings given on labels and stickers fitted 

to the vehicle’s components. These have been fitted 

for your health and safety. Do not ignore them! 

Wear clean, well-fitting clothing and, if necessary, apply 

protective cream to the body. 

Always wear clean protective clothing, dust goggles and 

a dust mask when working with the brake lining, brake 

pads or friction material. 

Always read the manufacturer’s safety instructions when 

replacing the clutch plate, brake lining and brake pads. 

Avoid inhaling dust from the clutch plate or brake lining. 

Always make sure there is good dust extraction when 

working on these components. 

Do not run the engine unnecessarily in a closed or 

unventilated area. In other words, make sure the exhaust 

fumes are properly extracted. 

Remain a safe distance from rotating and/or moving 

components. 

Never remove the cooling system’s filler cap when the 

engine is at the operating temperature. 

Be careful when changing the oil. Hot oil can cause serious 

injury. 

Avoid unnecessary contact with the drained oil. Regular 

contact causes skin damage. 

Various oils and other lubricants used on the vehicle can 

damage your health. This also applies to engine coolant, 

screen wash fluid, coolant in air conditioning systems, 

battery acid and diesel. Avoid internal and external bodily 

contact. 

To prevent the risk of fire, the engine and the area surrounding 

it must be free of highly inflammable liquids. 

When working on the engine encapsulation, the engine 

compartment including the encapsulation and the engine 

must be thoroughly cleaned, if necessary, after every 

0616 

maintenance service because there is a risk of fire if the 

encapsulation, engine or engine compartment is dirty 

Always disconnect the earth cable from 

the battery before working on the 

vehicle’s electrical system. 

Always use hoisting sheers when working under the 

vehicle (see “Lifting instructions”). 

When using lifting columns, check whether they are suitable 

for the vehicle’s wheel size. Refer to the manufacturer’s 

instruction manual for instructions on how to use 

lifting columns and for any safety instructions. If necessary, 

use wheel adaptors to prevent damage to the wheel 

bolts. 

Place the vehicle in the unconditional 

kneeling position before hoisting the 

vehicle. This will turn off the pneumatic 

suspension system. 

When charging the batteries, make sure there is good 

ventilation and avoid sparks or a naked flame. Only use 

a quick-charger if absolutely necessary. The positive and 

negative cables must be removed from the battery when 

using a quick-charger. 

1 - 1 

5

5 


Safety regulations 


1 - 2 0616




2. GENERAL INFORMATION 

2.1 INTRODUCTION 

This maintenance manual contains all the relevant maintenance 

work. It also contains safety regulations, which 

must be strictly observed. 

Work which is not described in this maintenance manual, 

such as revision, fault finding, etc., is described in the 

VDL Bus & Coach Workshop Instruction Manual or the 

Workshop Instructions for the component concerned. 

Whilst compiling this maintenance manual, it has been 

assumed that the mechanic has the necessary experience 

and has had the required education or training to be 

able to carry out the maintenance work in a responsible 

and safe manner. 

The technical information and the explanation of the 

maintenance work described in this maintenance manual 

have been compiled with the utmost care. The information 

in this maintenance manual only relates to the vehicle 

series: 

SB(R) 4000+ PF/XF Euro3 

SB(R) 230 PF Euro3 

0616 

2.2 TECHNICAL INFORMATION 

The technical information in this maintenance manual, 

such as the explanation of the maintenance work and the 

technical information required in order to carry out the 

maintenance work in a responsible manner, has been 

updated until the time of printing. 

VDL Bus & Coach maintains the right to make changes 

to the information given in this maintenance manual without 

prior notification. 

Comment 

Important alterations concerning technical information 

which have not/could not have been included in the 

maintenance manual will be passed on to you by means 

of a TI (Technical Information) sheet. 

2 - 1 

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2.3 WARNING SYMBOL 

When text is accompanied by a warning symbol shown 

here, the information given is essential for the health and 

personal safety of the mechanic. 

This warning symbol is also shown if there are circumstances 

which could affect the safety of the vehicle or 

which could damage the vehicle. 

An overview of symbols is given below: 

This symbol gives useful tips to simplify 

operations. 

This symbol indicates that extra care is 

required. 

This symbol indicates a situation which 

might result in damage to the vehicle. 


might result in personal injury. 


might result in a harmful situation for the 

environment. 

2.4 ENVIRONMENT 

Carrying out maintenance work regularly, on time and 

with the necessary skill helps to reduce pollution of the 

environment. 

This can be achieved by noticing and repairing any leaks 

in time and by keeping the engine in an optimal condition 

(adjusting the valves, replacing the air filter element, 

etc.), so that there is a smaller emission of harmful 

gases. 

It should also be mentioned that oils and fluids contain 

harmful elements which pollute the environment.Therefore, 

make sure the drained oils and coolants, as well as 

used oil filters and fuel filters, are collected in the appropriate 

separate containers. 

Always be conscious of the environment 

when carrying out maintenance work. 

2 - 2 0616




2.5 SPARE PARTS AND COMPONENTS 

All VDL Bus & Coach parts and components are accurately 

tuned to each other, which helps to determine the 

original VDL Bus & Coach quality. 

Logically, this quality can best be maintained when 

replacing components by using original VDL Bus & 

Coach parts and components. 

From a maintenance point of view, this applies to components 

such as the air drier element, gaskets, V-belts and 

filters. 

If, for example, non-original VDL Bus & Coach filters are 

used, insufficient protection may be provided against 

microscopic dust particles in the air, hardly noticeable 

metal shavings in the oil and contamination in the fuel. 

This will result in: 

– The early replacement of cylinders, pistons, bearings, 

valves, the injection pump and other moving parts. 

– A reduction in the engine performance. 

– An increase in fuel consumption. 

0616 

Therefore, always use original VDL Bus & 

Coach parts and components. 

2.6 MAINTENANCE GUIDELINES 

– When carrying out maintenance activities on the vehicle, 

it is important that the work is performed under the 

cleanest possible conditions. Filler caps, lubrication 

points, filler and drain plugs should be cleaned before 

and after maintenance activities. 

– When excessive leakage has been detected at oil 

seals and/or components, or in case of an excessive 

drop in the oil level, a report should be made and the 

cause should be remedied. 

– It is important to regularly check the bleed openings on 

the gearbox and rear axle for contamination and blockages. 

If the bleed openings are blocked by dirt, then the 

excess pressure may cause a leak. 

– Depending on the circumstances in which the vehicle 

is used, for example very poor roads, important bolt 

connections, such as the front/rear axle suspension, 

steering box attachment, bodywork attachment, etc., 

must be checked more often and, if necessary, retightened. 

– It is important to carry out a visual inspection and to 

take a test run following the maintenance activities. 

When doing so, particular attention should be paid to 

components directly related to driving safety. 

– Refer to the VDL Bus & Coach Workshop Instruction 

Manual when welding on or drilling in the chassis. 

Welding and/or drilling in the wrong places on or in the 

chassis will weaken the material. 

– Whilst carrying out welding work on the vehicle, make 

sure the wiring of the alternator and the positive and 

negative battery connections are disconnected. Place 

the earth clamp as close as possible to the place to be 

welded, but never on a rotating component, such as 

the drive shaft, hub, fan, etc., nor on an independently 

operating component which contains rotating components, 

such as the turbo compressor, etc. 

2 - 3 

5

0 




2 - 4 0616



Inspection and adjustment 

3. INSPECTION AND ADJUSTMENT 

3.1 INSPECTING THE PEDAL RUBBERS 

1. Check whether the pedal rubbers are securely attached 

to the pedals. 

2. Check whether the pedal rubbers are worm and whether 

there is still sufficient grip on them. 

3.2 INSPECTING THE ADJUSTABILITY OF 

THE STEERING COLUMN 

Pneumatically adjustable steering column 

1. Turn on the vehicle’s contact switch and apply the parking 

brake. 

Unlock the steering column using the switch on the floor. 

2. Move the steering wheel in the directions indicated. It 

must be easy to move the steering wheel. It must be possible 

to adjust the height of the steering wheel by 80 mm 

and by an angle of 20° - 31°. 

3. Release the switch on the floor. The steering wheel 

should now be locked and it should no longer be possible 

to adjust the steering wheel. 

Comment 

When driving the vehicle, it is not possible to adjust the pneumatic 

steering column using the foot-operated switch. It is 

only possible to adjust the steering column if: 

– The vehicle is stationary. 

– The contact switch has been turned on. 

– The parking brake has been applied. 

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03847B 

3 - 1 

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3.3 INSPECTING THE BATTERY 

Avoid sparks and naked flames near the 

batteries. 

Battery acid is an aggressive liquid. 

In the case of skin contact: neutralize the 

skin immediately with sodium carbonate 

or soapsuds and wash the affected area 

thoroughly with plenty of water. 

Contact a doctor if the affected area 

remains red or painful. Remove affected 

clothing and wash with plenty of water. 

In the case of eye contact: wash with 

clean, flowing water for at least 15 

minutes and contact a doctor. 

If swallowed: DO NOT instigate vomiting. 

Rinse your mouth, drink plenty of water 

and contact a doctor. 

If inhaled: get some fresh air, take a rest 

and contact a doctor. 

Checking the fluid level 

1. Check the electrolyte level. This must be approx. 10 mm 

above the plates or, if present, up to the level indicator. 

If necessary, top up the batteries (see “Draining and filling”). 

2. Check the battery housing for leaks. 

Comment 

– A visible white dividing line at 1/3 of the plate’s height indicates 

that a battery has been left standing in a highly discharged 

condition. 

– If the electrolyte is brown and the battery consumes a large 

amount of water, the battery has been overcharged. 

– If the electrolyte is murky or milky and the cells have a 

white deposit, the battery has been damaged by insufficient 

charging (highly discharged). 

In the above-mentioned cases, the battery must be replaced 

and the cause of the problem traced. 

Avoid quick-charging the battery. This 

will place an excessive load on the 

battery and reduce its life span. 

3 - 2 0616




Checking the battery charge 

1. With a battery acid weigher 

– If there are any doubts regarding the battery’s charge, 

check it using a battery acid weigher. 

– The specific weight of the battery acid at 27° C in kg/ 

0616 

dm 3 is: 

Charged battery 28 

Half-charged battery 1.20 

Discharged battery 1.10 

– Measurement corrections are necessary for strongly 

deviating temperatures. For each 10° C lower, 0.007 

points must be deducted from the measured reading. 

For each 10° C higher, 0.007 points must be added to 

the measured reading. 

– When a battery is in good condition, the specific weight 

will be the same in all the cells. The maximum difference 

between the highest and lowest specific weight 

may be 0.03 kg/dm3. 

2. With a digital voltmeter 

– This method can only be used 1 to 2 hours after the termination 

of charging or discharging. Measure the 

absolute voltage at rest (the battery’s positive and negative 

terminals must have been disconnected). 

– For a 12 V battery, the voltage should be: 

Charged battery 12.24 V 

Half-charged battery Approx. 12.24 V 

Discharged battery Approx. 11.75 V 

3. With a battery tester 

– The general condition of the battery can be tested 

quickly by using a battery tester. 

In this test, the battery is subjected to a load and then 

the discharge voltage across the battery poles is measured. 

The load placed on the battery must be at least 

three times the capacity of the battery. 

– As a rule of thumb, the test must be carried out when 

the battery is sufficiently charged (specific weight 1.25 

- 1.28 kg/dm3). At a normal temperature (10 - 20° C), 

the load voltage of a well-charged battery should be 10 

V after 10 seconds. At least 9 V must be measured for 

a partially discharged battery (specific mass 1.25 kg/ 

dm3). It is important that the voltage is measured 

directly across the battery poles. 

– Always follow the instructions issued by the manufacturer 

of the battery tester. 

– As a rule of thumb, the test must be carried out when 

the battery is sufficiently charged (specific weight 1.25 

- 1.28 kg/dm3). At a normal temperature (10 - 20° C), 

the load voltage of a well-charged battery should be 10 

V after 10 seconds. At least 9 V must be measured for 

a partially discharged battery (specific mass 1.25 kg/ 

dm3). It is important that the voltage is measured 

directly across the battery poles. 

– Always follow the instructions issued by the manufacturer 

of the battery tester. 

3 - 3 

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3.4 INSPECTING THE BATTERY 

CONNECTIONS 


batteries. 


Always apply insulated VDE tools whilst 

working on the batteries. 

1. Check for cracked or broken battery cables and clamps. 

If necessary, replace them. 

2. Visually check the battery terminals for corrosion. If necessary, 

clean the battery terminals (see “Cleaning”). 

3. Check the attachment of the battery clamps. If necessary, 

tighten them. 

3 - 4 0616




3.5 CHECKING THE BATTERY BOX 

ATTACHMENT 

1. Check whether the hook (4) of the battery box (5) locks 

firmly and without any play. If necessary, adjust the hook. 

Adjusting the hook (4) 

– Unscrew the lock nut (3). 

– Rotate the hook in steps of 180°. 

– Tighten the lock nut after adjusting the hook. 

2. Check whether the battery box rubs on the battery box 

frame when opening and closing the box. If necessary, 

adjust the battery box. 

Adjusting the battery box 

– Remove the batteries. 

– Close the battery box so that it rests against the rubber 

stop. 

DO NOT lock the battery box. 

– Only unscrew the nut/bolt (7) of the top hinge point. 

– Place a 6 mm thick adjusting plate under the sliding 

plate A. 

– Place a 9 mm thick adjusting plate under the sliding 

plate B. 

– Check whether the battery box rests against both 

adjustment plates and tighten the nut/bolt (7). 

– Open the battery box. Remove the adjusting plates and 

reinstall the batteries. 

– Check again whether the battery box opens and closes 

smoothly. 

– Lock the battery box and fit the lock pin (1). 

3. Check the attachment of the batteries. 

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1151341 

3 - 5 

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3.6 CHECKING THE EARTH AND POSITIVE 

FEED-THROUGH ON THE CHASSIS 

It is not permitted to disconnect the 

battery clamps whilst the engine is 

running. 

It is not permitted to use a voltage higher 

than 24 V. 

1. Check whether the connection points have become oxidized. 

2. Check whether there are any splits in the cables. 

3. Check whether these points are securely attached to the 

chassis. 

4. This is carried out as follows: 

Hold the bolt head in place using a suitable spanner. Use 

a different spanner to check whether the nuts are secure. 

3 - 6 0616




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1151413 

3 - 7 

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3.7 INSPECTING THE ANTI-CHIP COATING 

The underside of the chassis is treated with an anti-chip coating 

at the factory. 

This coating should be checked for damage every year. 

The underside of the chassis should be re-treated every five 

years. 

If the anti-chip coating becomes damaged, it should be 

treated as follows: 

Re-treatment/repair 

1. Remove all the loose dirt. 

2. Check the layer of paint for damage and, if necessary, 

repair it. 

3. Apply the anti-chip coating according to the manufacturer’s 

instructions. 

4. The layer thickness should be at least 60 - 80 microns 

when dry. 

Comment 

Cracks may appear after a time in the corners where the 

coating has been applied. 

The corners can be treated with a wax coating to prevent this 

from happening or to repair the cracks. 

The anti-chip coating should be re-applied if any large cracks 

appear. 

3 - 8 0616




3.8 ANTI-CORROSION TREATMENT 

Hollow cavities and the inside of beams should be checked 

every year for faults. 

They should be re-treated after 1, 3 and 6 years and then 

every 3 years. 

Hollow cavities and the inside of beams should be treated for 

corrosion after repair to prevent them from rusting. 

Re-treatment 

1. Remove all the loose dirt. 

2. Apply wax according to the manufacturer’s instructions 

using a flexible tube. 

3. The required layer thickness is 40-50 µm when dry. 

0616 

3 - 9 

5

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3.9 FAULT ANALYSIS 

3.9.1 DIAGNOSTIC TOOLS 

You can read in the schematic survey below with which diagnostic 

tool a certain system is to be diagnosed. 

Check the systems for faults. Note any faults and delete the 

fault memory. 

Repair any faults and repeat this procedure until all the faults 

have been rectified. 

How to operate the diagnostic tool, we refer to the documentation 

of the manufacturer. 

System Diagnostic tool 

ZF EST146C Pitcat ZF-Testman 

ZF AS Tronic Self diagnosis 

ZF EST42 DAVIE XD 

Voith R115E Pitcat Digiprop 

UPEC Pitcat+DCI DAVIE XD 

ABS/ASR Pitcat DAVIE XD 

ECAS CAN 

EGAS Pitcat DAVIE-XD 

ICM (CIPA) Pitcat 1.70 > 

Multibus+VFC Pitcat 1.70 > 

3 - 10 0616




3.9.2 READING ERROR MESSAGES ZF AS TRONIC 

1. Engine “OFF”. 

2. Turn ON the main switch and the contact switch. 

3. Turn rotary switch in position N and apply simultaneously 

the brake pedal. 

4. With applied brake pedal, push the tip lever forward (+) 

and hold the tip lever in this position. 

5. The stored error messages appear on the display. 

Note: 

If 4 bars are displayed in addition to the figures; this means: 

Add 100 to the displayed error code 

e.g.: Displayed error code no 74 

Read as code no 174 

If, in addition 4 bars and 2 arrows are displayed, this means: 

Add 200 to the displayed error code 

e.g.: Displayed error code no 27 

Read as code no 227 

Erase error codes ZF-AS Tronic 

1. Engine and contact switch “OFF”. 

2. Push the tip lever forward (+) and hold the tip lever in this 

position. 

3. Contact switch “ON”. 

4. Release the tip lever after 3 sec. (lever automatically 

returns in the mid-position). 

5. Push, after 3 sec., the tip lever forward (+) and hold the 

tip lever in this position. 

6. Switch after 2-3 sec. the contact switch “OFF”. 

7. The error codes are now erased. 

Note: 

Check after the test drive again for possible error codes. 

Repair any faults and repeat this procedure until all error 

codes have been rectified. 

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3.10 INSPECTING THE ENGINE OIL LEVEL 

3.10.1 PE ENGINE 

Inspecting the engine oil level 

1. Place the vehicle on a flat, horizontal surface. Check 

whether the vehicle is level both longways and crossways. 

2. Make sure the engine has not been running for at least 5 

minutes before checking the engine oil level. 

3. Remove the dipstick (2) from its holder. 

4. Clean the dipstick (2) with a lint-free cloth. 

5. Place the dipstick (2) back in the holder. 

6. Remove the dipstick again and read the oil level. 

7. Add oil via the filler opening with the red cap (1) until the 

oil level is at the maximum mark. Always use the specified 

oil (see “Liquids, oils and lubricants specifications”). 

Comment 

See “Technical information” for the difference between the 

maximum and minimum engine oil levels. 

8. Wait for 1 minute and then check the oil level again. 

3 - 12 0616 

1 

03570B




3.10.2 XE ENGINE 

Inspecting the engine oil level 



2. Make sure the engine has not been running for at least 5 

minutes before checking the engine oil level. 

3. Remove the dipstick (2) from its holder. 

4. Clean the dipstick (2) with a lint-free cloth. 

5. Place the dipstick (2) back in the holder. 

6. Remove the dipstick again and read the oil level. 

7. Add oil via the filler opening with the red cap (1) until the 

oil level is at the maximum mark. Always use the specified 

oil (see “Liquids, oils and lubricants specifications”). 

Comment 

See “Technical information” for the difference between the 

maximum and minimum engine oil levels. 

8. Wait for 1 minute and then check the oil level again. 

0616 

1 

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3.11 CHECKING FOR FUEL LEAKS 

1. Visually check all the fuel system’s hose/line connections 

and components for leaks. 

2. Pay extra attention to the flexible fuel hoses on vehicles 

which use biodiesel (EN14214). If perspiration or leakage 

is observed, the flexible fuel hoses must be 

replaced. 

1 Fuel tank 

2 Water separator 

3 Delivery pump / coarse filter 

4 Fine filter 

1147422 

3 - 14 0616




3.12 INSPECTING THE FUEL TANK 

CLAMPING STRAPS 

1. Visually check the attachment of the fuel tank for faults. 

2. Tighten the clamping straps to the specified torque (see 

“Technical information”). 

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3.13 INSPECTING AND ADJUSTING THE 

VALVE CLEARANCE 

1. Remove the cylinder head covers (see “Removal and 

installation”). 

2. Remove the protective plate from the flywheel housing 

and fit the special tool (A) (DAF no. 1310477) to the 

recess in the flywheel. 

3. Use the special tool (A) to crank the crankshaft clockwise 

as viewed from the distribution side (this is the same 

direction as the engine’s direction of rotation) until the 

valves of cylinder 1 start to tumble. The pistons of cylinder 

1 and 6 are now in the top dead centre position. 

Comment 

”Tumble” is understood to mean the moment when the inlet 

valve starts to open and the outlet valve finishes closing. 

4. Check and correct the valve clearance of cylinder 6. Set 

the correct valve clearance by loosening the lock nut and 

rotating the adjusting screw in the correct direction. 

(see “Technical information” for the correct valve clearance). 

3 - 16 0616




5. By rotating the crankshaft 1/3 of a turn, each time, using 

the special tool (DAF no. 1310477), the valves can be set 

according to the injection sequence 1-5-3-6-2-4. 

Valves of cylinder X Adjust valves of cylinder 

tumble 

1 6 

5 2 

3 4 

6 1 

2 5 

4 3 

6. Fit the cylinder head covers (see “Removal and installation”). 

7. Remove the special tool and fit the flywheel housing’s 

protective plate. 

0616 

3 - 17 

5

5 




3.14 INSPECTING THE COMPRESSOR LINE 

Remain a safe distance from rotating and/ 

or moving components. 

Comment 

Measuring a value which is too high, the inside of the air 

dryer housing and the silencer on the bleed opening should 

first be cleaned. 

Next, carry out the inspection again. 

Inspection 

1. Bring the engine to the operating temperature. 

2. Blow off the brake system to below the pressure regulator’s 

cut-in pressure. 

3. Remove the compressor line which is connected to port 

23 on the air dryer. 

Plug the opening of port 23. 

4. Pressurize the brake system (pressure regulator should 

cut in). 

5. When the engine is not running, remove the safety valve 

from the compressor line and replace it with a test nipple. 

6. Connect a pressure gauge (range 0 - 16 bar) to the test 

nipple. 

7. Start the engine and run it at the maximum speed. 

8. Check whether the pressure gauge indicates a pressure 

of less than 2 bar when the pressure regulator has cut 

out. 

If the measured pressure is higher than the given value, 

clean or replace the line between the compressor and 

the air dryer. 

Comment 

If the measured value is too high, then that means there is an 

excessive carbon deposit in the compressor line. This may 

be because the compressor is in a bad condition (oil consumption). 

The oil consumption can be checked by carrying out an oil 

consumption test (special tool Wabco 884.013.124.0). 

9. Idle the engine. 

10. Blow off the brake system until the cut-in pressure of the 

pressure regulator is reached and then turn off the 

engine. The pressure gauge’s needle must not drop 

quickly. If necessary, check the system for air leaks. 

Pay particular attention to the compressor line and the 

compressor. 

11. Fit the safety valve. 

12. Fit the compressor line to port 23 on the air dryer. 

3 - 18 0616




3.15 INSPECTING THE V-BELTS 

3.15.1 INSPECTING THE V-BELTS 

– Check whether the V-belts are worn or damaged. If necessary, 

replace them. Also pay attention to hairline cracks. 

– Check the V-belt tension using a tension gauge. 

3.15.2 CHECKING THE V-BELT TENSION 

Checking instruction 

1. Check the V-belt tension using the special tool (DAF no. 

1240443). 

2. Zero the gauge by pressing the measuring arm (1). 

3. Place the V-belt tension gauge on the V-belt in the middle 

position between the two pulleys. 

4. Slowly push the V-belt using the V-belt tension gauge 

until the gauge makes a clicking noise. Next, carefully 

remove the tension gauge. 

Make sure the measuring arm does not move. 

0616 

PE engine 

XE engine 

03928B 

03929B 

3 - 19 

5

5 




5. Read the value by viewing the position of the measuring 

arm on the scale. Compare the value with the recommended 

tension (see “Technical information”). 

3.15.3 ADJUSTING THE V-BELT TENSION 

Adjusting instruction 

1. Unscrew the threaded spindle’s counter nut (4). 

2. Unscrew the threaded spindle’s attachment bolt (5). 

3. Unscrew the alternator’s bottom attachment bolt (3). 

4. Loosen the threaded bush’s (1) counter nut (2). 

5. Move the alternator by turning the threaded bush (1) until 

the correct V-belt tension is obtained (see “Technical 

information”). 

6. Tighten the alternator’s bottom attachment bolt (3). 

7. Tighten the threaded spindle’s counter nuts (2 and 4). 

8. Tighten the threaded spindle’s attachment bolt (5) which 

is attached to the water pump. 

PE engine 

XE engine 

3 - 20 0616




3.16 INSPECTING THE POLY V-BELT 

Inspecting the poly V-belt 

1. Check the poly V-belt for damage and wear patterns. 

3.17 CHECKING THE AUTOMATIC 

POLY V-BELT TENSIONER 

1. Remove the poly V-belt (see “Removal and installation”) 

and place the automatic tensioner in the rest position (0). 

2. Place a torque spanner on the automatic tensioner’s hexagon. 

3. The torque must be of a certain value for the indicated 

rotation (A) (see “Technical information). The automatic 

tensioner must be replaced if the measured value is not 

the same as the inspection value. 

4. Fit the poly V-belt (see “Removal and installation”). 

0616 

3 - 21 

5

5 




3.18 CHECKING THE AIR CONDITIONING 

V-BELT 

Inspecting the V-belts 

– Check whether the V-belts are worn or damaged. If necessary, 

replace them. Also pay attention to hairline cracks. 

Checking the V-belt tension 

1. Check the V-belt tension according to the instructions 

provided by the manufacturer. 

Adjusting the V-belt tension 

1. Unscrew the quick-release coupling on the air cylinder’s 

bottom port (2). 

2. Check the running behaviour of the V-belts with an 

untensioned belt tensioner (pressureless) and a running 

engine. If the V-belts run irregularly, increase the belt 

tensioner’s spring tension using the adjusting ring (1). 

3. Reconnect the quick-release coupling on the air cylinder’s 

bottom port (2). 

Basic setting of the pneumatic belt tensioner: 

Adjust the belt tensioner so that it is in the middle of the 50 

mm stroke (with full air pressure and the belts fitted). 

The compressor’s shackle will then be almost horizontal. 

1145785 

3 - 22 0616




3.19 INSPECTING THE AIR FILTER BLOCK- 

AGE INDICATOR 

1. Check whether the yellow piston (2) has reached the 

maximum vacuum pressure (contamination limit) (see 

“Technical information”). The service indicator window 

will turn red when the maximum contamination limit has 

been reached. Note the vacuum pressure and compare 

this to the previous inspection. 

A sudden increase in the vacuum pressure may be an 

indication of a temporary blockage caused by snow or 

moisture. 

2. Press the reset button (1) to check the operation of the 

indicator. 

Check the vacuum hose and its connection for faults. 

3. Replace the air filter element if the indicator has reached 

the maximum contamination limit. 

4. After replacing the air filter element, the blockage indicator 

must be reset by pressing the yellow reset button (1). 

0616 

Indicator type RX00-2275 

A Normal, clean filter 

B Filter with maximum contamination 

Replace the air filter element 

03915B 

03920B 

Indicator type AE-36501-00332 

A Normal, clean filter 0% 

B Filter with maximum contamination 75% 

Replace the air filter element 

3 - 23 

5

5 




3.20 CHECKING THE AIR INLET 

DUST TRAPPING VALVE 

Check the condition of the rubber valve. 

Replace the valve when he: 

– doesn’t seals properly; 

– is damaged; 

– is turned inside out; 

– is missing. 

03925B 

3 - 24 0616




3.21 INSPECTING THE AIR INTAKE SYSTEM 

FOR LEAKS, DAMAGE AND ATTACH- 

MENT 

– Check the condition and attachment of the air inlet ducts, 

hoses and hose clips of the air intake system. 

– Check the air intake system for leaks by carrying out a 

pressure test if in doubt about whether the air intake system 

is airtight. This may be recognized by: 

The loss of power. 

High fuel consumption. 

Unusual sounds. 

Pressure-testing the air intake system 

1. Remove the air intake line (1) between the intercooler 

and the inlet manifold from the inlet manifold. 

2. Fit the special tool (DAF no. 0694831) to the air intake 

hose (2). 

3. Remove the air inlet hose (3) between the air filter housing 

and the suction side of the turbo. 

4. Fit the special tools (DAF no. 1329310 and DAF no. 

1329311) to the suction side of the turbo. 

5. Connect an air hose with a pressure reduction valve to 

the sealing cap (A) and pressurize the system to approximately 

1.0 bar. 

6. Use soapsuds to check the entire air intake system for air 

leaks. 

Check whether the pressure reduction valve’s pressure 

gauge drops. 

7. Remove the special tools. 

8. Fit the inlet hose between the air filter housing and the 

suction side of the turbo. 

9. Fit the inlet line (1) between the intercooler and the inlet 

manifold. 

0616 

Plugs may spring off if they are not 

properly secured. For this reason, and 

because of the risk of damage to the air 

intake system, the pressure must never 

be greater than 1.0 bar. 

1145799 

3 - 25 

5

5 




3.22 INSPECTING THE EXHAUST SYSTEM 

Exhaust fumes contain carbon 

monoxide. Carbon monoxide is a deadly, 

colourless and odourless gas which, 

when inhaled, deprives the body of 

oxygen, leading to asphyxiation. Serious 

carbon monoxide poisoning can result in 

brain damage or death. 

– Check the attachment of the exhaust system for faults. 

– Check the exhaust system for leaks. 

1 Silencer 

2 Clamp 

3 Vibration damper 

4 Flexible exhaust pipe 

6 Vibration damper 

7 Outlet 

1151915-1 

3 - 26 0616




3.23 INSPECTING THE EMINOX ESI 

Error code table 

Code Meaning Action 

Green LED lit ESI system active, BP below maximum 

permitted value. 

None. 

Orange LED lit BP above max. permitted value. 

CRT filter may have to be cleaned. 

Comments 

1. Checking the engine 

• Check the exhaust back pressure (BP). 

• Carry out a soot measurement. 

• Check for oil leaks. 

2. CRT filter 

• The service indicator indicates that an extra service 

interval is necessary. 

The normal service interval must be maintained. 

3. ECI unit power supply 

• The warranty for the ECI unit and the CRT system will 

become invalid if this warning is not observed. 

4. Exceeding the temperature range 

If the surrounding temperature exceeds 80° C, then the 

display of the ESI unit is turned off automatically in order 

to protect the electronic components. If the temperature 

then falls below 80° C, the display will be turned back on 

0616 

Check the max. static BP 

Check the engine (1) 

Red LED lit CRT filter must be cleaned immediately. Service the CRT filter (2) 

Display is not lit ESI unit does not have a power supply. 

Connect the ESI unit(3) 

Display is not lit 

Blue LED is lit 

The operating temperature is greater than 

80°C. The display has turned itself off. 

LEDs flash ESI sensor has not measured a pressure 

for 12 hours whilst the contact switch has 

been turned on. 

Check the wiring. 

Allow the ESI unit to cool down. Move the 

unit to a cooler location (4). 

Check the lines of the ESI system (5). Idle 

the engine for approx. 5 minutes (6). 

LEDs flash ESI sensor is not connected to the CPU. Check the wiring. Connect the sensor. 

Reset the ESI unit. 

Do not hold the reset magnet in the 

RESET position when connecting the 

power supply 

3 - 27 

5

5 




again. The fact that the display is turned off does not 

have an adverse effect on the operation of the ESI unit. 

5. Checking the CRT system 

If the ESI unit is turned on and a pressure is not measured 

for a period of 12 hours, the LEDs will start to flash 

in the order green and red alternating with amber. 

If the LEDs flash after the engine has been running, then 

there is a leak or blockage in a line. 

After the leak or blockage has been rectified, the engine 

must be run for approx. 5 minutes in order to reset the 

system. 

6. Contact switch on and engine off 

This error code also occurs if the vehicle has been stationary 

for more than 12 hours with the contact switch 

turned on. The sensor will then not register a pressure. 

The ESI system is reset by running the engine for 5 minutes. 

7. ESI sensor not connected 

All the LEDs will flash together if the sensor is not connected. 

If the sensor is then connected, the red LED will 

be lit and a higher exhaust back pressure than normal will 

be indicated. Use the magnet to reset the ESI unit. 

If the air line has been connected to the wrong connection 

port, then the 3 LEDs will flash simultaneously (when 

the engine is running). 

3 - 28 0616




3.24 CHECKING THE EXHAUST BACK 

PRESSURE 

0616 

Exhaust gases contain carbon monoxide. 

Carbon monoxide is a deadly, colourless 

and odourless gas which, when inhaled, 

deprives the body of oxygen, leading to 

asphyxiation. Serious carbon monoxide 

poisoning can result in brain damage or 

death. 

Always observe the safety instructions 

when working on the CRT filter. 

After turning off the engine, allow the 

CRT filter to cool down for a long time in 

order to prevent burns if the CRT filter is 

touched. 

Always wear well-fitting clothing, gloves, 

safety glasses and a dust mask when 

working on the CRT filter. 

Before starting work on the CRT filter, 

read the Health and Safety Data Sheet 

which is available from Eminox or see the 

Eminox website (www.eminox.com). 

The exhaust back pressure can be checked in two different 

ways when the engine is stationary. 

1153798 

1. Green LED 

2. Amber LED 

3. Red LED 

4. Blue LED 

5. Mxxx maximum exhaust back pressure 

Cxxx current exhaust back pressure 

6. ESI unit 

7. Magnet 

A. Reset position of the magnet 

3 - 29 

5

5 




3.24.1 IF THE VEHICLE HAS A SERVICE INDICATOR 

1. Turn the engine off. 

2. Reset the display of the service indicator so that it displays 

M000. 

To do so, place the magnet in position A. 

• All the LEDs, including the blue LED, will be lit for a 

short period of time. 

• The green LED will be lit. 

3. Place the gearbox in neutral N and apply the parking 

brake. 


5. Run the engine at the maximum speed for 15 seconds. 

6. Stop the engine. 

7. The display shows the maximum static exhaust back 

pressure (Mxxx). 

Record this value on the CRT filter maintenance form. 

8. When the contact switch is turned on and the engine is 

running, the display alternately shows the current 

exhaust back pressure (Cxx) and the maximum exhaust 

back pressure (Mxxx). 

9. Measure the exhaust back pressure at the maximum 

engine speed and compare the value with the maximum 

permitted value (see “Technical information”). 

10. If the maximum permitted value is exceeded, the CRT filter 

must be cleaned (see “Cleaning”). 

11. Carry out a soot measurement. 

3.24.2 BY CONNECTING A PRESSURE GAUGE 


2. Remove the plug and the sealing ring from the silencer 

and fit a suitable coupling with a line. Due to the high 

exhaust temperature, the first section of the line should 

be made of metal. 

3. Connect a pressure gauge with a range of up to approx. 

0.1 - 0.3 bar (10 - 30 Kpa) to the coupling. 

Connect a soot meter. 

Comment 

To prevent strong vibrations of the gauge’s needle, a dampened 

gauge should be used. 

4. Measure the exhaust back pressure at the maximum 

engine speed and compare the value with the maximum 

permitted value (see “Technical information”). 

5. If the maximum permitted value is exceeded, the CRT filter 

must be cleaned (see “Cleaning”). 

6. Carry out a soot measurement. 

1 Plug M10x1 

2 Copper sealing ring M10 

C Plug 11/4” BSP 

3 - 30 0616 

03922B




3.25 INSPECTING THE CATALYSER 

1. Remove the catalyser (see “Removal and installation”). 

2. Check the catalyser for blockages caused by soot and 

ash particles. Use a soft brush to remove any accumulated 

soot and ash particles (see “Cleaning”). 

3. Check the visible sections of the catalyser for cracks or 

indentations and check whether the ceramic bracket is 

firmly secured in the housing. 

Check the catalyser module if any faults are observed. 

0616 

3 - 31 

5

5 




3.26 INSPECTING THE HYDRAULIC FAN 

DRIVE FLUID LEVEL 

1. Check the oil level when the engine is idling. The oil level 

must be between the maximum and minimum marks. 

2. If necessary, top up the oil to the maximum mark. 

Clean the area around the filler cap before removing it. 

3. Check the bleed opening in the cap. 

1145788 

3 - 32 0616




3.27 CHECKING THE HYDRAULIC FAN 

LINES/HOSES 

1. Check the lines and hoses 

– Check all the lines and hoses for wear and leaks. 

In particular, porous suction lines with a vacuum pressure 

will cause a problem (air in the system). 

– If in doubt, always replace the lines and/or hoses. 

Comment 

The supply and return lines of the hydraulic motor manufactured 

since 1/1/2005 have “Texsleeve” protective sleeves. 

2. Line and hose connections 

– Check each line and hose connection for leaks. 

3. Path of the lines and hoses 

– The lines and hoses must not be twisted. 

To make it easier to check this, a mark may be drawn 

on the lines (sometimes text). 

– The lines and hoses must lay freely (think of the possibility 

of them rubbing through). 

– The hoses must not make any sharp turns, especially 

not the flexible suction line and the return line. 

– The hoses must not be pinched closed by other components. 

0616 

1145385-1 

3 - 33 

5

5 




3.28 CHECKING THE COOLING SYSTEM’S 

ANTIFREEZE CONCENTRATION 

There is excess pressure in the cooling 

system when the coolant becomes hot. 

Carefully remove the filler cap to remove 

the excess pressure. 

Coolant is a harmful liquid. 

Therefore, avoid skin contact to prevent 

poisoning. 

1. Check the antifreeze concentration of the coolant. 

2. Only fill the cooling system with demineralised water or 

coolant which meets the VDL Bus & Coach specifications 

(see “Liquids, oils and lubricants specifications”). 

No other coolant, additive or antifreeze 

may be added to the mixture. 

To prevent damage to the engine block, 

do not add cold coolant whilst the engine 

is warm. 

3 - 34 0616




3.29 INSPECTING/TOPPING UP THE 

COOLANT LEVEL 

1. Turn the heater’s rotary switch to “warm”. 

2. Start the engine and allow it to idle for a couple of minutes. 

0616 



poisoning. 





3. Turn off the engine and check the coolant level. 

4. The coolant level must be between the maximum and 

minimum levels. If necessary, top up the coolant to the 

maximum level via the filler cap (1). 

Only fill the cooling system with coolant which meets the 

VDL Bus specifications (see “Liquids, oils and lubricants 

specifications”) 

If the coolant level is below the minimum 

level, the cooling system should be filled 

and bled. 



is warm. 

No other coolant, additive or antifreeze 

may be added to the mixture. 

Comment 

The coolant reservoir has a minimum level sensor. If the 

coolant level is too low, the symbol shown opposite will be 

displayed on the main display of the dashboard. 

The symbol will disappear approximately 1 minute after the 

coolant has been topped up to the correct level. 

03411B 

03939B 

3 - 35 

5

5 




3.30 CHECKING THE COOLING SYSTEM FOR 

LEAKS AND DAMAGE 



poisoning. 

The cooling system can be checked for leaks using a pressurization 

pump. Any leaks can be spotted more quickly if 

this is carried out whilst the engine is warm. 

3.30.1 CHECKING FOR LEAKS 

1. Fill the cooling system to the maximum level. 



is warm. 

2. Increase the engine temperature (the engine does not 

have to be at the operating temperature). 





3. Remove the filler cap from the expansion tank. 

4. Fit the pressurization pump. 

5. Comment 

The pressure cap will also be checked by fitting the pressurization 

pump to the filler port on the expansion tank. 

See “Technical information” for the opening pressure of 

the pressure relief valve and vacuum valve. 

Pressurize the system to the specified pressure (see 

“Technical information”). The pressure must remain constant 

for at least 10 minutes. 

6. Check the cooling system for leaks. 

3 - 36 0616




3.30.2 CHECKING THE COOLING UNIT 

1. Check the suspension brackets and vibration damper of 

the cooling unit for faults. 

2. Check whether all the line clamps and suspension straps 

are present and check their attachment. 

3. Check the fan blade for damage. 

4. Check whether there is at least 3 mm of play between the 

fan blades and the wind tunnel. 

5. Check the bearings of the hydraulic motor for play. 

0616 

03917B 

3 - 37 

5

5 




3.30.3 

Instructions for assembling and disassembling the 

Oetiker hose clamp 

Assembly 

1. Open the hose clamp as far as possible (make sure the 

bolt (1) is not screwed out of the D nut (5)). 

2. Place the hose clamp over the hose. If necessary, open 

the hose clamp further. 

3. Set the hose clamp to the smallest possible diameter, 

making sure the tongue (3) and the hooks (4) fall into the 

correct recesses. 

4. Tighten the bolt until the coils of the spring (2) touch each 

other and then tighten the bolt a further 3 x 360° to obtain 

the correct pre-tension. 

5. The opening (A) between the D nuts must now be at least 

3 mm. 

Max. tightening torque of the hose clamp bolt: 

Colourless spring: 90 -100 Ncm 

Green spring: 135 - 200 Ncm 

Disassembly 

1. Unscrew the hose clamp by turning the bolt anticlockwise. 

2. Make sure the bolt is not screwed out of the D nut. 

If necessary, open the hose clamp further. 

1 Bolt 

2 Spring 

3 Tongue 

4 Hook 

5 D nut 

3 - 38 0616 

03921B




3.31 CHECKING THE RADIATOR AND INTER- 

COOLER FOR CONTAMINATION 

1. Visually check the wire screen for contamination. 

If necessary, clean the wire screen (see “Cleaning”). 

2. If the wire screen is very contaminated, visually check 

the oil cooler, the intercooler and the radiator for contamination. 

If necessary, clean them (see “Cleaning”). 

0616 

03913B 

3 - 39 

5

5 




3.32 CHECKING THE STEERING OIL LEVEL 

Clean the top of the reservoir, so dirt will 

not enter the reservoir. 

1. Check the fluid level in the reservoir using the dipstick 

(2). 

2. When the engine is running, the fluid level must reach the 

maximum mark on the dipstick. The fluid level will be 

approximately 2 cm higher if the engine is not running. 

3. If necessary, top up the oil via the filler cap (3). 

3 - 40 0616




3.33 INSPECTING THE STEERING MECHA- 

NISM’S LINES/HOSES/CONNECTIONS 

Hydraulic lines/hoses/connections 

1. Condition of the lines and hoses 

– Check all the hydraulic lines and hoses for wear and 

leaks. 

In particular, porous suction hoses with a vacuum pressure 

will cause a problem (air in the system). 

– If in doubt, always replace the lines and/or hoses. 

2. Line and hose connections 

– Check each line and hose connection for leaks. 

3. Path of the hoses 

– The hoses must not be twisted. To make it easier to 

check this, a mark may be drawn on the lines (sometimes 

text). 

– The lines and hoses must lay freely (think of the possibility 

of them rubbing through and noises that can be 

heard in the vehicle). 

– The hoses must not make any sharp turns, especially 

not the flexible suction line and the return line. 

– The hoses must not be pinched closed by other components. 

Attachment 

1. Make sure the weight of the vehicle rests on the front 

wheels. 


3. Jerk the steering wheel a couple of times and visually 

check the attachment of the steering box and the steering 

bracket. Pay attention to any marks on the attachment 

(corrosion, paint damage). 

Comment 

If there is any doubt regarding the attachment, the bolts may 

only be tightened in accordance with the Workshop Instruction 

Manual. 

0616 

3 - 41 

5

5 




3.34 INSPECTING THE STEERING 

MECHANISM’S BEVEL BOX 

1. Block the steering axle (2) and turn the steering wheel 

(1). No play must be felt. 

2. Check the bevel box (3) for leaks. The bevel box must be 

replaced if there are any leaks. 

1151104 

3 - 42 0616




3.35 INSPECTING THE PIVOT POINTS OF 

THE STEERING MECHANISM 

General points of attention 

1. Check whether all the locks of the pitman arm, steering 

rod and track rod are present and undamaged. 

2. Check whether there is any play on the spider of the 

steering box’s input shaft. 

3.35.1 CHECKING THE STEERING ROD BALLS AND 

TRACK ROD BALLS 

• The checks must be made in the operational condition with 

a loaded axle. 

• Clean the steering rod balls and track rod balls with a dry 

cloth (do not use a cleaning product or a solvent). 

• Visually check the steering rod balls and the track rod balls 

for: 

– Corrosion 

The steering rod, track rod, bearing housing, stud bolt and 

cover must not have any grooves deeper than 1 mm. 

– Bellows/dust cover 

Check whether grease escapes via the wall of the bellows 

by squeezing the bellows by hand. It is permitted for grease 

to escape through the bottom bellows opening. The bellows 

must not have any holes, cracks or wear. 

– Diaphragm spring and clamping ring 

The diaphragm spring and clamping ring push the bellows 

against the steering ball housing and the coupling ball. 

Check whether the diaphragm spring and the clamping ring 

lay correctly in the recesses. 

It must not be possible to rotate the bellows/dust cover by 

hand. 

– Castellated nut and split pin 

Check the attachment of the castellated nut and the split 

pin. Check the castellated nut and the split pin for excessive 

corrosion. 

– Steering rod and track rod clamped connection 

* The clamping screw must be correctly fitted. The nut 

must be flush against the saddle clamp. The screw 

must not be visibly deformed. Pitting caused by corrosion 

with a depth greater than 0.5 mm is not permitted. 

If it is observed that the clamped connection is loose or 

has been loose, the steering rod and track rod must be 

replaced as a precaution. Replace excessively corroded 

screws and nuts. 

* Place a finger on the clamped connection, turn the 

steering wheel from left to right and check whether the 

clamped connection moves. If movement is observed, 

the steering rod and the track rod must be replaced. 

* Visually check the steering rod and the track rod for 

damage. If serious damage is observed, the steering 

rod and the track rod must be replaced. 

0616 

1. Cover 

2. Top bearing shell 

3. Housing 

4. Compression spring 

5. Stud bolt 

6. Coupling ball 

7. Diaphragm spring 

8. Bottom bearing shell 

9. Bellows 

10. Clamping ring 

03927B 

3 - 43 

5

5 




3.35.2 RADIAL STEERING BALL JOINT PLAY 

1. Check the pivot points whilst the engine is not running. 

2. Turn the wheels to the straight ahead position. 

3. Make sure the weight of the vehicle rests on the front 

wheels. 

4. Push and pull the steering rods by hand in the direction 

of the steering ball joints. Do not use any tools to apply 

force, because this may damage the components. 

The steering ball joints must be replaced if any radial play 

can be felt. 

3.35.3 AXIAL (UPWARD) STEERING BALL JOINT PLAY 

1. Check the pivot points whilst the engine is not running 

with a load placed on the axles. 

2. Turn the steering wheel to the left and the right. 

3. Check the compression of the steering ball joint. Compare 

the reading with the maximum permissible steering 

ball joint play (see “Technical information”). 

If necessary, replace the steering ball joint. 

4. If in doubt, disassemble the steering ball joint and check 

the play using a suitable gauge. 

3 - 44 0616




3.35.4 CHECKING THE AXLE PLAY WITH SPECIAL TOOL DAF NO. 1329426 

1. Jack up the axle until the wheels come off of the ground 

and put the axle on hoisting sheers. 

2. Make sure the split pin of the castellated nut (if fitted) 

does not come into contact with the head of the stud bolt. 

3. Screw the thrust nut (8) onto the threaded spindle. 

4. Fit the spring retainer (3), spring (4) and thrust bush (6) 

into the bracket (1). 

Fit the lock screw (5). The thrust bush must move freely. 

Comment 

Fit the correct thrust bush (6). The thrust bush (6) must touch 

the outside edge of the steering ball joint (7). 

5. Screw back the thrust bolt (2) until the thrust bush (6) and 

its flange lay against the bracket (A = 0 mm). 

6. Fit the special tool over the steering ball joint (7) and turn 

the threaded spindle (9) by hand until the special tool 

clamps onto the steering ball joint (7). 

7. Tighten the thrust bolt (2) until its head lays against the 

bracket (1). 

8. Using a feeler gauge, measure the clearance “A” created 

between the pressure sleeve and the bracket. 

Compare the reading with the maximum permissible 

steering ball joint play (see “Technical information”). 

If necessary, replace the steering ball joint 

0616 

3 - 45 

5

5 




3.36 INSPECTING THE SWIVEL AXLE PLAY 

1. The vehicle should stand with the wheels on the ground. 

2. Measure the distance (A) between the swivel axle and 

the spacer ring around the entire circumference at the 

top of the axle end using a feeler gauge. 

Compare the measured value to the specified tolerance 

(see “Technical information”). 

Comment 

The play must be approximately the same around the entire 

circumference of the axle end. If the play is not equal, then 

this is an indication of radial play in the needle bearings. If the 

radial play of one of the needle bearings measured around 

the circumference of the axle end exceeds the permitted 

axial play tolerance, the needle bearings must be replaced. 

If too much axle play is measured around the entire circumference 

of the axle end, then the swivel axle’s thrust bearing 

is probably worn. 

3 - 46 0616




3.37 INSPECTING THE BLOCKING 

CYLINDERS OF THE 3RD AXLE 

1. Raise the vehicle. 

– Bleed the air bellows. 

Disconnect the ECAS unit’s connector. 

Apply the vehicle’s parking brake. 

– Jack up the vehicle using lifting columns. 

Place the lifting columns under the front axle and the 

trailing axle. 

– Place trestles under the vehicle’s trestle points. 

– Lower the vehicle onto the trestles, making sure the 

front wheels and trailing axle wheels can rotate freely. 

2. Connect pressure gauges to the blocking cylinder test 

port. 

3. Turn on the main switch and the contact switch. 

Both blocking cylinders should now be bled. Check 

whether both wheels can rotate freely. 

4. Turn off the main switch and the contact switch. 

Both blocking cylinders should now be aerated. Check 

whether both wheels are blocked. 

Play must not be felt. If necessary, remove any play (see 

workshop instruction manual). 

5. Check whether the blocking cylinders are bled/aerated 

when the steering wheel is rotated between 60° and 120° 

to the left and right (see table). 

6. Check the setting of the approach sensors if the blocking 

cylinders are NOT bled/aerated when the steering wheel 

is rotated between 60° and 120°. 

7. Simulate the driving speed using the MTCO tachograph. 

See the driver’s manual for instructions on how to operate 

the 3rd axle. 

– Up to a speed of 30 km/h, the “Block steered 3rd axle” 

switch on the dashboard can be used to block the 3rd 

axle. 

Both blocking cylinders will be aerated, so that both 

wheels are blocked. 

– The axle will always be blocked at a speed greater than 

30 km/h. 

8. Check the attachment of the dust covers and check the 

dust covers for cracks. 

0616 

1. Fork 

2. Hose clip 

3. Lock nut 

4. Dust cover 

5. Hose clip 

6. Piston rod 

7. Piston 

03911B 

3 - 47 

5

5 




Situation Main switch Switch for 

blocking the 

trailing axle 

Steering wheel 

rotation (in °) 

03935B 

Condition of the blocking cylinder 

A B 

1. OFF OFF All positions Aerated Aerated 

2. ON OFF 60° - 120° to the right Aerated Bled 

3. ON OFF 60° - 120° to the left Aerated 

4. ON ON All positions Aerated Aerated 

Right-hand bend 

A Left-hand blocking cylinder 

B Right-hand blocking cylinder 

C Approach sensor 

Left-hand bend 

A Left-hand blocking cylinder 

B Right-hand blocking cylinder 

C Approach sensor 

3 - 48 0616 

03934B




3.38 INSPECTING THE MAXIMUM WHEEL 

TURNING ANGLE 

Inspecting the wheel turning angle 

1. Apply the vehicle’s parking brake and place chocks in 

front of and behind the rear wheels of the driven axle. 

2. Turn off the main switch and the contact switch. 

3. Jack up the vehicle (only place the jack on the permitted 

jack points) and place turntables under the centre of the 

wheels of the front module, rear axle and trailing axle. 

Only use turntables which allow for wheel displacement 

caused by the wheel roll radius. 

4. Lower the wheels onto the turning plates. Zero the turning 

plates. 

5. Fit the alignment tool. 

Turn on the main switch so that the wheels can rotate 

freely. 

6. Check the wheel turning angle (see “Technical information) 

and, if necessary, adjust it. 

0616 

Work safely and block the vehicle so that 

it cannot slide off of the turntables. 

Adjusting the wheel turning angle 

1. The wheel turning angle is adjusted by changing the 

length of the stop bolt on the swivel axle. After the adjustment, 

secure the bolt using the lock nut. 

2. After finishing the adjustment, make sure the tyre does 

not come into contact with other components. 

03930B 

3 - 49 

5

5 




3.39 INSPECTING THE BRAKE COMPO- 

NENTS AND BRAKE LINES 

1. If the vehicle’s brake system has been charged to the 

maximum pressure and the vehicle has been standing 

stationary for 16 hours, it should generally be possible to 

drive the vehicle away without having to first bring the 

brake system to a sufficient operating pressure. This 

amounts to a maximum pressure drop of approximately 

0.4 bar per hour at the normal system pressure. 

2. Check whether all the brake components are securely 

attached using the correct fixing or locking compounds. 

3. Check all the brake components for damage and cracked 

or broken parts. 

4. Check the operation of the air compressor and pressure 

regulator as follows: 

– Visually check the cut-in and cut-out pressure of the air 

compressor and the pressure regulator using the pressure 

gauges on the dashboard by pressing the brake 

pedal a number of times whilst the engine is running 


– Check the capacity of the air compressor. 

The compressor must be able to bring an empty system 

to the operating pressure within the indicated time 

whilst the engine is running at the maximum speed. 

Vehicle type Cut-out pressure Filling time Air reservoir volume 

SB 8.6 bar ≤ 6 min. 70 l 

SBR 8.9 ≤ 6 min. 95 l 

5. Check for air leaks: 

– Bring the pneumatic brake system to the operating 

pressure (cut-out pressure of the pressure regulator). 

– Apply the foot brake and keep it depressed. 

– A leak must not be heard in the entire pneumatic brake 

system. 

6. Check the brake hoses for deformation and ageing. 

7. Check whether the brake hoses and brake components 

touch any moving parts. 

8. Check whether the wheels can rotate freely in both directions 

without the brake pads rubbing. 

9. Check whether the brake cylinders move whilst the service 

brake is applied. 

3 - 50 0616




3.40 INSPECTING THE BRAKE CALLIPER 

PLAY 

An inspection of the movement of the brake calliper guide is 

the most important thing to do. 

Therefore, a simple inspection of the axial movement of the 

brake calliper whilst it is assembled is carried out first on the 

vehicle. 

3.40.1 GENERAL INSPECTION 

1. Push and pull the brake calliper in the axial direction (A) 

a couple of times. Considerable force is necessary to do 

this. 

2. Check the axial brake calliper play (A) (see “Technical 


If the measured play is incorrect or if there is no movement 

at all along the guide bushes, the brake calliper must be 

more accurately inspected as follows. 

3.40.2 INSPECTING THE MOVABILITY 

1. Remove the brake pads. 

2. Use the adjusting bolt and the adapter to set the thrust 

pieces as far back as possible. 

3. Clean the guide bushes in the accessible areas. 

4. Check whether the brake calliper can be slid along the 

entire length (more than 25 mm) by hand (therefore, without 

the aid of tools). 

If this is not the case, apply grease to the guide bushes 

and bearing bushes, see chapter “Greasing guide buses 

and bearing bushes”. 

0616 

3 - 51 

5

5 




3.40.3 CHECK THE PLAY OF GUIDE PIN 4 AND RUBBER BUSH 6 

Method A 


2. Use the adjusting bolt and the adapter to set the thrust 

pieces as far back as possible. 

3. Pull the brake calliper as far as possible towards the outside 

of the vehicle (B). 

4. Push the brake calliper as far as possible in the direction 

of the brake calliper bracket (C). 

5. Measure the distance X. 

03924B 

3 - 52 0616




6. Push the brake calliper as far as possible in the opposite 

direction in the direction of the brake calliper bracket (D). 

7. Measure the distance Y. 

8. Determine the difference between the measured distances 

Y - X (see “Technical information”). 

9. Assemble the brake pads. 

Method B 

1. Remove the wheels. 

2. Remove the retainer (11), but DO NOT remove the brake 

pads from the brake calliper. 

3. Place the magnetic foot of the dial gauge on the brake 

calliper bracket on the same side as the rubber bush (6) 

(short bearing side). 

4. Position the needle of the dial gauge as shown. 

5. Push the brake calliper (1) in the direction of the bracket 

(2) and zero the dial gauge. 

6. Place a suitable tool (for example, a screw driver) 

between the bracket and the brake calliper and push the 

brake calliper in the opposite direction. 

7. Compare the measured value to the permitted play (see 


If the measured play is greater than the permitted value, 

then the rubber bush (6) must be replaced 

8. Fit the retainer (11). 

9. Fit the wheels. 

0616 

FD00221 

3 - 53 

5

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3.41 CHECKING THE THICKNESS OF THE 

BRAKE PADS 

1. The thickness of the brake pads can be checked whilst 

the wheels are still fitted by the position of the guide bush 

in relation to the rubber bush. 

2. The rubber sleeve is stretched when the brake pad is at 

the maximum thickness. The rubber sleeve will roll up as 

a result of wear to the brake pads and the brake calliper 

sliding over the guide bushes. 

3. The wheels must be removed and the thickness of the 

brake pads and the thickness of the brake discs must be 

checked once the transfer from the ribbed section of the 

rubber sleeve to the smooth section (A) starts to roll 

inwards (see “Technical information”). 

Checking whether the brake pads rub 

Check whether the brake pads come free from the brake disc 

once the brakes have been released. 

3 - 54 0616




3.42 CHECKING THE AUTOMATIC SLACK 

ADJUSTER 

1. Release the parking brake/door-operated brake. 


3. Press the brake calliper towards the vehicle. Push the 

inner brake pad away from the thrust pieces. 

4. Check the air gap between the thrust pieces and the rear 

of the brake pad. 

This air gap should be 0.6 - 1.1 mm. 

If the air gap falls outside the tolerance, the slack 

adjuster must be checked as follows. 

5. Remove the cover (37). 

0616 

To avoid damaging the sealing surface, never use a 

screw driver to remove the cover. 

Never rotate the adjusting hexagon 

without an adapter (61). The adapter 

forms a torque safety device. If the torque 

becomes too great, the adapter will no 

longer grip the adjusting hexagon. 

Without an adapter, the mechanics in the 

brake calliper may become damaged as a 

result of a too great torque, so that it will 

be necessary to replace the brake 

calliper. 

6. Turn the slack adjuster anticlockwise using a box spanner 

and an adapter until the slack adjuster clicks 2 or 3 

times (the play will be reduced). 

7. Operate the service brake 5 to 10 times and check 

whether the box spanner can rotate freely in the clockwise 

direction. 

The box spanner will turn clockwise in jerks if the slack 

adjuster works correctly. 

Comment 

When the clicks increase, the spanner’s angular displacement/rotation 

will become smaller/less. 

The slack adjuster works correctly if the spanner turns back 

as described. 

The brake calliper should be replaced if the following faults 

occur: 

The slack adjuster or box spanner turns: 

a. Not at all. 

b. Only the first time the brakes are applied. 

c. Back and forth each time the brakes are applied. 

3 - 55 

5

5 




8. Remove the box spanner. 

9. Replace the cover (37). Apply a small amount of Renolit 

HLT2 (white) to the new cover and then fit it. 

Check whether the cover is properly sealed. 

3 - 56 0616




3.43 INSPECTING THE BRAKE DISCS 


2. Measure the thickness of the brake discs. When doing 

so, measure the thickness in a number of places so as to 

find the thinnest measurement. Compare the measured 

value with the specified value (see “Technical information”). 

3. Check the brake discs for wear patterns (see “Technical 


Comment 

The brake discs may be turned (see “Technical information”). 

0616 

3 - 57 

5

5 




3.44 GREASING GUIDE BUSHES AND BEAR- 

ING BUSHES 

Do not use a cleaning product which 

contains mineral oil. 

Do not use metal tools with sharp edges. 

1. Remove the brake calliper (see “Removal and installation”). 

2. Remove the ring (58). 

3. Remove the guide bush (5). 

Do not remove the brass bearing bush (7). 

4. Grease the inside of the bearing bush (7) (see “Liquids, 

oils and lubricants specifications”). 

5. Lightly grease the guide bush (5) (see “Liquids, oils and 

lubricants”). 

6. Fit the guide bush (5). 

7. Push the ring (58) onto the guide bush (5) until it clicks 

into place. 

8. Remove the guide bush (4). 

Do not remove the rubber bearing bush 

(6) 

9. Grease the inside of the bearing bush (6) (see “Liquids, 

oils and lubricants”). 

10. Lightly grease the guide bush (4) (see “Liquids, oils and 

lubricants”). 

11. Fit the guide bush (4) into the guide bush (4) from the 

inside of the brake calliper. 

12. Fit the brake calliper. 

3 - 58 0616




3.45 INSPECTING THE BRAKE 

DECELERATION 

Preferably check the brake deceleration on a plate brake 

tester or a roller test bench. 

The brake deceleration on a dry or almost dry and approximately 

horizontal road must be at least 4.5 m/s2 for a maximum 

pedal force of 70 kg. 

Comment 

If a roller test bench is used, the difference in braking force 

between the wheels on the rear axle must not be greater than 

30% of the highest measured braking force (highest value) 

where the wheels do not lock. 

The difference in braking force between the wheels on the 

front axle must not be greater than 20% of the highest measured 

braking force. 

0616 

3 - 59 

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3.46 INSPECTING THE OIL SEPARATOR 

1. When the compressor is in operation, check the connections 

and seals for air leaks using a soap solution. 


Apply the foot brake once the compressor is in operation 

and then release the foot brake. 

Every time the foot brake is applied, a click will be heard 

from the electronic separator and air will be blown off 

(soft hissing sound) via the blow-off valve/collection 

cover. 

If the blow-off valve does not work, check the electrical 

unit. 

If the blow-off valve does not work, even though there is 

nothing wrong with the electrical unit, then the oil separator 

must be disassembled and inspected. 

3. Check all the components for carbon deposits, corrosion 

and contamination. Clean or replace the components 

concerned. 

Use compressed air to blow the blow-off valve’s filter dry 

before assembly. 

03914B 

3 - 60 0616




3.47 CHECKING THE ATTACHMENT OF THE 

SHOCK ABSORBERS AND CHECKING 

THEM FOR DAMAGE 

1. Visually check the shock absorbers for leaks and visually 

check the attachment. 

3.48 INSPECTING THE U-BOLTS 

Inspecting the U-bolts 

1. Visually inspect the attachment and condition of the Ubolts. 

2. When retightening the nuts of the U-bolts, the attachment 

nut must not first be loosened and then retightened to the 

specified torque (see “Technical information”). 

3.49 CHECKING THE PIVOT POINTS OF THE 

AXLE SUSPENSION AND THE 

PNEUMATIC SUSPENSION 

Torque rod 

1. Check the attachment of the torque rods and the torque 

rod brackets. 

2. Check the pivot points of the torque rods for wear and 

play. 

Stabilizer rod 

1. Check the attachment of the stabilizer rods and stabilizer 

rod brackets. 

2. Check the pivot points of the stabilizer rods for wear and 

play. 

0616 

3 - 61 

5

5 




3.50 INSPECTING THE PNEUMATIC 

SUSPENSION’S AIR BELLOWS 

The air bellows are not resistant to 

solvents, hydraulic oil and grease. 

1. Fully pressurize the system and place the pneumatic 

suspension in the highest position. 

2. Thoroughly clean the air bellows with soapy water. 

3. Remove the dirt on the outside of the seat using a rag or 

a brush. 

4. Check the air bellows for cracks and damage. The air 

bellows must be replaced if there are any cracks or damage 

where the fabric is visible. 

5. Check the air bellows, the bellows seats and the air connections 

for leaks. 

Replace the bellows seats if there is any deformation. 

Check whether the air bellows rub along components, 

such as air lines, etc., when in the highest position and at 

the highest driving height. 

6. Check the position of the rubber bumper stops and check 

them for damage. 

7. Return the vehicle to the driving height after completing 

all the checks. 

3 - 62 0616




3.51 INSPECTING THE CHASSIS’ PNEU- 

MATIC SUSPENSION 

1. Use the Kneel/Ferry Lift switch (see driver’s manual) to 

place the vehicle in the ferry lift position. 

The information symbol (vehicle not at driving height) will 

be lit to indicate that the vehicle is not at the driving 

height. 

0616 

The information symbol shown opposite will be lit when 

the vehicle is in the ferry lift position. 


place the vehicle in the kneeling position. The information 

symbol (vehicle not at driving height) will be lit to indicate 

that the vehicle is not at the driving height. 

The information symbol shown opposite will be lit when 

the vehicle is in the kneeling position. 

3. Operate the “standard driving height pneumatic suspension” 

switch. The vehicle must then return to the normal 

driving height and the information symbol (vehicle not at 

driving height) must be extinguished. 

4. If necessary, check the driving height and the ECAS unit. 

03937B 

03938B 

3 - 63 

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3.52 CHECKING THE DRIVING HEIGHT 

Mechanical 

1. Place the vehicle on a level surface. 



Be careful, there is a danger of becoming 

trapped! 

3. Turn off the contact switch. 

4. Place the special tool (1) (VDL Bus no. 1152749) 

between the shock absorber brackets. Use a tie-rap to 

keep the special tool in position. Do this on both sides of 

the vehicle. 

5. Place the special tool (2) (VDL Bus no. 1198824) 

between the chassis beam and over the bumper stop. 

The word “VOORKANT” should point towards the front of 

the vehicle. Do this on both sides of the rear axle. 

6. Turn on the contact switch. 


lower the vehicle until it rests on the adjustment gauges. 


9. Next, adjust the height control rods (3) and (4) so that the 

centring holes A and B are aligned (check this using a 4 

mm pin). 

10. The vehicle has now been mechanically calibrated. 

11. Turn on the contact switch. 

Use the Kneel/Ferry Lift switch (see driver’s manual) to 



13. Remove the adjustment gauges. 

14. Turn on the contact switch and return the vehicle to the 

driving height. 

03912B 

3 - 64 0616




3.53 CHECKING THE DIFFERENTIAL 

3.53.1 CHECKING THE DIFFERENTIAL FOR LEAKS 

1. Visually check the differential for leaks. 

3.53.2 CHECKING THE DIFFERENTIAL OIL LEVEL 

Comment 

Do not check the oil level immediately after a journey. Allow 

the oil to settle and cool down for approximately half an hour. 



2. Check the oil level via the oil spill plug (A). 

3. The oil level must reach the edge of the oil spill plug 

opening. 

4. If necessary, top up the oil via the hole in the oil spill plug 

(A) to the required level. 

5. Fit the oil spill plug (A) using the special Torx spanner 

(DAF no. 1329422) and tighten it to the specified torque 


3.53.3 INSPECTING THE DIFFERENTIAL LOCK 

1. Jack up the rear axle and support it using hoisting 

sheers. 

2. Pressurize the pneumatic system to the operating pressure 

(8.6 – 9.6 bar). 

3. Turn on the differential lock. 

The warning light should come on. 

0616 

To prevent skin damage, avoid 

unnecessary contact with the drained oil. 

Note! There is a danger of being burnt by 

hot oil. 

IC6_WC5 

3 - 65 

5

5 




4. Check whether there is a rigid connection between the 

driven wheels. 

5. Turn off the differential lock. The warning light should go 

out and there should no longer be a rigid connection 

between the driven wheels. 

Comment 

If the differential lock does not function correctly, check: 

– The command pressure. 

– The inside of the blocking cylinder for contamination. 

– The electrical system. 

00068B 

3 - 66 0616




3.54 INSPECTING THE DRIVE SHAFTS, 

SLIDING JOINTS AND UNIVERSAL 

JOINTS FOR WEAR 

1. Inspect the universal joints for play and damage. 

2. Inspect the sliding joint for axial and radial play. 

3. Play must not be felt on the universal joints nor on the 

sliding joint. 

4. Check the radial play of the sliding joint by hand. 

5. Check the drive shaft for damage and twisting/deformation. 

6. Check whether all the retaining rings are still in place and 

whether they are fitted correctly. 

7. If there is excessive noise or jerky movements when driving 

at a certain speed, check the balance plates on the 

drive shaft (unbalanced). 

8. Place the removed drive shaft on a flat workbench and 

support the shaft in positions A and B. 

9. Slide out the sliding joint approximately 45 mm. 

10. Place the universal measuring tool at position C on the 

drive shaft. 

11. Place the dial gauge at position D on the drive shaft 

(directly next to the weld). 

12. Move the centre of gravity of the drive shaft (see arrows) 

upwards and measure the radial play of the sliding joint. 

See “Technical information” for the maximum permitted 

play. 

0616 

If radial play of the sliding joint is 

observed, then it must be checked to 

make sure that this is not the result of 

play of the universal joint.The drive shaft 

must be removed and inspected in order 

to be sure that the observed play is within 

the maximum permitted value. 

3 - 67 

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3.55 INSPECTING THE GREASE LUBRI- 

CATED WHEEL HUBS 

1. Check the wheel hubs for leaks. 

ZF hubs 

– If serious traces of grease are observed on new or recently 

fitted wheel hubs, then this may indicate excessive use of 

assembly grease. 

– If the wheel hubs were not recently fitted, serious traces of 

grease may indicate a leak from the gasket (3) or oil seal 

(4). Replace the gasket/oil seal. 

DAF hubs 

– If serious traces of grease are observed on new or recently 

fitted wheel hubs, then this may indicate excessive use of 

assembly grease. 

– If the wheel hubs were not recently fitted, serious traces of 

grease may indicate a leak from the oil seal (1). This 

means that the entire wheel hub unit must be replaced. 

– If a serious oil leak is observed, then this may indicate that 

O-ring (2) is not properly sealed.In this case, the hub unit 

must be disassembled in order to rectify the problem. 03936B 

ZF wheel hub 

1. Oil seal 

2. O-ring 

DAF wheel hub 

1. Oil seal 

2. O-ring 

G000196 

3 - 68 0616




3.56 INSPECTING AND ADJUSTING THE 

WHEEL BEARING PLAY (ZF HUBS) 

Checking the wheel bearing play 

1. Use the special tool (ZF no. 5870 200 055 and 5870 200 

057) to get a reliable measurement of the wheel bearing 

play. 

2. Remove the hub cap. 

3. Fit the magnetic dial gauge holder to the hub. 

4. Place the dial gauge in the dial gauge holder (3) so that 

the dial applies some pressure against the swivel axle. 

5. Determine the bearing play by pulling and pushing the 

hub. 

6. Take the dial gauge reading and compare it to the specified 

value (see “Technical information”). 

If the measured value falls outside the tolerance, the 

wheel bearing play should be adjusted. 

7. Fit the hub cap and the gasket. Tighten the bolts to the 


Adjusting the wheel bearing play 

1. Unscrew the clamping nut’s lock screw. 

2. Rotate the clamping nut until the correct bearing play is 

reached. 

Tighten the clamping nut’s lock screw to the specified 

torque (see “Technical information”). 

3. Check the wheel bearing play again and, if necessary, 

correct it. 

0616 

03931B 

3 - 69 

5

5 




3.57 INSPECTING THE TYRES AND WHEEL 

RIMS 

Checking the tyres 

– Check the depth of the tread. The advised minimum depth 

for traffic safety is 1 mm. 

The wear indicator in the tyre is for 1.6 mm. (The legally 

permitted tread depth may vary per country.) 

– Check the side walls for incisions, damage (caused by 

manhole covers, pavements, etc.), wear caused by rubbing, 

and abnormal deformation. 

– Check the tread for incisions, local deformation and foreign 

objects (stones, nails, etc.). 

– Check whether the wear pattern of the tread is evenly distributed 

over the entire surface. 

Comment 

Possible causes of uneven wear are: 

– Incorrect tyre pressure. 

– Play in the spring suspension, swivel axles, steering ball 

joints and reaction arms. 

– The axles of the vehicle not being in line. 

– Deviating wheel positions, etc. 

It is important to trace the cause of abnormal tyre wear, for 

example, by aligning the vehicle. 

Checking the wheel rims 

1. Inspect the wheel rims for the following: 

– Deformation of the edges of the rims and the wheel 

disc. For a double assembly, also inspect the inside 

wheel. 

– Deformation of or cracks in the wheel bolt holes. 

– Corrosion, including on the tyre side of the rim and the 

rim ring. 

2. Cracked or damaged wheel rims or wheel rims with torn 

or deformed wheel bolt holes must be replaced. It is not 

permitted to weld wheel rims or to repair them in any 

other way. In time, the dynamic load placed on them will 

cause the weld to crack again. 

When removing a damaged wheel rim from 

the vehicle, deflate the tyre (remove the tyre 

valve) to remove any tension in the wheel 

rim. 

3. Only use original wheel rims permitted for the vehicle 

concerned, as stated in Overview combination of tyres 

and rim sizes (�3 -71) 

3 - 70 0616




4. To prevent damage to the tyre and/or indirect tension 

cracks (notching) due to corrosion, the anti-corrosion 

treatment of the wheel rim should stay fully intact. When 

respraying, the old layer of paint must be removed in 

order to prevent the total layer of paint from becoming too 

thick. The total paint thickness must not exceed 50 

microns. 

Overview combination of tyres and rim sizes 

Table 1 

Tyre size 

0616 

With a total paint layer thickness (wash 

primer and finishing paint) of more than 50 

microns, the pre-tension of the wheel bolts 

might be reduced if this layer is crushed. 

This could result in the wheel nuts coming 

loose. 

SB230 SB 4000+ 

275/70 

R22,5 

295/80 

R22,5 

315/80 

R22,5 

SBR 230 

Single deck 

275/70 

R22,5 

295/80 

R22,5 

SBR 4000+ 

single deck 

315/80 

R22,5 

SBR 4000+ 

double deck 

315/70 

R22,5 

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

Additional 

parts a 

Spacer disc 

Extended 

bolts 

Spacer disc 

Extended 

bolts 

Spacer disc 

Extended 

bolts 

a. Spacer discs are necessary when fitting 9.00"x22.5" rims on the front axle (IFS). The thickness of the spacer discs for steel rim is 15 mm and for 

aluminium rims is 10 mm. Also fit the extended wheel bolts. 

3 - 71 

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3.58 CHECKING THE ATTACHMENT OF THE 

WHEELS (RETIGHTENING) 

When fitting new wheel bolts, the wheel 

nuts must be retightened twice. The first 

time after 100 km and the second time 

after 500 km. 

Comments 

The rims and wheel nuts used on the vehicle are of the wheel 

hub centring type. 

Only use original wheel rims permitted for the vehicle concerned 

Characteristics of wheel hub centring are: 

– Wheels with cylindrical holes. 

– Wheel nuts with a loose, non-removable, flat thrust 

washer. 

– The rim lies tight against the cams of the wheel hub. 

For aluminium wheels, check whether the correct Allen 

screws are used (recognizable by three circles on the 

flange). Two different types are used: 

– The short shaft type for single assembly (A = 12 mm). 

– The long shaft type for double assembly (B = 34 mm). 

Tightening the wheel nuts 

1. Remove the plastic cap from each wheel nut. 

2. Tighten the wheel nuts in the order shown in the diagram 

to the correct torque (see “Technical information”) using 

a torque spanner. 

3. Refit the plastic caps. 

3 - 72 0616 

03933B 

03932B




3.59 CHANGING WHEELS 

Wheels and tyres are increasingly being changed as a complete 

unit when the seasons change. A number of things 

must be taken into consideration when changing the wheel 

and tyre as a unit. 

0616 

When removing a wheel with a cracked or 

damaged wheel rim, always deflate the tyre 

first (remove the tyre valve) to remove any 

possible tension in the wheel rim. 

Aluminium wheels may not be heated by, 

for example, welding or direct heating. Fit a 

new wheel! 

Comments 

– Only fit tyres and wheel rims that are permitted for use on 

the vehicle concerned see Table , “Overview combination 

of tyres and rim sizes,” on page 71 

– Mark the position of the wheel and tyre that are being 

removed so that the new wheel and tyre can be fitted in the 

same position. 

– Take into consideration the driving direction/direction of 

rotation if this is indicated on the tyre. 

– Make sure the same type of tyres and rims are fitted on 

both sides of the axle. 

– Cleaning contact surfaces sufficient and tighten the wheel 

nuts even to prevent vibrations during driving or braking. 

– Replace all wheel bolts on the wheel concerned when one 

must be replaced. 

A. Spacer washer 

B. Wheel bolt 

C. Wheel bolt 

03862B 

3 - 73 

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Changing the size of the tyre 

Spacer discs and longer wheel bolts must 

be used on the front axle if 315/70 or 315/80 

tyres are fitted instead of 295/80 tyres. 

The workshop must also check the 

maximum wheel turning angle and, if 

necessary, correct it. The corrections must 

be made according to the instructions given 

in the workshop manual. 

The spacer discs must be removed and 

shorter wheel bolts must be used on the 

front axle if 295/80 tyres are fitted instead of 

315/70 or 315/80 tyres. 

If the load capacity of the 295/80 tyre is less 

than that stated on the type plate, then the 

workshop must order and fit a new type 

plate. 

Removing the wheels 

1. Clean the screw thread of the wheel bolts using a wire 

brush. 

2. Lightly lubricate the screw thread of the wheel nuts with 

oil. 

3. Unscrew the wheel nuts. 

4. Place a jack as close as possible to the wheel which is 

going to be replaced. Only use the jack point intended for 

this purpose. 

5. Jack up the vehicle and place a trestle under the vehicle. 

Only use a trestle point intended for this purpose. 

6. Remove the wheel nuts and take the wheel off of the hub. 

Fitting the wheels 

1. Clean the fitting edge of the rim and the cams on the 

wheel hubs by scraping off any dirt and corrosion from 

the edge using a scraper.Rub the fitting edges clean and 

dry. If necessary, apply a new layer of paint. 

Comment 

For aluminium wheels, only use Freylube or an equivalent 

assembly grease. Assembly grease with a water base or with 

heavy metals may cause corrosion and is, therefore, unsuitable. 

3 - 74 0616




2. Apply a thin layer of grease to the fitting edge of the 

wheel hub and the top of the wheel hub cams 

3. Also apply a thin layer of grease to the fitting edge of the 

wheel rim. This grease layer should prevent the wheel 

rim and the wheel hub from rusting together. 

4. Check whether the contact surfaces of the wheel rim and 

the wheel hub are clean. If necessary, clean them. 

5. Clean the wheel nuts and then apply one drop of oil 

between the thrust washer and the nut. 

6. Also apply one drop of oil to the first turn of the wheel 

bolts’ screw thread. 

7. Fit the wheel nuts and tighten them evenly in the 

sequence shown in the diagram. 

A pneumatic spanner may be used, but the torque is not 

very reliable. 

It will, therefore, be necessary to retighten the wheel nuts 

to the specified torque using a torque spanner. See 

“Technical information” for the correct torque. 

0616 

Use of COPASLIP or MOLYKOTE is not 

permitted. 

The wheel nuts should always be 

tightened and retightened when cold. 

However, tightening wheel bolts in 

extreme cold should be avoided. 

8. Check the tyre pressure. 

9. Use a torque spanner to retighten the wheel nuts after 

100 km. If new wheel bolts have been fitted, retighten the 

wheel nuts again after 500 km. 

3 - 75 

5

5 




3.60 CHECKING THE TYRE PRESSURE 

(INCLUDING THE SPARE TYRE) 

The driving comfort and fuel consumption are influenced by 

the tyre pressure. The required tyre pressures depends on 

the position of the tyre on the vehicle, the axle load and the 

size of the tyre. 

Comments according to the tyre pressure table 1 

1. The required tyre pressures are for cold tyres. 

2. Unnecessary tyre wear is frequently caused by vehicle 

operation with tyre pressures which do not match the 

axle load. 

3. In case of double assembly: 

– The tyres pressure of both tyres must be the same. 

– The depth of tread must be near enough the same. 

4. A too high or too low tyre pressure causes the tyres to 

wear quickly and may have an adverse effect on the 

vehicle’s steering and suspension. 

5. Vehicles equipped with ABS: the following faults in the 

tyres may cause the vehicle’s ABS braking system to 

partially or completely stop operating: 

– Excessive tyre wear. 

– Too low tyre pressure. 

– Tyres which do not match or which are incorrectly fitted. 

6. Use an accurate tyre pressure gauge to check the tyre 

pressure of every tyre on the vehicle and, if necessary, 

change the tyre pressure to the value stated in the tyre 

pressure table. 

7. Make sure all the tyre valves are in good condition and 

have a valve cap. 

Tyre pressure table 

SB230 SB 4000+ 

275/70 

R22,5 

295/80 

R22,5 

315/80 

R22,5 

SBR 230 

Single deck 

275/70 

R22,5 

295/80 

R22,5 

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

SBR 4000+ 

single deck 

315/80 

R22,5 

SBR 4000+ 

double deck 

315/70 R22,5 

Front axle 9.0 8.5 8.0 9.0 8.5 8.0 9.0 

Rear axle 9.0 7.75 6.75 8.0 6.75 6.0 7.75 

Trailer axle 8.0 6.75 6.0 9.0 

3 - 76 0616




3.61 CHECKING THE GEARBOX OIL LEVEL 

3.61.1 GO-170/190/210 

1. Check the gearbox oil when it is at the operating temperature. 

2. Make sure the vehicle is horizontal, both longways and 

crossways. 

3. Wait a couple of minutes so that the oil can flow back. 

4. Remove the oil spill/filler plug (1) and the sealing ring (2). 

The oil level must reach the edge of the oil spill/filler 

opening. If necessary, top up the oil. 

5. If there is excessive oil loss, check the gearbox for leaks. 

6. After the inspection, refit the oil spill/filler plug (1) using a 

new sealing ring (2). 

Tighten the oil spill/filler plug to the specified torque (see 


3.61.2 ZF-AS TRONIC 

1. Switch OFF the retarder foot control function by activating 

the rocker switch on the dashboard. Do not activate 

the retarder by using the right-hand combination switch 

on steering column before checking the oil level. 

2. Position the vehicle on a horizontal surface, both longways 

and crossways. 

3. Turn OFF the engine. 

4. Check the oil level after the gearbox oil has cooled down 

to

5 




6. Fit the level check plug (A), tightening it to the specified 


3.61.3 ZF ECOMAT 



There is a danger of being burnt by hot 

oil. 

1. Check the oil level at the operating temperature (80 - 90° 

C). 

2. Make sure the vehicle is horizontal, both longways and 

crossways. 

3. Select neutral gear. 


5. Wait approximately 2 minutes and then use the dipstick 

to check the oil level. When at the operating temperature 

(80 - 90° C), the oil level must be between the marks (A). 

6. If necessary, top up the oil. 

3 - 78 0616 

A 

00736B




3.62 CHECKING THE SGS SETTING 

1. Check whether the sealing wax of both lock nuts is still 

intact. If this is not the case, check the distance A and, if 

necessary, adjust it. 

Adjustment distance A: 

– Unscrew the lock nuts (2). 

– Rotate the adjusting nut (1) so that A = 260 mm. 

– Tighten the lock nuts (2) so that the valve (3) is upright 

and does not touch the bolt (4) when changing gears. 

– Lock the lock nuts (2) with yellow sealing wax. 

2. Check the cable ball joints. Replace them if: 

– The spring force has been lost. 

– The play is so large that it effects the gear changing 

characteristics. 

– The clamping force is insufficient. 

3. Check whether the gear lever knob is in the middle position 

(when the cables are fitted). 

If the gear lever knob is not in the middle position or if a 

clear centre point cannot be felt, then the middle position 

of the gear lever must be adjusted. 

0616 

1. Adjusting nut 

2. Lock nut 

3. Valve 

4. Bolt 

A. Adjustment distance 260 mm 

03907B 

03916B 

3 - 79 

5

5 




4. Adjusting the middle position of the gear lever: 

– Remove the gear lever cover at the bottom and pull it 

inside out over the gear lever.-Remove the Philips 

screws (5) and the two Allen screws (6) on the side of 

the gear change pattern symbol. 

– Pull the casing forwards and then remove it by pulling 

it over the gear lever knob. 

– Disconnect both cables from the balls. 

– To do so, insert a 11 mm open-ended spanner 

between the ball joint and the ball and remove the ball 

joint. 

– Fit the adjusting plate (see “Special tools”) to the console 

using the standard Allen screws (6). 

– Use the nuts (7 and 10) to adjust the cables so that the 

ball joint of the cable can be pressed onto the ball without 

moving the gear lever. 

– Remove the adjusting plate. 

– Fit the casing and secure it in position using the Philips 

screws (5) and the two Allen screws (6). 

– Fit the gear lever cover. 

5. Check the dust covers (11 and 12) of the lift cylinder and 

operating cables for cracks and check whether they have 

been fitted without being twisted. 

3 - 80 0616 

03908B 

03926B




3.63 CHECKING THE CLUTCH SYSTEM FOR 

LEAKS 

1. Pressurize the pneumatic system to the operating pressure 

(8.6 - 9.6 bar). 

2. Check whether there is a leak via the clutch booster ventilation 

opening. 

3. Press the clutch pedal and check whether there is an air 

leak via the clutch booster bleed opening. 

Comment 

When the clutch pedal is moving upwards, the clutch booster 

should be bled via the bleed opening. 

4. Press the clutch pedal and check whether there is a fluid 

leak via the clutch booster bleed opening. 

5. Check whether there is an oil leak via the clutch booster 

ventilation opening. 

Comment 

A drop of oil at the ventilation opening is normal and is not a 

reason to replace the clutch booster. 

If there is a constant leak, the clutch booster must be 

repaired or replaced. 

If in doubt as to whether it is a normal situation or if there is 

a leak in the clutch booster, the fluid level in the clutch reservoir 

can be checked. 


leak via the clutch booster ventilation opening. 


leak via the pin feed-through of the clutch booster wear 

indicator. 

0616 

3 - 81 

5

5 




3.64 INSPECTING/TOPPING UP THE 

HYDRAULIC CLUTCH FLUID 

Hydraulic fluid is poisonous and harmful 

to your health. 

Therefore, avoid direct or indirect skin 

contact. 

Hydraulic fluid reacts aggressively with 

the vehicle’s paint. Therefore, avoid 

hydraulic fluid coming into contact with 

the paint of the vehicle. 

Always use new, clean hydraulic fluid 

from a closed container which meets the 

specifications. 

Hydraulic fluid which has absorbed water 

(from the atmosphere) can have an 

adverse effect on the operation of the 

clutch system. 

Avoid contact with mineral oil. One drop 

of mineral oil in the system will affect the 

seals. 

1. Check whether the fluid level lies between the maximum 

and minimum marks. 

If necessary, top up with the specified hydraulic brake 

fluid (see “Liquids, oils and lubricants”). 

2. Check the bleed opening in the cap. 

Comment 

If the bleed opening is closed, a residual pressure will start to 

build up in the system. 

1151127 

3 - 82 0616




3.65 CHECKING THE CLUTCH PLATE FOR 

WEAR 

The clutch plate lining is worn when the front of the pin (4) 

and the front of the sleeve (2) are flush. 

0616 

Clutch wear indicator 

1. Dust cover 

2. Sleeve 

3. Adjusting bolt 

4. Pin 

5. Lock nut 

03919B 

03918B 

3 - 83 

5

5 




3.66 CHECKING THE OIL LEVEL OF THE 

R115E RETARDER 

1. Check the retarder’s oil level when it is at the operating 

temperature. 



3. Turn off the contact switch and then turn it back on again. 

4. When stationary, place the right-hand combination 

switch in retarder position A for approximately 5 seconds 

and then return the combination switch to the rest position 

E (retarder turned off). Repeat this procedure twice. 

5. Turn off the retarder and the contact switch. 

Wait approximately 5 minutes before checking the oil 

level. 

The oil spill/filler plugs are hot (oil 

temperature). 

The retarder oil may only be topped up 

via the oil filler plug. 

6. Remove the oil spill plug (1). 

The oil level must reach the edge of the spill opening. If 

necessary, slowly top up the oil via the oil filler plug (2) 

with oil which meets the oil specifications (see “Liquids, 

oils and lubricants”). 

7. If there is excessive oil loss, check the retarder for leaks. 

8. Clean the oil spill plug and oil filler plug (1 and 2). Check 

the sealing ring and, if necessary, replace it. 

9. Tighten the plugs to the specified torque (see “Technical 


Checking the retarder for leaks 

1. Check the heat exchanger’s attachment screws. 

2. Check the attachment of all the plugs and check them for 

leaks. 

3. Visually check the retarder for damage and leaks. 

03923B 

3 - 84 0616




3.67 CHECKING THE OPERATION OF ALL 

THE DRIVING AND BRAKING 

FUNCTIONS 

0616 

Consider traffic safety during a test drive. 

– When checking the brakes, braking must not cause the 

vehicle to make any unexpected movements on the road. 

– Check whether the vehicle can remain on the intended 

path when driving in a straight line. 

– Check the correct operation of the inspection lights and 

gauges on the instrument panel. 

3.68 CHECKING THE OPERATION OF THE 

RETARDER 

Check the operation of the retarder whilst driving by lightly 

pressing the brake pedal or by operating the control switch 

(see Driver’s instruction Manual). It must be possible to hear 

and notice the retarder working. 

3 - 85 

5

5 




3.69 CHECKING THE INSTRUMENTS AND 

INSPECTION LIGHTS 

The instrument panel will perform a self-test when the main 

switch (20) is turned on. 

The operation of the following can be checked: 

– The lights of the warning indicators (10) will be lit. 

– The buzzer will sound briefly. 

– The needles of the speedometer, rev counter, fuel gauge 

and temperature gauge will go to the maximum position 

and then return to the rest position. 

– The main display (11) will be black for a couple of seconds 

and then turn grey to indicate that the display works correctly. 

The air pressure gauges will become visible. 

See the driver’s manual for further information. 

3.70 INSPECTING THE GEARBOX AND THE 

GEAR CHANGING PATTERN 

GO-gearbox 

1. Move the gear lever through the gears. There should be 

almost no play and it must be possible to change gears 

in a H-pattern. 

The servo-cylinder should be felt changing gears when 

changing gear. 

Check whether the gear lever centres itself. 

2. Check whether the engine will only start when the gearbox 

is in neutral. 

ZF Ecomat 2 

1. Apply the foot brake pedal. 

2. Apply the parking brake. 

3. Put the gearbox lever in position “D” or “R”. 

4. Check in both positions that the engine can not be 

started. 

5. The engine can only be started if the gearbox lever is in 

the “N” position. 

03910B 

3 - 86 0616



Removal and installation 

4. REMOVAL AND INSTALLATION 

4.1 REMOVING AND INSTALLING THE MAIN 

FUSE(S) 

Mega fuses 

1. Remove the earth cable (-v) from the battery terminal. 

2. Remove the cover from the main switch box near the battery 

box. 

3. Remove the attachment nuts for the fuses. 

4. Replace the fuses. 

5. Fit new fuses. Tighten the attachment nuts. 

6. Fit the cover to the main switch box and connect the 

earth cable (-v) to the battery terminal. 

Maxi fuse (bodywork builder) 

1. Remove the earth cable (-v) from the battery terminal. 

2. Remove the cover from the main switch box near the battery 

box. 

3. Replace the fuse. 

4. Fit the cover to the main switch box and connect the 

earth cable (-v) to the battery terminal. 

0616 

E223 Mega fuse 100A 

E224 Mega fuse 100A 

E353 Maxi fusebody-builder 

max. 250A 

1151702 

4 - 1 

5

5 




4.2 REMOVING AND INSTALLING THE 

ENGINE OIL FILTER 



Dispose of the engine oil filter. 

Removal 

1. Place a container under the engine oil filter. 

2. Clean the filter housing (1) and the surrounding area. 

3. Unscrew the screw cap (2) a couple of turns until the 

lubricating oil flows out of the filter and allow the filter 

housing to drain dry. 

4. Remove the screw cap (2) once the oil filter is empty. 

5. Remove the filter element (3) from the filter housing (1). 

Installation 

1. Replace the sealing rubber in the cap (2). 

2. Lightly lubricate the sealing rubber with engine oil. 

3. Place the new filter element (3) in the filter housing (1). 

4. Fit the screw cap (2) and tighten it to the specified torque 


5. Start the engine and check for leaks. 

6. Check the engine oil level. 

4 - 2 0616





CENTRIFUGAL FILTER ROTOR 

Removal 

1. Clean the cap (3) and the surrounding area. 

2. Remove the central bolt (4) and remove the cap (3). 

3. Remove the rotor (2) from the cap (3). 

Installation 

1. Clean the inside of the cap (3). 

2. Check the central bolt (4) for damage. 

3. Replace the sealing ring (5). 

4. Fit the rotor (2) in the cap (3). 

5. Lightly lubricate the sealing ring (5) with engine oil and fit 

the cap (3). 

6. Tighten the central bolt (4) to the specified torque (see 


7. Start the engine and check for leaks. 

8. Check the engine oil level. 

0616 



4 - 3 

5

5 




4.4 REMOVING AND INSTALLING THE FUEL 

FILTER 

A quantity of fuel may be released when 

removing the fuel filter. Collect this fuel 

and be aware of the fire risk. 

Removal 

1. Unscrew the cover from the filter housing and remove the 

cover, together with the filter element, from the filter 

housing. 

Comment 

The fuel filter element is a disposable filter and may not be 

cleaned and reused. Dispose of the filter as if it is chemical 

waste. 

2. Remove the filter element from the cover. 

Installation 

1. Replace the cover’s O-ring. 

2. Lightly lubricate the sealing rubber with engine oil. 

3. Fit a new fuel filter element in the cover. 

4. Fit the filter cover with the fuel filter element onto the filter 

housing. 

5. Tighten the filter cover to the specified torque (see “Technical 


6. Pump for approximately 1 minute using the hand pump 

so that the filter housing is partially filled with fuel. 

7. Start the engine and idle it for a couple of minutes to 

allow any air to escape from the filter housing. 

8. If the engine does not start or runs irregularly, the fuel 

system must be bled (see “Draining and filling”). 

9. Check the fuel system for leaks 

4 - 4 0616





CYLINDER HEAD COVER 

Removal 

1. Clean the area around the cylinder head cover. 

2. Remove the cylinder head cover’s attachment bolts. 

3. Remove the cylinder head cover and the cylinder head 

cover’s gasket. 

Installation 

1. Clean the sealing surfaces of the valve sleeve and the 

cylinder head cover. 

2. Fit the cylinder head cover using a new cylinder head 

cover gasket. 

3. Tighten the cylinder head cover’s attachment bolts to the 


0616 

When opening the engine or parts of the 

engine, dirt may enter the engine, which 

may cause serious damage. Therefore, 

clean the engine before it is opened. 

4 - 5 

5

5 




4.6 REMOVING AND INSTALLING THE AIR 

FILTER ELEMENT 

Removal 

1. Remove the clamps from the dust collector (1). 

2. Remove the dust collector (1) from the air filter housing 

(2). 

3. Use a rotating movement to remove the air filter element 

(3). 

4. Clean the inside of the air filter housing, the air intake 

duct and the cover. 

Clean the sealing surface of the air filter with the air 

intake duct. 

5. Check the cover for deformation. A damaged cover will 

not produce a good seal. 

Installation 

1. Replace the air filter element (3). Check the new air filter 

element for damage. 

Never fit a damaged filter element. 

Lightly lubricate the ring (A) with Vaseline. 

2. Fit the new air filter element in the air filter housing. 

Check whether the filter element is flush. 

3. Fit the dust collector (1) to the air filter housing (2) and 

secure it in place using the clamps. 

4. Reset the contamination indicator by pressing the reset 

button. 

1145804 

4 - 6 0616




4.7 REMOVING AND INSTALLING THE CRT 

FILTER/CATALYSER 

Removal 

1. Before removing any exhaust components, mark their 

position with regard to each other and with regard to the 

exhaust elbow piece of the turbo compressor. 

2. Remove the exhaust pipe between the exhaust elbow 

piece and the exhaust silencer. Remove the silencer and 

the end pipe. 

3. Loosen the exhaust silencer’s clamping straps and 

remove the silencer. 

4. Remove the V-clamp (1) and remove the end cover (4). 

5. Remove the V-clamp (2) and remove the filter holder (5). 

6. Remove the CRT filter (6) and the catalyser (7). 

7. Clean the catalyser/CRT filter (see “Cleaning”). 

0616 

Exhaust gases contain carbon monoxide. 

Carbon monoxide is a deadly, colourless 

and odourless gas which, when inhaled, 

deprives the body of oxygen, leading to 

asphyxiation. Serious carbon monoxide 

poisoning can result in brain damage or 

death. 

Inhalation of smoke and dust particles 

may have serious consequences for your 

health. Therefore, take necessary 

precautions, such as wearing protective 

goggles or a dust mask. 

1151915 

4 - 7 

5

5 




Installation filter module 

Pay attention to the following when installing the filter 

module. 

1. Always use new gaskets (B and C) when servicing the filter 

module. 

2. Check whether the connecting rings (A) and gaskets (B 

and C) have been fitted correctly. 

3. Make sure the type plate is always readable. 

4. Tighten the V-clamps (1 and 2) to the specified torque 


Fit the exhaust silencer’s clamping straps through the 

suspension brackets. 

Installation exhaust silencer/CRT filter and exhaust pipes 

Pay attention to the following points when installing the 

exhaust silencer/CRT filter and the exhaust pipes. 

1. Replace the gasket before fitting the elbow piece. 

2. Fit the original expansion ring. 

3. Clean the thread of the attachment bolts and studs and 

apply heat-resistant grease. 

4. Fit all the exhaust system’s components free from tension. 

1151915 

4 - 8 0616




5. Check whether the pipes (1 and 3) between which the 

flexible exhaust pipe (2) is fitted are aligned. The flexible 

pipe (2) must not be bent. 

6. Fit the flexible exhaust pipe (2) between the fixed pipes 

(1 and 3) so that the flow of the exhaust gases is in the 

same direction as the arrow. 

7. Push the flexible exhaust pipe (2) together and then pull 

the flexible exhaust pipe (2) apart as far as possible. 

Secure the flexible exhaust pipe (2) in the middle position 

to that it can expand and shrink. 

8. Fit the clamp (4) in the position indicated. 

9. Apply heat-resistant grease to the bolts. 

Tighten one of the bolts to a torque of 35 Nm. 

Tighten the other bolt to a torque of 70 Nm. 

Tighten both bolts to the specified torque (see “Technical 



Idle the engine for 5 minutes and then gradually increase 

the speed of the engine to the maximum speed. Next, 

turn off the engine. Check the exhaust system and the 

catalyser/CRT filter for leaks. 

White smoke may escape from the exhaust pipe for 

some time after turning over/cleaning the CRT filter. This 

is normal. For this reason, it is best to not carry out a 

smoke test for at least 4 weeks. 

11. Measure the back pressure and record the measurement 

on the maintenance form. 

12. Take a test drive and retighten all the nuts, bolts, clamping 

straps and V-clamps. 

0616 

03865B 

03864B 

4 - 9 

5

5 





HYDRAULIC FAN FILTER 



Comment 

The oil should be changed, the filter element should be 

replaced and the reservoir should be cleaned if there is 

serious damage to the hydraulic pump or hydraulic motor. 

Removal 

1. Clean the cover (1), the reservoir and the surrounding 

area. 

2. Remove the cover. 

Unscrew the attachment bolt and slowly remove the filter 

holder (2) together with the filter element (3) from the reservoir 

so that no dirt falls out of the filter element into the 

reservoir. 

3. Replace the filter element. 

Installation 

1. Fit the filter holder and the new filter element into the reservoir. 

2. Tighten the attachment bolt to the specified torque (see 


03947B 

4 - 10 0616





STEERING MECHANISM’S FILTER 

Removal 

1. Clean the cover and its surrounding area so that no dirt 

can enter the reservoir. 


3. Unscrew the filter holder (5) a quarter of a turn. 

Slowly remove the filter holder and the filter element (6) 

from the reservoir so that not dirt from the filter element 

can fall into the reservoir. 

4. Disassemble the filter element (6) from the filter holder 

(5). 

Installation 

1. Fit a new filter element (6) to the filter holder (5). 

2. Fit the filter holder (5) and the filter element into the reservoir 

(1). Make sure the filter holder falls into the lock. 

3. Check the cover’s (3) sealing ring (4) and fit the cover. 

4. Use the dipstick (2) to check the fluid level (see “Inspection 

and adjustment”). 

0616 



4 - 11 

5

5 




4.10 REMOVING AND INSTALLING THE AIR 

DRYER FILTER ELEMENT 

Comment 

In order to be sure the air dryer works correctly, the air reservoirs 

must be regularly checked for condensation. If more 

water is regularly drained than is to be expected, then the air 

dryer’s filter element must be replaced. 

Under normal circumstances, the filter element must be 

replaced at least once EVERY year. 

Removal 

1. Bleed the air dryer by regenerating it or by disconnecting 

the compressor line, so that the inside of the air dryer 

becomes pressureless. 

2. Remove the filter element by turning it anticlockwise 

using a strap spanner. 

Dispose of the filter element as if it was an oil filter. 

Always observe the instructions 

provided with the new filter element. 

Comment 

If an excessive amount of oil is observed in the air dryer or 

the supply line whilst removing the filter element, then check 

the condition of the compressor and check for carbon deposits 

in the compressor line. 

3. Clean the inside of the air dryer. 

4. Check the screw thread (2) of the air dryer for damage. 

Lightly lubricate the screw thread with grease. 

Installation 

1. Lightly lubricate the new filter element’s sealing ring with 

grease. 

2. Fit the filter element by tightening it by hand until it 

touches the seal. Next, tighten the filter element further 

by hand (maximum of one full revolution). 

3. Pressurize the system and check the air dryer for leaks. 

4. Use an indelible marker to write on the sticker the date 

that the filter element must be replaced by (maximum 1 

year after assembly). 

4 - 12 0616





BRAKE PADS 

4.11.1 SAFETY INSTRUCTIONS 

The following safety precautions must be observed before 

commencing work on the brakes: 

0616 

Always wear protective clothing, a face 

mask and safety goggles. 

DO NOT breathe in dust from the brake 

pads/lining or blow it away. Before 

starting work on the brakes, clean them 

using the appropriate equipment and 

follow the manufacturer’s instructions. 

Remove any dust using a damp cloth or a 

vacuum cleaner and dispose of all used, 

damp cloths in accordance with the 

appropriate legal regulations. 

Only hold the brake calliper by the edges, 

never between the brake calliper and the 

brake carrier. DANGER OF BECOMING 

TRAPPED. 

The brake pads/lining must NOT be 

drilled or turned unless otherwise stated. 

ALWAYS follow the manufacturer’s 

safety instructions when grinding the 

brake linings. 

ALWAYS follow the manufacturer’s 

safety instructions when replacing the 

brake pads/lining. 

If a cleaning agent is necessary, only use 

methylated spirits. 

4 - 13 

5

5 




4.11.2 REMOVING THE BRAKE PADS 

If one brake pad needs replacing, then all 

the brake pads on the same axle must be 

replaced. 

The brake lining wear indicators must 

always be replaced when the brake pads 

are replaced. 

Always install the same type of brake 

pads to a vehicle. 

When replacing brake components, only 

use components which have been 

approved by the vehicle manufacturer. 

1. Jack up the vehicle according to the instructions. 


3. Check the operation of the automatic slack adjuster (see 

“Inspection and adjustment”). 

4. Remove the retaining clip (26) and washer (45). 

5. Push the pad retainer (11) backwards with a screwdriver 

and remove the locking pin (44) and the pad retainer 

(11). 

6. Check the pad retainer (11). If it is rusty or deformed, 

then it must be replaced. 


To avoid damaging the surface of the sealing ring, never 

use a screw driver to remove the cover. 

Never rotate the adjusting hexagon 

without an adapter (61). The adapter 

forms a torque safety device and if the 

torque is too great, it will no longer grip 

the adjusting hexagon. If the adjusting 

hexagon (23) cannot be turned again 

using a new adapter, the brake calliper 

must be replaced. 

8. Turn the adjusting hexagon anticlockwise using a suitable 

spanner (SW-8) until the outer brake pad can be 

removed. 

FD00221 

4 - 14 0616




Comment 

Turning any further than the stop will activate the slack 

adjuster’s overrunning clutch and a clicking noise will be 

heard. 

9. Push the brake calliper inwards and remove the inner 

brake pad. 

10. Clean the parts of the brake calliper and brake carrier 

that come into contact with the brake pad and apply 

Copaslip to these areas. 

4.11.3 FITTING THE BRAKE PADS 

1. Check the brake calliper play (see “Inspection and 

adjustment”). 

2. Clean the parts of the brake calliper and brake carrier 

that come into contact with the brake pad and apply 

Copaslip to the rear of the brake pad holder and the contact 

surfaces. 

3. Use the adapter (61) to rotate the thrust pieces anticlockwise 

as far as possible. 

4. Carefully push the brake calliper (1) to the outside of the 

vehicle and fit the outer brake pad (12) into place. 

5. Carefully push the brake calliper to the inside of the vehicle 

and fit the inner brake pad into place. 

6. Turn the slack adjuster’s adjusting hexagon clockwise 

using a suitable spanner (SW-8) until the brake pads lie 

against the brake disc. 

7. Next, turn the slack adjuster back 2 clicks. 

8. Depress the brake pedal a couple of times to give the 

slack adjuster a chance to set the brake’s optimal operating 

play. 

9. Check whether the wheel hub can rotate freely. 

If necessary, increase the play. 

0616 

FD002231 

FD00223 

4 - 15 

5

5 




10. Lightly grease the new cover (37) with Renoliet HLT2 

(white) and then fit the cover as shown in the diagram. 

Check whether the cover is properly sealed. 

11. Assemble the brake pad retainer (11) and fit the locking 

pin (44). Next, fit the washer (45) and the retaining clip 

(26). 

12. Fit the wheels. 

13. Take a test drive. 

Brake carefully when using new brake 

pads. 

Avoid repeated, long-lasting braking and 

emergency stops. 

4 - 16 0616 

03944B 

FD00221





(SPRING) BRAKE CYLINDER 

Removing the brake cylinder 

1. Remove the air line on the brake cylinder (line must be 

pressureless). 

2. Remove the attachment nuts from the brake cylinder and 

remove the brake cylinder. 

Installing the brake cylinder 

Comment 

For a new brake cylinder, only remove the lowest drain plug 

(A). All other drain holes must be plugged. 

1. Clean the assembly surface of the brake cylinder and 

lubricate the ball joint (19) with Renoliet HLT2 (white). 

2. Clean the brake calliper’s assembly surface. 

The assembly surface must not be damaged. 

3. Check whether the seal (A) and the thrust pin (B) are 

clean and dry. 

4. Check the thickness of the sealing ring (A). 

Replace the brake cylinder if the thickness is less than 3 

mm. 

5. Replace the attachment nuts. Place the brake cylinder on 

the bracket and tighten the attachment nuts to the specified 


6. Connect the air line. 

0616 

A Seal 

B Thrust pin 

C 3 mm 

FD00229 

FD00231 

FD00350 

4 - 17 

5

5 




Removing the spring brake cylinder 

1. Place chocks in front of and behind the wheels and make 

sure there is sufficient system pressure (> 7.5 bar). 

2. Place the parking brake valve in the “Drive” position 

(make sure there is sufficient system pressure: approx. 6 

bar). Using a 24 mm spanner, unscrew the release bolt 

as far as possible out of the spring brake cylinder (anticlockwise). 

3. Place the parking brake valve in the “Park” position. 

4. Disconnect the two air lines from the spring brake cylinder 

(the lines must be pressureless). 

5. Remove the attachment nuts and remove the spring 

brake cylinder from the bracket. 

Installing the spring brake cylinder 

Comment 

For a new spring brake cylinder, only remove the lowest 

drain plug (A). All other drain holes must be plugged. 

1. Clean the assembly surface of the spring brake cylinder 

and lubricate the ball joint (19) with Renoliet HLT2 

(white). 

2. Clean the brake calliper’s assembly surface. 

The assembly surface must not be damaged. 

3. Check whether the seal (A) and the thrust pin (B) are 

clean and dry. 

4. Check the thickness of the sealing ring (A). Replace the 

brake cylinder if the thickness is less than 3 mm. 

5. Place the spring brake cylinder on the bracket and 

tighten the attachment nuts to the specified torque (see 


6. Connect the air lines. 

7. Place the parking brake valve in the “Drive” position 

(make sure there is sufficient system pressure: approx. 6 

bar). Fully screw in the release bolt and tighten it to the 


8. Check the connections for leaks. 

4 - 18 0616





BRAKE CALLIPER 

Removing the brake calliper 


2. Remove the (spring) brake cylinder. 

3. Disconnect the plug of the brake pad wear indicator. 

To avoid an electric shock, do not touch the electrical 

contacts. 

4. Remove the steel cap (10) from the brake calliper. To do 

so, use a screw driver (or another suitable tool) to hit a 

hole in the middle of the cap (10). When doing so, the cap 

can move 10 mm inside the bore. 

0616 

Do not insert your fingers between the 

brake calliper and the brake calliper 

carrier on a new brake calliper when or 

after removing the brake pads (danger of 

becoming trapped). Only hold the brake 

calliper by the outside. 

To avoid damage, do not attach any 

hoisting tools to the brake pad retainer. 

To prevent damage, do not drive any tools between the 

cap and the brake calliper bore. Damage to the bore can 

lead to the brake calliper becoming stuck. 

5. Use a suitable tool to remove the cap (68). Make sure the 

rubber boot (6a) does not become damaged. 

4 - 19 

5

5 




6. Remove the Allen screws (39 and 40). 

7. Remove the brake calliper. 

Installing the brake calliper 

1. Clean all the components and check them for damage. In 

particular, the sliding surfaces of the moving parts must 

be clean and free of damage. 

2. Make sure the guide pin in the brass bearing bush is 

positioned so that the inside of the collapsible rubber 

boot is pushed together. 

3. Place the brake calliper on the brake calliper bracket. 

4. Fit the two Allen screws (39 and 40) and tighten them to 

the specified torque (see “Technical information”). These 

bolts must never be reused. Always use new bolts and 

apply a locking compound. 

5. Check whether the brake calliper slides easily. 

6. Check the position of the collapsible boot (9) on the guide 

bush (5) and check the position of the ring (58). 

7. Check whether the automatic adjustment device functions 

correctly. 

4 - 20 0616




8. Make the driving tool (H) using T2 (only the handle) and 

T17 from the special tool set (VDL no. 1329495). 

9. Clean the bore in the brake calliper. The bore and steel 

cap (10) must be clean and free of grease. 

10. Push the brake calliper to one side so that the collapsible 

boot (9) is pushed fully together. Hold the brake calliper 

in this position whilst assembling the steel cap (10) in 

order to prevent air from becoming trapped. 

0616 

Hit the driving tool (H) with a hammer until the steel cap 

(10) lies against the stop in the brake calliper. 

11. Use a hammer and the driving tool T11 (part of the special 

tool set VDL no. 1329495) to hit the cap (68) into the 

guide pin (4) until it touches the Allen screw (39). 

12. Assemble the brake pads. 

13. Connect the plug of the brake pad wear indicator. 

14. Fit the (spring) brake cylinder. 

4 - 21 

5

5 





BRAKE CALLIPER BRACKET 

Removing the brake calliper bracket 

1. Remove the brake calliper. 

2. Remove the brake calliper bracket’s (2) attachment bolts. 

3. Remove the brake calliper bracket. Replace the attachment 

bolts. 

Installing the brake calliper bracket 

1. Clean the brake calliper bracket and the contact surfaces 

of the swivel axle or brake anchor plate. Give special 

attention to the screw thread holes and the sliding surfaces 

of the brake pads. 

2. Fit the brake calliper bracket against the swivel axle or 

the brake anchor plate. 

3. Fit new attachment bolts and tighten them to the specified 


4. Assemble the brake calliper. 

4 - 22 0616





WHEEL HUB 

0616 

03948B 

Removing the wheel hub 

1. Jack up the vehicle according to the instructions. 

2. Remove the wheel. 

3. Remove the brake calliper and the brake calliper bracket. 

4. Remove the bolts (6) and remove the hub cap (4) and the 

gasket (5) from the wheel hub (12). 

5. Unscrew the lock bolt (3). Remove the lock nut (2) and 

the thrust washer (1). 

6. Attach a suitable hoisting tool to the wheel hub (12). 

7. Use the special tool (A) (ZF no. 5870 000 090) to pull the 

wheel hub (12) from the axle stub. 

Pay attention to any wheel bearings which may be 

released. 

8. Remove the wheel bearings from the wheel hub. 

03942B 

4 - 23 

5

5 




9. Remove the sealing rings (15 and 16) from the wheel hub 

(12). 

Comment 

If the bearings are removed from both wheels, the bearings 

should be marked. 

Each bearing should be reinstalled in its original hub. 

10. Remove the wheel hub and the wheel from the axle stub. 

11. Remove the grease from the wheel hub (12) and clean 

the wheel hub. 

12. Thoroughly clean the bearings cages of the wheel bearings 

(13 and 14) using a cleaning liquid. 

Installing the wheel hub 

1. Check the hub, the wheel bearings and the inner and 

outer bearing races for wear and damage. If necessary, 

replace them. 

The wheel bearings and the inner and outer races must 

be replaced as pairs. 

2. Use compressed air to blow the bearing cages of the 

wheel bearings (13 and 14) dry. 

Comment 

A liquid gasket must be applied to the outer circumference of 

the sealing rings without a vulcanized rubber outer ring. 

3. Fit a new sealing ring (15) in the bearing (14) using the 

special tool (ZF no. 5870 053 017). 

4. Fill the wheel bearings with the specified wheel bearing 

grease (see “Fluids and lubricants”). Also apply a layer of 

grease to the circumference of the wheel bearing 

5. Fit the wheel bearing (14) in the hub (12). 

Comment 

A liquid gasket must be applied to the outer circumference of 

the sealing rings which do not have a vulcanized rubber outer 

ring. 

6. Fit a new sealing ring (16) in the wheel hub (12) using the 

special tool (ZF no. 5870 053 017). 

7. Fill the wheel hub with 90 grams of wheel bearing grease 

(see “Fluids and lubricants”). 

8. Apply a small amount of grease to the sealing lips of the 

sealing ring (16). 

9. Check whether the wheel speed sensor is clamped in the 

swivel axle. 

If necessary, replace the sensor’s clamping bush. 

4 - 24 0616 

03950B 

03951B




10. Fit the spindle (A) of the special tool (ZF no. 5870 000 

090) to the axle stub. 

11. Fit the brace (B) of the special tool (ZF no. 5870 000 090) 

to the wheel hub. 

12. Position the wheel hub (12) and the brace (B) over the 

spindle (A). 

Screw the wheel hub over the axle stub as far as the 

stop. 

Remove the special tool. 

13. Place the outer wheel bearing (13) in the hub. 

14. Fit the thrust washer (1) and the lock nut (2). 

15. Tighten the lock nut to a torque of 240 Nm. 

Whilst gradually tightening the lock nut, rotate the hub so 

that the wheel bearings can settle. 

16. Check the wheel bearing play (see “Inspection and 


17. Use the lock bolt (3) to lock the lock nut after adjusting 

the wheel bearing play. Tighten the lock bolt to the specified 


18. Fit the hub cap (4) with a new gasket (5). Tighten the 

bolts (6) to the specified torque (see “Technical information”). 

19. Fit the brake calliper and the brake calliper bracket. 

20. Fit the wheel. 

0616 

03941B 

03942B 

03949B 

4 - 25 

5

5 





V-BELTS 

4.16.1 ALTERNATOR V-BELT 

Always fit the same type of V-belt. V- belts 

which lay next to each other over the 

same pulley must always be replaced 

together. 

Removal 

1. Unscrew the threaded spindle’s counter nut (4). 

2. Unscrew the threaded spindle’s attachment bolt (5). 

3. Loosen the alternator’s bottom attachment bolt (3). 

4. Loosen the threaded bush’s (1) counter nut (2). 

5. Move the alternator by rotating the threaded bush (1) 

until the V-belts can be removed. 

Installation 

1. Inspect the pulleys for damage, rust and grease deposits. 

2. Assemble the new V-belt(s). 

3. Move the alternator by rotating the threaded bush (1) 

until the correct V-belt tension is obtained (see “Technical 


4. Tighten the alternator’s bottom attachment bolt (3). 

5. Tighten the threaded spindle’s counter nuts (2 and 4). 

6. Tighten the attachment bolt (5) of the threaded spindle 

which is attached to the water pump. 

PE engine 

XE engine 

4 - 26 0616




4.16.2 POLY V-BELT 

Removal 

1. Remove the V-belt(s) from the extra alternator. 

2. Push the tension pulley (1) against the spring force and 

block the tension pulley using a 4 to 5 mm thick pin (drill 

bit). 

3. Remove the poly V-belt from the pulleys. 

4. Check the automatic slack adjuster (see “Inspection and 


Installation 

1. Check the pulleys for damage, rust and grease deposits. 

2. Fit the poly V-belt. 

3. Push the tension pulley against the spring force so that 

the blocking pin can be removed. Allow the tension pulley 

to be tensioned against the belt. 

4. Check to see whether the poly V-belt lies in all the 

grooves on all the pulleys. 

5. Fit the V-belt(s) of the extra alternator. 

0616 

Always fit the same type of poly V-belts. 

1 2 3 

03028B 

4 - 27 

5

5 




4.16.3 AIR CONDITIONING COMPRESSOR V-BELTS 

Removal 

1. Loosen the quick-release coupling on the air cylinder’s 

bottom connection (2). 

2. Slacken the V-belts by connecting the air line to the air 

cylinder’s top connection (3). 

The air conditioning compressor will tilt 

when slackening the V-belts. There is a 

danger of becoming trapped! 

3. The V-belts can now be removed. 

Installation 

1. Inspect the pulleys for damage, rust and grease deposits. 

2. Assemble the new V-belt(s). 

3. Loosen the quick-release coupling on the air cylinder’s 

top connection (3). 

4. Check the running behaviour of the V-belts with an 

untensioned belt tensioner (pressureless) and the 

engine running. If the V-belts run irregularly, then 

increase the belt tensioner’s spring tension using the 

adjusting ring (1). 

5. Connect the air line to the belt tensioner’s bottom connection 

to tighten the belts. 

1145785 

4 - 28 0616




4.17 REMOVAL AND INSTALLATION GEAR- 

BOX OIL FILTER ELEMENT 

4.17.1 ZF ECOMAT2 

Removing the oil filter element 

1. Remove the oil filter cover (1). 

2. Pull the oil filter cartridge out. Check whether the oil filter 

is seriously contaminated. Replace the oil filter cartridge. 

Note: 

Do not clean the oil filter. The oil filter element must always 

be replaced. 

Installing the oil filter element 

1. If suction pipe was pulled out with old filter, remove Oring 

from suction pipe. 

Insert new O-ring into transmission housing and push in 

suction pipe. 

2. Check whether the O-ring in the new filter cartridge is 

damaged and, if necessary, replace it. Lightly lubricate 

the O-ring with gear oil and fit the new filter cartridge. 

3. Replace the filter cover’s O-ring and fit the cover. Tighten 

the attachment bolts to the specified torque (see “Technical 


0616 



Discharge the oil filter element 

4 - 29 

5

5 




4.17.2 ZF AS TRONIC WITH INTARDER 



Discharge the oil filter element. 

Removing the oil filter element 

1. Remove the attachment bolt (1) of the oil filter. 

2. Pull the oil filter cover with the oil filter from the oil filter 

housing. 

3. Remove the oil filter (3) from the filter cover (2). Do not 

clean the filter. The filter must always be replaced. 

Note: 

If the magnetic disk is still attached to the back of the filter, 

separate it from the filter element and fit it on the new filter 

element. 

4 - 30 0616




Installing the oil filter element 

1. Check the O-ring of the oil filter cover (2) for damage. If 

necessary, replace the O-ring. Grease the O-ring. 

2. Grease the O-ring of the new oil filter (3) and place the oil 

filter on the oil filter cover. 

3. The insert the oil filter and the oil filter cover into the oil 

filter housing. 

4. Use a plastic mallet to tap the oil filter cover into the oil 

filter housing. 

5. Tighten the attachment bolt (1) to the specified tightening 

torque, see main group “Technical data”. 

0616 

4 - 31 

5

5 




4 - 32 0616



Draining and filling 

5. DRAINING AND FILLING 

5.1 TOPPING UP THE BATTERY FLUID 

Topping up the battery fluid 

1. Clean the top of the battery. If the top of the battery is 

contaminated with acid, then it should be rinsed with 

water. 

2. Remove the plugs and fill the batteries with distilled water 

until approximately 10 mm above the plates or until the 

“Max.” level indicator (never fill the batteries to the top). 

3. Refit the plugs. 

0616 


batteries. 


For skin contact: wash the affected area 

thoroughly with plenty of water. Contact 

a doctor if the affected area remains red 

or painful. Remove affected clothing and 

rinse with water. 

For eye contact: wash for at least 15 

minutes with plenty of water and visit a 

doctor. 

If swallowed: DO NOT instigate vomiting, 

rinse your mouth, drink two glasses of 

water and visit a doctor. 

After inhaling: get some fresh air, take a 

rest and contact a doctor. 

5 - 1 

5

5 




5.2 DRAINING AND FILLING THE ENGINE 

OIL 



Extreme care must be taken when 

draining engine oil. Hot engine oil can 

cause serious personal injury. 

Draining 

– Preferably drain the engine oil when the engine is at the 

operating temperature. 



2. Place a suitable container under the engine’s oil sump. 

3. Drain the oil via the sump’s drain plug. 

4. Replace the drain plug’s sealing ring and tighten the 

drain plug to the specified torque (see “Technical information”). 

Filling 

1. Fill the engine via the filler opening with the red cap (1) 

with the specified quantity of engine oil (see “Technical 


PE engine 

XE engine 

5 - 2 0616 

1 

1 

03570B 

03569B




5.3 DRAINING THE WATER SEPARATOR 

1. Place a container under the water separator. 

2. Unscrew the bleed nipple (1) on the top of the water separator 

to allow some air to enter. 

3. Unscrew the drain plug (2) a couple of turns. 

4. Allow liquid to flow out of the water separator until clean 

diesel escapes. 

5. Tighten the drain plug and the bleed nipple. 

0616 

01518B 

2 

1 

5 - 3 

5

5 




5.4 DRAINING AND FILLING THE 

HYDRAULIC FAN DRIVE 



Drain off all the hydraulic oil if there is 

excessive foaming. 

Trace and repair the leak. The system 

should then be refilled and bled. 

Draining 

1. Clean the filler cap (5), the line connections (1, 2, 3 and 

4) and the surrounding area. 

2. Place a container under the line connections (1, 2, 3 and 

4). 

3. Remove the filler cap (5) on the oil reservoir. 

4. Remove the lines (1, 2, 3 and 4). 

The drained hydraulic oil must not be 

reused. Keep the hydraulic oil separate 

from other oil which has been drained and 

hand it over for processing to a body that is 

authorised to dispose of it correctly. 

When filling and bleeding, make sure the 

reservoir is always filled with oil to prevent 

both pumps from sucking in air and causing 

the oil to foam. 

Air in the hydraulic system can seriously 

damage the tandem pump. It can also cause 

the steering mechanism to become stuck, 

either constantly or occasionally. 

If a shrieking noise can be heard when the 

steering wheel is turned or when the fan is 

in operation there is air in the system. 

Filling 

1. After draining the oil, reconnect the lines (1, 2, 3 and 4). 

2. Fill the system to the maximum level with the specified oil 

(see “Fluids and lubricants”). 

3. Fit the filler cap. 

Bleeding 


2. The hydraulic system is self-bleeding. 

3. Check the oil level and, if necessary, top it up to the maximum 

level. 

5 - 4 0616 

03952B




5.5 DRAINING AND FILLING THE COOLANT 

General 

– Preferably fill the cooling system with a ready-mixed coolant 

containing antifreeze and anti-corrosion additives. 

– The coolant must satisfy the specifications specified by 

VDL Bus & Coach (see lubricant specifications). 

Draining the cooling system 

1. Set the temperature setting to maximum. This will fully 

open the heater tap. 

2. Remove the filler cap from the coolant reservoir. 

3. Collect the coolant by placing a suitable container under 

the drain ports. 

0616 







poisoning. 

Coolant is harmful to the environment 

and must be processed as industrial 

waste after use. 

Collect the coolant in a suitable 

container. 

Coolant is harmful to the environment 

and must be processed as industrial 

waste after use. 

4. Drain the engine block. 

PE engine 

Drain the engine block via the drain tap (B) on the oil cooler. 

XE engine 

Drain the engine block by disconnecting the water hose (A) 

on the oil cooler. 

A 

03571B 

03954B 

5 - 5 

5

5 




5. Drain the radiator by opening the radiator’s drain tap (C). 

6. Drain the gearbox oil cooler. 

GO -170/190/210 

Remove the drain plug from the heat exchanger’s bottom 

coolant connection and drain the remaining coolant. 

ZF Ecomat2 and ZF AS Tronic 

The oil cooler cooling circuit can only be drained by disconnecting 

the supply and return hose. 

7. See the bodywork builder’s documentation for instructions 

on how to drain the heating system. 

Pressure-filling the cooling system 

1. Remove the filler cap from the coolant reservoir. 

Check whether the drain ports are closed again. 

2. Connect the filler hose to the quick-filling nipple and start 

the pump. 

3. Fill the system (whilst the engine is not running) with the 

specified coolant (see “Fluids and lubricants”) up to the 

maximum mark on the gauge glass. 

4. Turn off the pump and disconnect the filling hose (fit the 

cap onto the quick-filling nipple). 

5. Idle the engine for one minute (with an open expansion 

tank) so that the cooling system bleeds itself and then 

turn the engine off for one minute. Repeat this procedure 

five times. 

6. Check the coolant level and, if necessary, top it up to the 

maximum level. 

7. Check the cooling system for leaks (see “Inspection and 


5 - 6 0616 

C 

03572B 

03953B 

03956B




5.6 DRAINING AND FILLING THE STEERING 

OIL 

Draining 

1. Clean the line connections on the steering box and the 

reservoir. 

2. Jack up the front axle. 

3. Place a container under the steering box. Remove the 

return line from the steering box. 

4. Remove the filter from the steering oil reservoir. 

5. Without running the engine, slowly turn the steering 

wheel from one axle stop to the other until no more oil 

flows out of the steering box line connection. 

6. Reconnect the return line. 

7. Fit a new filter in the reservoir. 

Filling and bleeding 

0616 



Drain off all the hydraulic oil if there is 

excessive foaming. 

Trace and repair the leak. The system 

should then be refilled and bled. 

The drained hydraulic oil must not be 

reused. Keep the hydraulic oil separate 

from other oil which has been drained 

and hand it over for processing to a body 

that is authorised to dispose of it 

correctly. 

When filling and bleeding, make sure the 

reservoir is always filled with oil to 

prevent both pumps from sucking in air 

and causing the oil to foam. 

Air in the hydraulic system can seriously 

damage the tandem pump. It can also 

cause the steering mechanism to become 

stuck, either constantly or occasionally. 

If a shrieking noise can be heard when 

the steering wheel is turned or when the 

fan is in operation there is air in the 

system. 

The steering box is equipped with an automatic bleeding system. 

This only works if the system is at the circulation pressure. 

5 - 7 

5

5 




1. Fill the reservoir to the rim with clean steering oil which 

meets the specifications. Wait and then fill the reservoir 

to the rim again. 

2. Turn the engine over for a few seconds using the starter 

motor. Make sure the reservoir does not run empty. Stop 

turning the engine over immediately if the level threatens 

to become too low. Top up the steering oil. 

3. Turn the engine over for approximately 10 seconds using 

the starter motor. Make sure the reservoir does not run 

empty. Stop turning the engine over immediately if the 

level threatens to become too low. 

4. Top up the steering oil to the max. mark. 

5. Repeat points 3 and 4 until the steering oil level no longer 

falls. 

6. Jack up the front axle until the wheels come off of the 

ground. 

Comment 

If there is a possibility that the poppet valves are incorrectly 

set, e.g. because the maximum wheel turning angle has 

been increased, these valves should be correctly set first 

(see the workshop instructions). 

7. Start the engine and slowly turn the steering wheel 

(approximately 1/2 a turn of the steering wheel per second) 

to the left and right axle stops whilst the engine 

idles. Continue doing this until the oil level no longer falls. 

Make sure the reservoir does not run empty. 

8. Idle the engine for a further 2 minutes. Do not turn the 

steering wheel during this time. 

9. Check the steering oil level whilst the engine idles. If necessary, 

top up the oil to the top mark on the dipstick. 

10. Stop the engine. The steering oil level must not rise more 

than 2 cm above the maximum mark (A in the diagram). 

If the steering oil level rises more than 2 cm, then there 

is still some air in the system. 

11. Refit the filler cap to the reservoir and lower the front 

axle. 

12. Check the line connections for leaks. 

13. Take a test drive. After the test drive, check the oil level 

and check the line connections for leaks. 

5 - 8 0616




5.7 DRAINING THE CONDENSATION FROM 

THE AIR RESERVOIRS 

1. Check all the air reservoirs for condensation and oil by 

pulling the ring on the drain valve. 

2. Use your hand to feel the air flow. It must feel dry and be 

free of oil. 

3. The air drier’s cartridge must be replaced if the air flow 

contains moisture or oil mist. Also check the regeneration. 

Oil mist in the air flow may mean that the air compressor 

is damaged. 

Checking the regeneration of the air drier 

1. Pressurize the pneumatic brake system (pressure regulator 

must cut out). 

2. Turn the engine off. 

3. The regeneration air should escape for some time via the 

air drier’s bleed opening. 

0616 

Damp air in the pneumatic brake system 

is a great danger, because it may cause 

the brake pressure to be lost if the brake 

valves freeze during cold weather. 

5 - 9 

5

5 





DIFFERENTIAL OIL 



There is a danger of being burnt by hot 

oil. 

Draining 



2. Remove the oil filler/spill plug (A) and the oil drain plug 

(B). Drain the oil (preferably whilst the oil is warm). 

3. Clean the oil drain plug. Fit the drain plug (B) using the 

special Torx spanner (DAF no. 1329422) and tighten it to 

the specified torque (see “Technical information”). 

Filling 

1. Fill the differential with the specified quantity of oil via the 

oil spill/filler plug (A) (see “Technical information”). 

2. Check the oil level after approximately 5 minutes (see 

“Inspection and adjustment”). 

3. Clean the oil spill/filler plug (A). Fit it using the special 

Torx spanner (DAF no. 1329422) and tighten it to the 


5 - 10 0616




5.9 DRAINING AND FILLING THE GEARBOX 

OIL AND REPLACING THE FILTER 

5.9.1 ZF ECOMAT 2 

Draining 

1. Bring the gearbox to the operating temperature (80 - 90° 

C). 



3. Turn off the engine. 

4. Remove the oil drain plug (2) and drain the oil. 

5. Replace the oil filter element, see “Removal and installation”. 

Filling 

1. Clean the oil drain plug (2). Fit a new sealing ring to the 

drain plug and tighten the drain plug to the specified 


2. Remove the dipstick. 

Fill the gearbox with no more than 10 litres of oil via the 

dipstick holder. 

3. Place the gearbox in neutral (N), idle the engine and 

slowly add another 4 litres of oil immediately. 

0616 



Note! There is a danger of being burnt by 

hot oil. 

5 - 11 

5

5 




4. Check the oil level. 

After 3 to 5 minutes, the oil level must be in area B or 

higher on the dipstick. 

If necessary, top up the oil. 

DO NOT drain the oil if the level is higher. 

5. Bring the gearbox to the operating temperature (80 - 90° 

C). 

Place the gearbox in the neutral (N) and idle the engine. 

6. Wait approximately 2 minutes and then use the dipstick 

to check the oil level. 

When at the operating temperature (80 - 90° C), the oil 

level must be between the marks (A). 

7. If necessary, top up the oil. 

Comment 

It is very important for an automatic gearbox that the oil level 

is correct. 

A too low oil level may lead to poor operation or damage to 

the gearbox. 

A too high level may lead to the gearbox overheating. 

The oil level reading at the operating 

temperature (80 - 90° C) is decisive. 

5.9.2 GO 170/190/210 





2. Drain the gearbox whilst it is at the operating temperature. 


temperature). 

5 - 12 0616 

A 

B 

C 

01681B




3. Remove the drain plugs (1) and the sealing rings (2). 

Drain the oil. 

4. Clean the drain plugs (1) and fit them using new sealing 

rings. 

Tighten the plugs to the specified torque (see “Technical 


5. Remove the plug (3) and the sealing ring (4), the oil sieve 

(5) and the spring (6). 

6. Clean the oil sieve (5) using cleaning spirit or another 

suitable cleaning product. 

Blow the oil sieve dry using compressed air. 

Check the oil sieve for damage. If necessary, replace it. 

7. Fit the spring (6), the oil sieve (5) and the plug (3) using 

a new sealing ring (4). 

Tighten the plug to the specified torque (see “Technical 


8. Remove the oil spill/filler plug (7) and the sealing ring (8). 

9. Slowly fill the gearbox with the specified oil (see “Technical 

information”) until the oil reaches the edge of the filler 

opening. 

10. Fit a new sealing ring (2) and tighten the oil filler/spill plug 

(1) to the specified torque (see “Technical information”). 

5.9.3 ZF AS TRONIC WITH INTARDER 

Draining 

1. Before draining take a short test drive. 

Switch OFF the retarder foot control function by activating 


the retarder during the test drive or to slow down the vehicle. 



3. Drain the gearbox at operating temperature. 

0616 



Before draining, DO NOT activate the 

retarder. 

03957B 

5 - 13 

5

5 




4. Remove the drain plugs (B) and (C) and the check/filler 

plug (A) and drain the oil. 

5. Replace the filter element in the gearbox, see “Removal 

and installation”. 

Filling 

1. Clean the drain plugs (B) and (C) and tighten them to the 

specified torque, see “Technical data”. 

2. Top up oil through the level check/filling opening (A) until 

the oil reaches the rim of the filling opening. 

3. Fit the level check/filler plug (A), tightening it to the specified 

torque, see “Technical data”. 

4. After filling take a short test drive. 

Switch OFF the retarder foot control function by activating 


the retarder by using the right-hand combination switch 

on steering column during the test drive. 

5. Check the oil level after having taken the test drive. The 

oil level must reach the rim of the level check/filling opening 

(A). 

6. Fit the level check/filler plug (A), tightening it to the specified 

torque, see “Technical data”. 

5 - 14 0616





HYDRAULIC CLUTCH FLUID 

Draining the clutch system 

1. Place a container under the clutch booster. 

2. Disconnect the supply line from the clutch booster and 

drain the oil from the reservoir by depressing and releasing 

the clutch pedal. 

3. Reconnect the supply line. 

0616 

Hydraulic fluid is poisonous and harmful 

to your health. Therefore, avoid direct or 

indirect skin contact. 

Hydraulic fluid reacts aggressively with 

the vehicle’s paint. 

Therefore, avoid hydraulic fluid coming 

into contact with the vehicle. 

Always use new, clean hydraulic fluid 

from a closed container which meets the 

specifications. Hydraulic fluid which has 

absorbed water (from the atmosphere) 

can have an adverse effect on the 

operation of the clutch system. 

Avoid contact with mineral oil. Just one 

drop of mineral oil in the system will 

affect the seals. 

Filling the clutch system 

1. Fill the clutch system with the specified liquid (see “Fluids 

and lubricants”). 

2. Bleed the clutch system. 

5 - 15 

5

5 




5.11 BLEEDING THE CLUTCH SYSTEM 

Bleeding the clutch system using the “servo” bleed tank 

1. Connect the “servo” bleed tank to the reservoir. 

Comment 

When the reservoir is filled too quickly, foam will be formed 

and bleeding will be almost impossible. 

2. Fill the system via the “servo” bleed tank. 

3. Connect a transparent hose to the clutch booster’s bleed 

nipple. Hang the hose in a container. 

4. Unscrew the bleed nipple two full rotations. 

Close the bleed nipple when no more air bubbles can be 

seen through the transparent hose. 

5. Check the fluid level in the reservoir. 

Bleeding the clutch system using the clutch pedal 

1. Fill the system with the specified liquid (see “Liquids, oils 

and lubricants”). 

2. Connect a transparent hose to the clutch booster’s bleed 

nipple. 

Hang the hose in a container containing the specified 

fluid. Make sure the end of the hose is under the surface 

of the liquid. 

3. Open the bleed nipple. 

4. Slowly depress the clutch pedal and close the bleed nipple. 

Allow the clutch pedal to move slowly upwards. 

Repeat this procedure. The fluid in the reservoir must be 

topped up each time. 

5. Repeat pumping the clutch pedal and topping up the fluid 

until no more air bubbles can be seen through the transparent 

hose. 

6. Check the fluid level in the reservoir (see “Inspection and 


Bleeding the clutch system via the clutch booster 

Comment 

It may be difficult to bleed the system using the method given 

above. 

If that is the case, the clutch system can also be bled via the 

bleed nipple on the clutch booster using a hand pump. Make 

sure the inside of the hand pump is clean. 

5 - 16 0616




1. Fit a transparent hose to the hand pump (you may use an 

oil can) and fill the hand pump with the specified fluid. 

2. Pump using the hand pump until the fluid coming out of 

the hose no longer contains air bubbles. 

3. Next, fit the hose to the bleed nipple on the clutch booster 

and open the bleed nipple. 

4. Pump fluid into the system using the hand pump. 

Pay attention to the following: 

– Do not use the clutch pedal. 

– Make sure no more air bubbles enter the system. 

– Pay attention to the fluid level in the hand pump. 

– Pay attention to the fluid level in the clutch reservoir. 

0616 

03955B 

5 - 17 

5

5 





RETARDER OIL 



2. Drain the retarder whilst it is at the operating temperature. 

3. Turn the retarder and the contact switch off. 


temperature). There is a danger of being 

burnt. 

4. Remove the oil drain plugs (1) and (2). 

5. Clean the oil drain plugs (1 and 2) and clean the sealing 

ring and, if necessary, replace them. 

6. Tighten the oil drain plugs to the specified torque (see 


7. Remove the plug (3) together with the sieve. 

8. Clean the sieve using cleaning spirit or another suitable 

cleaning product. Blow the sieve clean and dry using 

compressed air. 

9. Check the plug’s (3) sealing ring for damage. If necessary, 

replace it. 

10. Tighten the plug (3) to the specified torque (see “Technical 


11. Remove the oil filler plug (4). 

12. Top up the oil via the filler plug opening to the specified 

quantity of oil (see “Technical information”). 

Top up the oil slowly (this should take longer than 3 minutes) 

to ensure that the retarder is bled correctly. 

The retarder oil may only be topped up 

via the oil filler plug. 

13. Check the oil filler plug’s (4) sealing ring for damage. If 

necessary, replace it. 

5 - 18 0616 

03945B 

03958B




14. Tighten the oil filler plug to the specified torque (see 


15. Take a test drive. Operate the retarder handle at a speed 

of at least 50 km/h and place it in position 1. Return the 

handle to position 0 (retarder off) after approximately 5 

seconds. Repeat this procedure at least five times. 

16. Check the oil level again after the test drive. 

0616 

5 - 19 

5

5 




5.13 BLEEDING THE FUEL SYSTEM 

The engine will only fire after several 

lengthy starting attempts. 

Failure to follow the starting instructions 

below may cause damage to the starter 

motor or the batteries. 

1. Bleed the fuel system using the hand pump (1). 

First, unscrew the button on the hand pump by turning it 

anticlockwise. 

2. Operate the hand pump until a build-up of pressure can 

be clearly felt. 

3. Wait a couple of minutes and then pump again until a 

pressure can be clearly felt. Tighten the button on the 

hand pump by turning it clockwise. 

4. Continuously operate the starter motor until the engine 

starts. The maximum time that the starter motor can be 

used is 1 minute. 

If the engine does not start during this time, allow the 

starter motor to cool down for 2 minutes. 

5. Continuously operate the starter motor again until the 

engine starts. The maximum time that the starter motor 

can be continuously used is 1 minute. If the engine does 

not start during this minute, allow the starter motor to cool 

for at least 30 minutes before repeating the start procedure 

described above. 

6. The engine will run erratically for some time after it has 

been started. 

Next, tighten the hand pump’s black button (1). 

5 - 20 0616



Cleaning 

6. CLEANING 

6.1 CLEANING THE BATTERY TERMINALS 

1. Remove the earth cable (-) from the battery terminal. 

2. Remove the positive cable (+) from the battery terminal. 

3. Clean the battery terminals, the battery cables and the 

top of the battery (oxide and dirt will cause the battery to 

discharge). 

4. If the top of the battery is contaminated with acid, then 

this should be rinsed with water. 

Dry the battery after cleaning 

5. Grease the terminals with acid-free Vaseline. 

6. Check the earth cable connection on the chassis and 

lubricate it using Vaseline. 

7. Fit the positive cable (+) to the battery terminal. 

8. Fit the earth cable (-) to the battery terminal. 

9. Check the position and attachment of the battery cables. 

0616 


batteries. 


For skin contact: wash the affected area 

thoroughly with plenty of water. Contact 

a doctor if the affected area remains red 

or painful. Remove affected clothing and 

rinse with water. 

For eye contact: wash for at least 15 

minutes with plenty of water and visit a 

doctor. 

If swallowed: DO NOT instigate vomiting, 

rinse your mouth, drink two glasses of 

water and visit a doctor. 

After inhaling: get some fresh air, take a 

rest and contact a doctor. 

6 - 1 

5

5 


Cleaning 


6.2 CLEANING THE WATER SEPARATOR 

1. Place a container under the water separator. 

2. Unscrew the bleed nipple (1) and the drain plug (2) a couple 

of turns and allow the water separator to drain. 

3. Remove the fuel filter bowl (3) by rotating it anticlockwise. 

4. Disconnect the fuel lines and remove the housing (4). 

5. Thoroughly clean all the water separator’s components 

in clean diesel. 

6. Assemble the housing (4) and the fuel lines. 

7. Lightly lubricate the new sealing ring (5) with engine oil or 

diesel. 

8. Fit the fuel filter bowl (3) with a new sealing ring and 

tighten the fuel filter bowl by hand. 

9. Bleed the fuel system using the hand pump. Operate the 

pump until the resistance increases. 

01518B 

6 - 2 0616 

2 

1



Cleaning 

6.3 CLEANING THE COARSE FUEL FILTER 

ELEMENT 

1. Place a sufficiently large container under the coarse fuel 

filter. 

2. Unscrew the cap (4) by turning it anticlockwise and 

remove it from the housing. 

3. Remove the filter element (2) from the cap (4). 

4. Rinse the filter element (2) in clean diesel and blow it 

clean using compressed air. 

5. Check the O-ring and the filter element for damage. If 

necessary, replace them. 

6. Lightly lubricate the O-ring (3) with engine oil. 

7. Fit the filter element and the O-ring in the cap (4). 

8. Screw the cap (4) clockwise to fit it to the filter housing 

(1). 

Tighten the cap by hand. 

9. First, unscrew the button on the hand pump (A) by turning 

it anticlockwise. 

10. Pump the cap (4) full with fuel. 

11. Tighten the button (A) on the hand pump by turning it 

clockwise. 

12. Start the engine and check for leaks. If necessary, 

tighten the cap (4) by hand. 

0616 

Diesel is an inflammable liquid and must 

not be exposed to a naked flame or other 

heat sources. Collect any drained fuel in 

a suitable container. 

6 - 3 

5

5 


Cleaning 


6.4 CLEANING THE CRT FILTER 

Wear suitable protective clothing and a 

face mask to prevent the inhalation of 

soot or soot particles. 

Use an industrial vacuum cleaner to 

remove soot particles from the filter. 

Follow the manufacturer’s instructions 

when doing so. 

The following tools are required to clean the CRT filter. 

– An enclosed area with an extraction unit which is separate 

from the rest of the workshop. 

– A compressor (7 bar - 100 psi) with a special spray head 

for blowing the compressed air directly into the filter’s 

ducts. 

– An industrial vacuum cleaner which is suitable for harmful 

materials and which has a suction strength of at least 400 

litres per minute. 

See the Eminox website for a summary of suitable cleaning 

equipment. 

www.eminox.com 

It is not permitted to clean the CRT filter 

with a steam cleaner or a high-pressure 

hose. As a result, the soot and ash 

particles will clot in the filter. 

Checking the CRT filter 

1. A large quantity of soot and ash particles on the inlet section 

of the filter may indicate overheating. Overheating 

may cause serious internal damage to the filter. Black 

spots or individual black cells on the outlet side of the filter 

are an indication of overheating. 

2. Replace the CRT filter if any of the above are observed. 

3. Check the visible surfaces of the catalyser and the filter 

module for cracks and dents and check whether the filter 

module is securely fitted into the housing. 

4. Check whether the seal of the inlet module and the catalyser 

module are broken. 

5. If no faults are observed on the filter module, then it must 

be refitted in the opposite order to which it was removed. 

Normal appearance 

Local internal damage 

Extensive internal damage 

03883B1 

03883B2 

03883B3 

6 - 4 0616



Cleaning 

6.5 CLEANING THE CATALYSER 

1. Use a soft brush to clean the surface of the catalyser. 

2. Check the various components for external damage, in 

particular the assembly flanges. 

A deep dent in the catalyser or CRT filter may have damaged 

the ceramic section. 

3. Check the visible sections of the catalyser for cracks or 

indentations and check whether the ceramic bracket is 

firmly secured in the housing. 

0616 

Wear suitable protective clothing and a 

face mask to prevent the inhalation of 

soot or soot particles. 

1145116 

6 - 5 

5

5 


Cleaning 


6.6 CLEANING THE RADIATOR AND THE 

INTERCOOLER ELEMENT 

Inhalation of dust may serious harm your 

health. 

Therefore, take necessary precautions, 

such as wearing dust goggles or a dust 

mask. 

6.6.1 CLEANING THE WIRE SCREEN 

1. Remove the wire screen. 

2. Use a hard brush to clean the wire screen and blow it 

clean with compressed air. 

1. Oil cooler 

2. Radiator 

3. Intercooler 

P. Compressed air 

6 - 6 0616 

03913B



Cleaning 

6.6.2 CLEANING THE RADIATOR/INTERCOOLER/OIL COOLER ELEMENT 

1. Use compressed air to blow the radiator element clean 

from the back of the cooling unit until no more dirt 

escapes. 

When doing so, protect the rear of the oil cooler/intercooler 

from dirt penetrating. 

2. Once finished, clean the oil cooler and intercooler with a 

tool you have made yourself. 

Place to tool between the radiator and the oil cooler and 

then between the radiator and the intercooler and blow 

the oil cooler/intercooler clean until no more dirt escapes. 

6.6.3 WITH A STEAM CLEANER 

If it is difficult to clean the radiator/intercooler element and 

the oil cooler using compressed air, the radiator/intercooler 

element and the oil cooler must be disassembled and 

cleaned with a steam cleaner. 

0616 

Avoid using a too high pressure, because 

this may damage the lamellae. 

A general car paint cleaner can be added to 

the water. Do not use any aggressive 

cleaning agents. 

Follow the manufacturer’s instructions 

when using cleaning products. 

6.6.4 INSIDE OF THE RADIATOR 

Advice 

If the specifications for the coolant and additives are 

observed, then the inside of the radiator will only be polluted 

in exceptional circumstances. 

• Light pollution 

– Rinse with hot water. If necessary, add a mild cleaning 

agent. 

• Surface contaminated with minerals, such as lime. 

– Fill the radiator with water and add a slightly alkaline 

cleaning agent for limestone, such as diluted acetic 

acid or a mild household cleaning product. 

• Heavy pollution 

– Heavy pollution on the inside is difficult to remove. If 

heavily polluted, the radiator should be cleaned by a 

specialized company. 

After using a cleaning agent, rinse the 

radiator using plenty of water until all the 

cleaning agent has been removed. 

03959B 

6 - 7 

5

5 


Cleaning 


6.6.5 INSIDE OF THE INTERCOOLER ELEMENT 

• Light pollution 

– Rinse with hot water. If necessary, add a mild cleaning 

agent. 

– Neutral to light alkaline cleaning agents and additives, 

such as wetting agents, improve the cleaning process. 

– The temperature and concentration may be altered 

according to the manufacturer’s instructions 

• Heavy pollution 

– Heavy pollution on the inside is difficult to remove. If 

heavily polluted, the radiator should be cleaned by a 

specialized company. 

Before assembling the intercooler element, 

it is vitally important that the internal 

surface of the intercooler element is free of 

liquids and cleaning agent residue. 

6 - 8 0616



Cleaning 

6.7 CLEANING THE REAR AXLE BREATHER 

1. Clean the breather and the surrounding area. 

2. Remove the breather from the rear axle. 

3. Rinse the breather and breather hose in a cleaning fluid. 

4. Blow the breather and hose dry from the inside using 

compressed air. 

5. Install the breather with hose on the rear axle. 

0616 

1437467 

6 - 9 

5

5 


Cleaning 


6.8 CLEANING THE GEARBOX 

BREATHER(S) 

1. Clean the breather(s) and the surrounding area. 

2. Remove the breather(s) from the gearbox. 

3. Rinse the breather(s) and breather hose(s) in a cleaning 

fluid. 

4. Blow the breather(s) and breather hose(s) dry from the 

inside using compressed air. 

5. Install the breather with hose on the gearbox. 

03901B 

6 - 10 0616



Cleaning 

6.9 CLEANING THE VEHICLE 

Before cleaning the vehicle, check whether there are any 

leaks from the engine, axles, gearbox, etc., because this will 

no longer be possible during the maintenance work after the 

vehicle has been cleaned. 

– Make sure that doors, windows and roof hatches are 

securely closed when using a high-pressure hose. 

– Never direct the jet of the high-pressure hose/steam 

cleaner directly at the steering box. 

– When cleaning the universal joint on the steering box, the 

spider seals may be forced open by the high-pressure jet 

of water, so that the grease behind them will be flushed 

away. As a result, the spider may get stuck and cause the 

steering mechanism to jam. 

– A bleed valve is fitted to the steering mechanism’s powersteering 

reservoir. Water may enter the reservoir through 

this valve, causing damage to the steering mechanism. 

– Be careful not to damage the lamellae when cleaning the 

radiator/intercooler element. 

– Do not direct the jet of the high-pressure hose too long at 

the air conditioning system’s condenser. As a result of the 

high temperature, excessive pressure will build up in the 

system, which may cause damage to the system. 

– Ensure that no water can enter the differential or the gearbox 

via the bleed openings. 

– The engine and engine compartment can be cleaned with 

a high-pressure hose. Make sure, in this case, not to spray 

directly onto the oil seals/seals and the electrical components, 

such as the starter motor, alternator, etc. 

– When cleaning a UPEC engine with a high-pressure hose, 

do not aim the hose directly at the pump units. Water may 

enter the protection caps via the bleed openings, which 

may cause faults with the electrical connections of the 

pump units. 

– The encapsulation must be thoroughly cleaned after every 

maintenance service, because there is a risk of fire if the 

inside of the encapsulation is dirty. When spraying the 

engine encapsulation, maintain a minimum distance of 50 

cm between the engine encapsulation and the spray nozzle 

to prevent damage to the engine encapsulation. 

– Do not aim the jet directly at electrical connections, such as 

connectors, lighting feed-through connections, etc. 

– Make sure no water can enter the air intake system via the 

air inlet or the flexible seals when cleaning the vehicle. 

– Do not direct the jet of the high pressure hose directly onto 

the seals on the drive shaft, such as the seals in the spider, 

the intermediate bearing and the slip joint. 

– Lubricate the vehicle after it has been cleaned using a 

grease gun or via the central lubrication system. This is 

important, because it prevents the penetration of moisture 

and dirt at the various pivot points. 

0616 

6 - 11 

5

5 


Cleaning 


6 - 12 0616



Lubrication 

7. LUBRICATION 

7.1 LUBRICATING ACCORDING TO THE 

LUBRICATION SCHEDULE 

– Lubricate according to the lubrication schedules. Clean the 

grease nipples before and after lubricating. 

– Remove any excess grease after lubricating. 

Grease quality 

See the lubrication specifications. 

Front axle suspension 

1. Lubricate the front axle suspension (see “Fluids and 

lubricants” for the grease specifications) until grease 

escapes. 

Swivel axle 

1. Lubricate the swivel axle (see “Fluids and lubricants” for 

the grease specifications) until grease escapes. 

Auxiliary pitman arm 

1. Lubricate the intermediate arm (see “Fluids and lubricants” 

for the grease specifications) until grease escapes 

from the seal (C). 

Steering box 

1. Check whether there is any grease in the space behind 

the dust rings A and B. 

2. If necessary, fill the space behind the dust rings with 

grease which has a melting point > 130° C (see “Fluids 

and lubricants” for the grease specifications). 

0616 

1150189 

1149413a 

7 - 1 

5

5 


Lubrication 


Drive shaft (SB version) 

1. Clean the grease nipples before and after lubricating. 

Remove any excess grease after lubricating. 

2. Lubricate the universal joints and sliding joint of the drive 

shaft until grease escapes. See “Fluids and lubricants” 

for the grease specifications. 

3. The maximum lubrication pressure must not exceed 15 

bar. 

7 - 2 0616



Lubrication 

7.2 LUBRICATION DIAGRAM 

1 Clutch control reservoir 

2 Spare wheel 

3 Steering box 

4 Auxiliary pitman arm 

5 Lower supporting arm 

6 Kingpin (top and bottom) 

7 Wheel bearings 

8 Upper supporting arm 

9 Differential 

10 Drive shaft (SB-only) 

11 Kingpin (top and bottom) 

12 Wheel bearings 

13 Retarder 

14 Gearbox 

15 Engine 

16 Fan drive reservoir 

17 Power steering reservoir 

0616 

03960B 

Multi-purpose grease 

Engine oil 

Transmission fluid 

Hypoid oil 

Automatic transmission fluid 

C= CHECK 

S = SYMMETRICAL 

V = CHANGE/REPLACE 

7 - 3 

5

5 


Lubrication 


7 - 4 0616



Jacking and lifting instructions 

8. JACKING AND LIFTING INSTRUCTIONS 

8.1 JACKING INSTRUCTIONS 

0616 

Turn off the ECAS system by turning off 

the main switch, because the ECAS 

system will otherwise try to correct the 

angle of the vehicle 

Always observe the manufacturer’s 

instructions when using a jack. 

Only place the jack at the indicated 

jacking points. 

Jacking up the front wheels 

When jacking up the front wheels, place the jack under the 

steering swivel as indicated. 

Place the jack under the steering swivel so that the vehicle 

cannot slide off of the jack. 

In order to prevent damage to the wheel suspension/chassis, 

the jack must never be placed in the region between the two 

steering swivels. 

Jacking up the driven axle 

To jack up the driven axle, place the jack under the yoke in 

the middle of the four leaf-spring clips, as indicated. 

In order to prevent deformation of the axle beam, the jack 

must not be placed directly under the axle beam or differential 

housing. 

03968B 

03965B 

8 - 1 

5

5 




Jacking up the trailing axle 

When jacking up the trailing axle, place the jack under the 

axle beam as indicated. 

03967B 

8 - 2 0616




8.2 LIFTING INSTRUCTIONS 


These instructions are only intended as a guide to increase 

safety when raising and/or jacking up the vehicle. 

Following these instructions does not relieve the user of his 

responsibilities for carrying out his duties safely. VDL Bus & 

Coach cannot be held responsible for any consequential 

damage caused as a result of lifting and/or supporting the 

vehicle, regardless of whether this is carried out in accordance 

with these instructions or not. 

Kneeling on the bumper stops 

A function (EFREQ1 on IOU2) is offered to the bodywork 

builder. This function make it possible to kneel the vehicle on 

the bumper stops around the vehicle. 

If this function is not present, manually bleed the air bellows. 

Next, disconnect the ECAS unit’s connector and apply the 

vehicle’s parking brake. 

Aids when raising the vehicle 

When using wheel jacks 

If necessary, place a wheel adapter on each wheel jack so 

that if there is a a puncture, the wheel rim cannot get between 

the support bracket. 

Tools for lifting columns 

Use the specified supports with the appropriate separate 

tools for the axles and slide them sufficiently far enough onto 

the lifting column’s fixed support (see the instruction manual 

provided by the manufacturer of the lifting columns). 

Lifting columns 

0616 

Always place trestles under the chassis 

when carrying out work under a raised 

vehicle. 

Make sure the bodywork does not 

become damaged when lifting the 

vehicle. 

Always read the instruction manual and 

the supplier’s instructions before using 

the lifting columns and the accessories. 

1. Place the appropriate supports for the axles in the correct 

positions on the lifting column and, if necessary, use a 

locking compound (see the supplier’s instructions). 

2. With the vehicle at the highest driving height, drive it as 

straight as possible between the lifting columns. 

8 - 3 

5

5 




3. First, place the lifting column correctly under the rear axle 

and raise it until the tyres come off of the ground. 

4. For an SBR, place the lifting columns under the trailing 

axle. 

5. Place the lifting column correctly under the steering 

swivel and raise it until the tyres come off of the ground. 

Make sure the shock absorber/shock absorber attachment or 

other components do not become damaged. 

6. Lower the vehicle onto the bumper stops. 

Warn people in the immediate vicinity 

before lifting the vehicle and stand in a 

convenient and safe location. 

8 - 4 0616 

03965B 

03967B 

03968B




Wheel jacks 

1. Drive the vehicle as straight as possible to the middle of 

the workshop. 

2. Lower the vehicle onto the bumper stops. Pay attention 

to avoid damage to the bodywork. 

3. If necessary, place wheel adapters on the wheel jacks 

(see the supplier’s instructions). 

0616 

Always read the instruction manual and 

the supplier’s instructions before using 

the wheel jacks and any accessories. 

For an SBR, place the wheel jacks under the front axle and 

the trailing axle. 

4. Use the wheel jacks to lift the vehicle until all the tyres 

just come off of the ground. Check the position of the 

wheels in the wheel jacks and pay attention to avoid 

damage to the bodywork. 

Warn people in the immediate vicinity 

before lifting the vehicle and, if possible, 

stand in a convenient and safe location. 

5. Use all the columns simultaneously to lift the vehicle to 

the desired height. 

8 - 5 

5

5 




8.3 SUPPORTING THE VEHICLE 

First read the instructions concerning: 

- Kneeling on the bumper stops 

- Lifting instructions (lifting columns/ 

wheel jacks) 

When the vehicle has been lifted to the correct height, always 

place 6 trestles in the support points. 

1. Under the flat, horizontal areas at the ends of the crossbeam 

just behind the front wheels 

2. Under the steering swivels. This will prevent damage to 

the shock absorber suspension caused by the shock 

absorbers hanging. 

3. Under the flat, horizontal areas at the ends of the crossbeam 

just in front of the rear wheels. 

8 - 6 0616 

03964B 

03963B 

03961B




4. Under the longitudinal beams in the same place as the 

gearbox. 

Points of attention when carrying out work on the front 

axle, rear axle or trailing axle: 

0616 

First read the instructions concerning: 

- Kneeling on the bumper stops 

- Lifting instructions (lifting columns/ 

wheel jacks) 

Front axle 

If the chassis is supported when carrying out work on the 

front axle, the wheel jacks or lifting column under the front 

axle can be safely moved into a lower position or removed. 

See the supplier’s instructions. 

Rear axle/trailing axle 

If the chassis is supported when carrying out work on the rear 

axle/trailing axle, the wheel jacks or lifting column under the 

rear axle/trailing axle can be safely moved into a lower position 

or removed. See the supplier’s instructions. 

1. The lifting column or wheel jacks must be replaced in the 

opposite order to which they were removed. Attention 

must be given to make sure the rear axle/trailing axle 

returns to the correct position. 

– Raise the lifting column or the wheel jacks until they 

just touch the vehicle. Make sure that the support of the 

lifting column falls between the nuts of the leaf-spring 

clips. 

– Make sure the air bellows are placed correctly on the 

centring. 

03962B 

8 - 7 

5

5 




8 - 8 0616


DOCUMENTATION REPLY FORM 

Documentation Reply Form 

If you have any suggestions and/or comments concerning 

this manual or if you find any faults, please fill out this 

form and send it to: 

VDL Bus & Coach 

Training and Documentation 

Company name : ........................ .................................................. 

P.O. box 5 

Name : ............................................................. 

5550 AA Valkenswaard 

Die Niederlande 

Signature : ........................................................................... 

Fax: +31 (0)40 2019477 

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

Applicable 

dokument ordernumber: ............................................... Version: ......................................... 

Type of dokument: 

(set marker id applicable) 

Kind of inaccurracy 

(set marker id applicable) 

Additional information 

(text, page number, etc.) 

VDL Bus & Coach will take your report seriously and, if 

necessary, we directly make an update in the document. 

Driver Climate 

Maintenance Electrical diagrams 

Workshop Training 

Parts Übriges 

Linguistic (Definition) not correct Mistake in technical data (values) Images 

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5 - Training Registration System - VDL Bus & Coach

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