trans island bus services singapore driver's manual sb 220

TRANS ISLAND BUS SERVICES
SINGAPORE
DRIVER’S MANUAL
SB 220
Date 9528 DW 050149

CONTENTS
INTRODUCTION ............... 3
IDENTIFICATION ............... 5
GENERAL INSTRUCTIONS ....... 9
INSTRUMENTS AND CONTROLS . . . 10
Instrumentpanel ................10
Switches, gauges and warning
lamps ........................14
Warning lamps on the display panel . . 20
Multi function switch .............22
Adjustable steering column ........23
DRIVING .....................24
Contact/starter key ..............24
Operating panel in engine
compartment ..................24
Preheating system ..............25
Cold start device ................25
Start procedure .................25
Driving with an automatic
gearbox ......................26
Retarder ......................29
Steering ......................29
Brakes .......................29
Parking and stopping the engine ....30
MAINTENANCE ................31
General ......................31
Before the winter season .........31
After the winter season ..........32
Daily maintenance ..............33
Weekly maintenance ............35
Periodic maintenance ............37
EMERGENCY REPAIRS ..........43
Serious oil leakage ..............43
Bleeding the fuel system ..........43
Renewing the V-belts ............43
Releasing the parking brake .......44
Faults in the Anti-lock Brake
System (optional) ...............44
Wheels .......................45
Inflating tyres ..................46
Leakage in the air suspension
system .......................46
Towing .......................46
Replacing bulbs ................47
Fuses ........................47
SPECIFICATIONS ..............48
LUBRICATION CHART ...........53
CENTRAL E-PANEL .............54
CONTENTS 1

INTRODUCTION
This manual contains all you need to know
about using the vehicle which has been
entrusted to your care. Read it carefully
before making your first journey. A
thorough knowledge of the operating
instructions will make driving easier and
extend the vehicle’s life. We have tried to
make the instructions practical and easy to
understand. They contain an explanation of
the identification data, operating
instructions and how to drive the vehicle in
the most efficient way. They also deal with
daily, weekly and periodic maintenance and
describe minor repairs which you may be
able to carry out yourself.
We would like to wish you
A GOOD JOURNEY
Please note
This manual is based on the chassis and
accompanying fittings as it left the DAF
BUS factory. Depending upon the type of
body and fittings, the bodybuilder may
make fundamental changes to various
items of equipment such as the instrument
panel, the lighting or the electric wiring.
The manual deals with a range of various
types and models. Every vehicle has been
constructed in accordance with the legal requirements
in the country concerned and in
accordance with anticipated operating conditions.
The manual may therefore contain
texts and illustrations which do not correspond
exactly to what you find on your vehicle.
However, this does not make any difference
as to how you should operate and
maintain the vehicle.
IMPORTANT
Make sure the manual is in the vehicle at
all times and read it carefully before making
your first journey. Only then will you be
able to benefit from all of the many
possibilities offered by your DAF BUS.
INTRODUCTION 3

IDENTIFICATION
CHASSIS NUMBER
The chassis number is stamped in the right
hand side member of the chassis between
the front axle cross member and the rear
bracket of the suspension bellows.
ENGINE NUMBER
The engine number is stamped in the lower
part of the engine between the two push
rod covers.
IDENTIFICATION 5

ENGINE IDENTIFICATION PLATE
The engine identification plate is mounted
on top of the coolant pipe in the engine
compartment .
This plate shows the engine specification
number, the type and the serial number, as
well as the adjusting data.
When carrying out repairs and ordering
spare parts, it is important to mention the
specification number.
IDENTITY CARD
Every vehicle has its own identity card
which can be used to identify the exact
component parts used in the construction
of the vehicle.
Any subsequent modifications to the vehicle
should therefore be recorded on the
identity card.
It is important to have the identity card
available when calling ITS for assistance,
but also for finding the correct part
numbers in case of repairs.
VEHICLE IDENTIFICATION PLATE
The vehicle identification plate is fitted by
the bodybuilder.
This identification plate is illustrated on the
next page together with an explanation of
the vehicle identification number as required
by law in all member states of the
E.E.C. with effect from October, 1982.
6
IDENTIFICATION

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

IDENTIFICATION NUMBER
X M G D E 02 L T 0H000001
Netherlands
Chassisnumber
-
Engine variant
DAF BUS A Tuned inlet system
INTERNATIONAL B Downrated and turbocharged
C Turbocharged
02 MB 230/ D Downrated and naturally
SB 220/DB 250
aspirated
Other vehicles 03 SB 2300/2700 N Naturally aspirated
B. TB bus (front engine) 33 SB 3000/3015 S Turbocharged and
C. MB bus (mid engine) 23 SB 2750 intercooler
D. SB bus (rear engine) 21 SB 2100 T Turbocharged
X Extra
E4x2
R6x2 single
Engine family
wheels on B 2.5 litre
trailing axle C 5.85 litre
A6x2 MBG N 6.20 litre
P6x2 SBG H 8.25 litre
K 11.60 litre
L 11.60 litre (horizontal)
W 11.60 litre (cross-flow)
R 8.65 litre
G 8.65 litre (horizontal)
8
IDENTIFICATION

GENERAL INSTRUCTIONS
During the running-in
period the new vehicle
should not be exposed to
excessive loads.
This also applies when an overhauled
engine, gearbox or differential has been installed.
Therefore, for the first 1500 km/1000 miles:
- Do not drive with a full load.
After a cold start continue to drive in a
low gear and at a moderate engine speed
until the coolant temperature has reached
50°C. Check the instrument panel
regularly when driving and take the
necessary steps to rectify possible
problems at the first sign of trouble.
Do not let the engine idle for longer
than necessary. This is harmful for the
engine and also causes unnecessary
pollution of the environment.
Whenever possible, before switching off the
engine after a long trip let it run at idle for
a few minutes.
The engine cooling system is thermostatically
controlled, so never use a
muff on the radiator grille in cold
weather.
The removal of a thermostat on account
of (too) high a coolant temperature serves
no useful purpose since this will only cause
the temperature to rise to an even higher
level.
If the pressure in the air reservoirs drops
rapidly with the engine switched off, this indicates
a leak in the compressed air
system. Since this affects the safety of the
brake system, the leak should be repaired
as quickly as possible.
The vehicle is equipped with an alternator;
therefore the following precautions should
be observed:
- Never disconnect the battery pole
clamps while the engine is running.
- Always disconnect the pole clamps
from the batteries before commencing
work on the electrical system and when
charging the batteries.
- Disconnect the pole clamps from the
batteries before doing any electrical
welding on the vehicle.
- Attach the earth clamp of the welding set
as close as possible to the area on the
vehicle where the welding is to be carried
out.
GENERAL INSTRUCTIONS 9

INSTRUMENTS AND CONTROLS
INSTRUMENTPANEL
10
INSTRUMENTS AND CONTROLS

1. Vehicle lighting switch
2. Instrument lighting switch
Indication and warning lamps
3. Front fog light switch
4. Warning lamp main switch
5. Warning lamp retarder off
6. Warning lamp glowing
7. Warning lamp headlight
8. Warning lamp direction
9. Warning lamp direction indicator
10. Warning lamp main beam
11. Warning lamp red (SWS)
12. Warning lamp parking brake
13. Warning lamp halt brake
14. Warning lamp retarder on
15. Warning lamp vehicle not on driving
level
16. Warning lamp ASR
17. Warning lamp central lubrication
19. Hazard warning switch
20. Coldstart switch
21. Preheating switch
22. Rear foglight switch
23. Fuel gauge
24. Voltmeter or gearbox oil temperature
gauge
25. Air pressure gauge
26. Coolant temperature gauge
27. Rev. counter
28. Tachograph
30. Master switch
INSTRUMENTS AND CONTROLS 11

12
INSTRUMENTS AND CONTROLS

Instrument panel
32. Retarder in/out switch
36. Switch vehicle backward second
control
37. Cigar lighter
Display panel
Depending on the systems installed in the
vehicle, the relevant warning lamp will light
up in the event of a fault.
Red warning lamps
A1 spare
A2 retarder oil temperature too high
A3 engine compartment temperature too
high
A4 brake fluid level too low
A5 engine oil level too low
A6 spare
B1 fault in gearbox (Diwa.3)
B2 fault in ABS
B3 brake pressure too low
B4 battery charge warning lamp
B5 oil pressure too low
B6 gearbox fluid level too low
C1 fault in EGAS
C2 spare
C3 coolant temperature too high/level too
low
C4 alternator voltage too high
C5 steering pump oil level too low
C6 fault in ECAS
D5 engine compartment fan inoperative
Orange warning lamps
D1 brake lining worn down
D2 door or hatch open
D3 fault in steering circuit 1
D4 fault in steering circuit 2
D5 (see red warning lamps)
D6 spare
E1 emergency door not locked
E2 limited speed exceeded
E3 air filter clogged
E4 fuel reserve down to minimum
E5 fault in central timer
E6 fault in automatic lubrication system
INSTRUMENTS AND CONTROLS 13

SWITCHES, GAUGES AND WARNING
LAMPS ON THE INSTRUMENT PANEL
1. VEHICLE LIGHTING SWITCH
The vehicle lighting switch is a rotary type
switch with three positions:
- Position 0: vehicle lighting switched
off.
- Position I: parking lamps and end/
outline marker lamps.
- Position II: headlights, parking lamps
and end/outline marker
lamps.
When the vehicle lighting switch is in
position II, the warning lamps in the various
switches light up at half strength for easy
identification and location of the switches.
2. INSTRUMENT LIGHTING SWITCH
When the vehicle lighting switch is in
position I or II, the instrument lighting also
glows.
The intensity of this lighting can be
adjusted with the instrument lighting switch.
3. FOGLIGHT SWITCH
This switch actuates the foglights. When
the foglights are on the warning lamps in
the switch also lights up.
4. MASTER SWITCH WARNING LAMP
This lamp lights up as soon as the master
switch is operated.
When the engine is running, this lamp
extinguishes again.
5. RETARDER WARNING LAMP
DISENGAGED
This warning lamp lights up as soon as the
retarder is disengaged.
6. PREGLOWING WARNING LAMP
This lamp lights up during the glowing
procedure. Also see the "DRIVING" section
of this book.
7. DIPPED BEAM WARNING LAMP
This lamp lights up when the headlight
dipped beams are switched on.
8. DIRECTION INDICATOR WARNING
LAMP
This lamp flashes together with the
direction indicators on the vehicle.
9. DIRECTION INDICATOR WARNING
LAMP
This lamp flashes together with the
direction indicators on the vehicle (option).
10. MAIN BEAM WARNING LAMP
This warning lamp lights up when the
headlamps are on main beam and when
the headlamps flash is operated.
11. RED CENTRAL WARNING LAMP
The red central warning lamp comes on
when an important malfunction occurs in a
vehicle system. In the event of too hight
coolant fluid temperature or a high engine
compartment temperature or a low
pressure in the pneumatic system a buzzer
will sound. The information panel shows
which vehicle function has activated the
warning.
Stop without delay and switch off the
engine immediately when the red central
warning lamp lights up.
12. PARKING BRAKE WARNING LAMP
This lamp comes on when the parking
brake is applied. It also indicates if air
pressure is high enough to allow the
parking brake to be released.
13. DOOR-CONTROLLED BRAKE
This lamp comes on when the doorcontrolled
brake is actuated.
14
INSTRUMENTS AND CONTROLS

14. RETARDER WARNING LAMP
ENGAGED
This lamp lights up as soon as the retarder
is engaged.
15. WARNING LAMP VEHICLE NOT ON
DRIVING LEVEL
This warning lamp will flash if the air
pressure for the chassis height adjustment
is to low.
This warning lamp will not operate if the
chassis is not drive height.
16. ASR WARNING LAMP
The instrument panel contains an ASR
lamp to check the ASR installation.
This lamp will light up when:
- Contact is switched on. If the
installation functions correctly, the
lamp should go off.
The lamp remains "off", even if the
vehicle is stopped with the engine
running. The lamp will only come on
again if contact is switched off for at
least 20 seconds and then switched
back on.
- The ASR installation is started.
- Max. speed is exceeded (Wabco
speedlimiter).
- Speedlimiter system defective.
- ASR system defective.
The ASR installation is defective when the
red warning lamp lights up while vehicle
speed is over 7 km/h and the ASR system
is not working. In this case, the fuses in the
Central E-panel should be checked. If the
defect cannot be resolved by changing a
fuse, you can still drive on. Have the defect
repaired at a DAF BUS Dealer.
17. CENTRAL LUBRICATION WARNING
LAMP
This lamp will light up during 42 seconds
when the central lubrication system is
started. In case of a fault in the central
lubrication system, the lamp will remain on.
19. HAZARD WARNING SWITCH
Pushing in this switch causes all the
direction indicators to flash simultaneously.
The hazard warning lights are switched off
by pushing in the switch again. The
warning lamp in the switch indicates that
the hazard warning lights are in operation.
20. COLD STARTING SWITCH
The cold starting system is operated by
depressing the tumbler switch. Also see
under "driving".
21. PREHEATING SWITCH
With the contact switched on, this switch
will operate the preheating system. Also
see under "DRIVING".
22. SWITCH FOR REAR FOG LAMPS
This switch actuate the rear fog lamp.
When the lamp is on the warning lamp in
the switch also lights up.
23. FUEL GAUGE
The fuel gauge only operates when the
contact is on.
24. GEARBOX OIL TEMPERATURE
GAUGE
The gearbox oil temperature should be in
the green zone. Also see under "driving".
INSTRUMENTS AND CONTROLS 15

25. AIR PRESSURE GAUGE
Each pointer indicates the pressure in the
reservoir of the service brake circuits. If the
pressure in one of the circuits drops below
5 bar, a buzzer goes off and bulb B2 of the
information panel will light up. If the
pressure is over 5 bar, the brakes can be
released with the parking brake lever. The
buzzer only works with the contact
switched on; the pressure gauge works at
all times.
It is not permitted to drive the vehicle if the
pressure in one of the circuits is below 5
bar.
26. COOLANT TEMPERATURE GAUGE
The coolant operating temperature should
be between 75°C and 95°C (black zone).
Never run the engine at full load when the
coolant temperature is below 50°C (orange
zone). If a sudden rise in coolant
temperature is observed and/or the gauge
reading enters the red zone, then the
following should be checked:
- The coolant level; unscrew the filler
cap with caution!
- The V-belts and water hoses.
- The hydraulic operation of the engine
cooling fan.
27. REV-COUNTER
Shaded green( * ) : very economical
Green : economical
Yellow : less economical
Shaded red : Only permitted when
going downhill; use
exhaust brake
Red
: To be avoided
( * ) Only for unladen vehicle.
28. TACHOGRAPH (COMPACT)
(for two drivers)
Inserting tachograph discs
- Open the tachograph when the vehicle is
stationary, using the key.
- Lift the centre plate (3).
- Insert the co-driver’s disc with the green
side facing upwards.
- Lower the centre plate (3) and push it
home.
- Insert the driver’s disc with the green
side facing upwards and place it on top
of the centre plate.
- Close the tachograph and remove the
key.
Note
In this type of tachograph, there must
always be two discs present, even when
there is only one driver. A blank or blind
disc can be placed under the centre plate.
This can be used for an unlimited period.
Driver and co-driver have their own disc.
16
INSTRUMENTS AND CONTROLS

When the driver and co-driver change
places, the disc of the person driving the
vehicle must be placed in the top part of
the tachograph. The time group switch (1)
controls the upper disc. The co-driver’s disc
must always be under the centre plate. The
time group (2) controls the lower disc.
(If someone changes vehicle, he should
take his own disc with him to the new
vehicle).
Operating the time group recorder
The time group recorder is controlled by
the time group switches 1 and 2.
Driving times and all other
duties
Waiting time
Daily rest period
Front of tachograph disc
K: Time scales
J: Speed registration
L: Time group registration
M: Distance registration
Completion of the middle part of the
front of the tachograph disc
Before inserting the disc:
Name of driver/co-driver
Place where working time
commenced
Date of commencement of working
time (top line)
Registration mark of vehicle
Odometer reading at start of
working time
INSTRUMENTS AND CONTROLS 17

Completion of the middle part of the
rear and of the tachograph disc
Here a maximum of three vehicle switches
can be recorded:
Time of switching vehicles
Registration mark of new vehicle
Odometer reading at start
Odometer reading at end
Total number of kilometres driven
After removing the disc:
Place where working time ended
Date end of working time
(bottom line)
Odometer read. at end of working time
Total number of kilometres driven
Completion of the outer edge of the rear
of the disc
This part of the disc can be used to fill in
the time groups by hand if necessary. This
may be the case if the driver/co-driver is
working away from the vehicle or if the
tachograph breaks down. In these cases a
line must always be drawn after the
symbol.
Setting the time
Adjust the timepiece with the knob (6); note
the difference between for instance 06.00
hrs and 18.00 hrs. The line on the second
disc (1) shows whether the clock is
working. The exact time on the tachograph
disc can be checked at the red point (7).
18
INSTRUMENTS AND CONTROLS

Warning lamps
Warning lamp (2) comes on when the
tachograph is not ready for use, i.e.:
- tachograph discs not inserted
- cover not properly closed
- recording pen faulty
Warning lamp (2) flashes if the working
time is not being recorded correctly.
Warning lamp (3) comes on if a certain
speed is exceeded. This speed can be set
with screw (4). The value set is shown in
display (5).
Self-test
The electronic circuits in the tachograph
continuously check the equipment for:
- interruption of the power supply
- faults in the input signal from the
gearbox.
The tachograph will not work without power
supply.
When the voltage returns, the speedometer
will briefly sweep over to max. and a line
will be drawn on the disc. If the cover has
been opened while the power supply was
interrupted, the following must be carried
out:
- set the time
- insert the tachograph discs
- close the cover
- briefly move the vehicle
The speedometer should now return to
zero.
In the case of faults in the input signal line,
the speedometer will sweep over every 8
seconds. This will also be recorded on the
disc.
30. MASTER SWITCH OPERATION
When the master switch is turned off, the
electrical system is de-energized with the
exception of the hazard warning lights and
the tachograph.
32. RETARDER SWITCH
With this switch the operation of the
retarder can be engaged or disengaged.
36. SWITCH REVERSE GEAR SECOND
CONTROL
This switch must be depressed following
the reverse gear solution on the DNR
switch to operate the reverse gear.
37. CIGAR LIGHTER/INSPECTION
LAMP SOCKET
- Push in the cigar lighter and wait: it will
spring back automatically when ready for
use.
- Withdraw the lighter from the socket.
When the vehicle lighting is switched on,
the cigar lighter is also illuminated.
The cigar lighter socket can also be used
to connect up an inspection lamp.
INSTRUMENTS AND CONTROLS 19

WARNING LAMPS ON THE DISPLAY
PANEL
The function of various lamps on the
display panel is explained below.
WARNING LAMP GEARBOX OIL
TEMPERATURE (A2)
If the oil temperature in the gearbox rises
above 150°C, the warning lamp (A2) starts
to flash. If this happens the retarder should
be disengaged. Also see under "Driving".
WARNING LAMPS ENGINE
COMPARTMENT (A3)
If the temperature in the engine
compartment rises above 110°C, the
warning lamp (A3) will come on and a
buzzer will sound. If this happens, let the
engine idle for a few minutes before
shutting it off.
WARNING LAMP FAULT IN GEARBOX
(B1)
In the event of a serious failure of the Voith
Diwa.3 automatic gearbox this lamp will
flash simultaneously with the lights of the
DNR switch. The vehicle must be stopped
without delay to prevent consequential
damage to its drive line.
WARNING LAMP BRAKE PRESSURE
TOO LOW (B3)
If the pressure in either of the circuits drops
below 5 bar, a buzzer will sound and this
warning lamp will light up. Providing that
the pressure is higher than 5 bar the wheel
brakes can be released with the parking
brake lever.
WARNING LAMP BATTERY CHARGE
(B4)
The battery charge warning lamp will come
on if:
A The contact is switched on and the
engine is not running.
B The batteries are not charged by the
alternating current alternator.
C The overvoltage cut-out is activated.
First, switch off the engine and the contact.
Restart the engine. If the light does not
come on again, driving can be resumed. If
the light stays on while the engine is
running, the first thing to check is if the V-
belts are broken or slipping. If this is not
the case, find a repair shop as soon as
possible.
WARNING LAMP OIL PRESSURE (B5)
The oil pressure warning lamp will come on
if oil pressure drops too low. If the engine
is running, turn it off immediately.
WARNING LAMP COOLANT
TEMPERATURE (C3)
This warning lamp will come on if the
coolant’s temperature rises above 100°C.
WARNING LAMP OVERVOLTAGE (C4)
If the charging voltage of the alternator
rises above 30V, this warning lamp will
come on. The battery voltage is than too
high and the battery may start to boil. In
that case, switch on as many electrical
consumers as possible and drive to the
nearest repair shop. If the warning lamp
does not stop burning, driving may under
no circumstances be continued.
WARNING LAMP DOOR OR HATCH
OPEN (D2)
This lamp will come on when a door or
hatch is open (option).
WARNING LAMP EMERGENCY EXIT (E1)
This warning lamp will come on when the
emergency exit is not locked (option).
20
INSTRUMENTS AND CONTROLS

WARNING LAMP SPEED LIMITER (E2)
This light will come on as soon as the set
speed is exceeded (e.g. when driving
downhill).
WARNING LAMP AIR CLEANER (E3)
This warning lamp lights up if the air
cleaner is blocked or unduly fouled. The
filter element should in that case be
cleaned or renewed at the first opportunity.
INSTRUMENTS AND CONTROLS 21

MULTI FUNCTION SWITCH
Dipped beam/main beam
A Dipped beam only when the
lighting switch is
pushed in
B Main beam completely
Against spring pressure: headlamp flash.
Direction indicators
To operate the lane-change mode of the
direction indicators, move the switch
against the spring pressure. The direction
indicators only operate with the contact
switched on.
C Direction indicators, right turn
D Direction indicators, left turn
Horn
The horn is operated by pressing the knob E.
Windscreen wipers
The windscreen wipers are operated by
turning switch F.
Position O : off
Position l : low speed
22
INSTRUMENTS AND CONTROLS

Position II
Position J
: high speed
: intermitted wipe: one
single sweep every 8
seconds
The windscreen wipers only operate with the
contact switched on.
Windscreen washers
Pushing in the ring G will actuate the
screenwash jets and also cause the wipers
to make two sweeps across the windscreen.
The windscreen washers only operate with
the contact switched on.
ADJUSTABLE STEERING COLUMN
The position of the steering column and the
height of the steering wheel can be adjusted.
For these adjustments the sidemounted
handle must be moved to position
B. Both new settings (position and height)
can be made at the same time. The steering
column is locked by turning the handle to
position A.
Option:
Pneumatically controlled adjustable
steering column
The steering column may be adjusted
depressing a floor switch but only if the halt
brake is applied.
INSTRUMENTS AND CONTROLS 23

DRIVING
OPTIONAL:
CONTACT/STARTER KEY
Position St: rest position
Steering wheel locked. The key can be
removed.
Position M: contact on
Provided the master switch is closed, the
electrical equipment can be switched on.
Position D: starting position
When the key is released, it automatically
returns to position .
Caution: When the engine is running, the
key cannot be removed or turned to position
St.
OPERATING PANEL IN ENGINE
COMPARTMENT
To enable the engine to be started from the
engine compartment, there is an operating
panel on the engine with a number of push
buttons for various functions.
As a safety precaution the starter button will
only operate with the gear lever in the
neutral position (N).
The switch serves to enable starting the
engine either at the driver’s seat or in the
engine compartment. When this switch has
been set to the latter position, the engine
can be preheated, started and stopped with
the corresponding buttons.
24
DRIVING

PREHEATING SYSTEM
With the contact switched on, the preheating
system is energised with the
tumbler switch in the instrument panel or
with the push button in the engine
compartment control panel.
COLD-START DEVICE (fuel pump)
The cold-start device is activated by pressing
in the spring-loaded tumbler switch.
START PROCEDURE
- Apply the parking brake.
- Switch on the master switch.
- Turn the key to the contact position (on
vehicles not fitted with such a key, the
contact has already been made by closing
the master switch).
- Check whether the battery charge warning
lamp, the oil pressure warning lamp
and the parking brake warning lamp
light up.
- Check whether the gauges indicate.
- Put the gear lever in neutral (N).
- At low outside temperatures use the
preheating system to facilitate starting.
Outside temperature above + 5°C
Vehicles fitted with a contact/starter key:
Depress the accelerator pedal and turn the
contact key to position D. If the engine
misfires, release the key and repeat the
start procedure. Vehicles fitted with a starter
switch: Depress the accelerator pedal and
operate the tumbler switch. If the engine
misfires, release the switch and try again.
DRIVING 25

Outside temperature between 0°C and
+5°C
- Depress the accelerator pedal.
- Press in the spring-loaded tumbler
switch of the cold-start device.
- Start the engine (see above
procedure). If the engine still fails to
start, operate the cold-start tumbler
switch once again.
Outside temperature below 0°C
- Depress the accelerator pedal.
- Press in the spring-loaded tumbler
switch of the cold-start device.
- Preheat for 50-60 seconds.
At extremely low temperatures:
preheat for max. 2-2.5 minutes.
- If necessary, repeat the entire start
procedure.
When the engine starts, do not increase
the engine speed until the oil pressure
warning lamp has gone out and the oil
pressure gauge indicates sufficient
pressure.
DRIVING WITH AN AUTOMATIC
GEARBOX (VOITH D 863, ZF 4HP500,
ZF 5HP500)
These automatic gearboxes have 3, 4 or 5
forward speeds and 1 reverse gear and
also have a built-in hydraulic retarder. The
gearboxes are electrically operated by
selecting the required gear from a row of
gear selector buttons on the instrument
panel.
Depending upon the specific application of
the vehicle, the automatic gearbox offers
the following gear selector positions:
Position D:
In this position the gearbox automatically
changes up and down through all the forward
speeds depending upon the road
speed and the position of the accelerator
pedal. This is the normal automatic driving
program.
On some control panels the D-key is missing.
In such a case press the key with the
highest number (usually the 3) for the normal
automatic driving program.
26
DRIVING

Position N:
This is the neutral position of the gearbox.
Position R:
In this position reverse gear is engaged.
Voith Diwa.3:
Use only little throttle while driving reverse.
Positions 1, 2 and 3:
Depending upon the position selected, the
gearbox will not change up to a higher gear
than the selected one.
In POSITION 1 only the first speed is used.
In POSITION 2 the gearbox can only
change up as far as the second speed. If
the road speed diminishes, the gearbox will
automatically change down to a lower
speed.
In POSITION 3 the same occurs, albeit that
in this case the gearbox will automatically
change up and down through the first, second
and third speeds.
These positions are very important when
the driver wishes to lock the gearbox in a
certain speed to stop it changing up, for example
when driving in mountainous
country.
Starting
The engine can only be started when
position N is engaged.
ZF automatic gearbox
At temperatures below -10°C, start the engine
and run it warm in position N for approx.
10 minutes at 1000 rpm before
driving away.
Driving away from rest
With the vehicle stationary, the parking
brake applied and the engine idling, select
the desired position, wait for 1-2 seconds,
release the brakes, depress the accelerator
pedal and drive away.
Caution: Never engage the selected position
while simultaneously depressing the
accelerator pedal because this will set the
vehicle in motion with an abrupt jerk.
Should you unintentionally engage position
N while the vehicle is in motion, then you
must again select position D in order to
prevent damage to the drive line.
Kick down
A kick-down switch is fitted under the accelerator
pedal. When fast acceleration is
required, the accelerator pedal should be
pushed down to its full extent. Depending
upon the road speed, this will cause the
gearbox to change down automatically to a
lower forward speed.
This is useful, e.g. when driving uphill,
because it enables to select a lower gear
when the vehicle is losing power in the
higher gear.
Driving in mountainous country
Driving uphill
If, for example, and incline is too steep for
the second speed when driving uphill with
position D engaged, but not steep enough
for the first forward speed, then the
gearbox will continuously change UP and
DOWN when full throttle is given. Naturally,
this has a negative influence on the life
expectancy of the gearbox. The gearbox
can, however, be prevented from changing
Up by giving less throttle or, if fitted on the
gearbox, by engaging position 1. After
position 1 has been selected the first
forward speed is locked and the gearbox
can no longer change gear automatically.
DRIVING 27

In principle, this also applies to gear
selector positions 2 and 3 (if fitted on the
gearbox). The gearbox will never change
UP past the selected position. The
kick-down can likewise be used in these
positions.
Driving downhill
When driving downhill in a vehicle
equipped with a fully automatic gearbox,
the gearbox quite often changes UP
automatically to a higher speed, which is
precisely what we do not want. Having the
possibility to select a lower lock-up speed
(by engaging position 3, 2 or 1) prevents
the gearbox from changing UP. In this case
the engine braking effect is retained and
there is less wear on the wheel brakes.
Before commencing to drive downhill be
sure to engage the correct gear selector
position: this is dependent upon the safe
speed of descent.
In order to avoid overspeeding the engine,
the gearbox will change UP under extreme
circumstances, even though the 1st, 2nd or
3rd gear has been selected.
Stopping
The vehicle can always be brought to a halt
irrespective of the selected speed.
After the vehicle has stopped the electronically
controlled gear selector unit
always engages the 1st forward speed. For
brief stops, for example at a traffic light, the
gearbox can be left in position D or in any
one of the selected speeds. In that case,
however, the brake pedal must be applied
to prevent the vehicle from creeping. When
the vehicle is halted for longer periods,
position N should be engaged.
The gearbox is fitted with neutral at stand
still (NBS). This NBS is engaged 3 seconds
after reaching the conditions below:
1 Speed is below 3 km/h.
2 Revs are below 900 rpm.
3 Throttle is in idle position.
4 Brakes on parking brake is applied.
5 Gearbox still in drive (D).
Note This NBS is not real neutral i.e. the
gearbox is not disengaged from the
engine but only from the drive axle.
When normal neutral is selected on
the gear selection panel(N), the gearbox
is disengaged from both rear
axle and engine, the NBS is
inoperative.
Note If the above mentioned 4
conditions are not achieved, the
gearbox will directly switch to first
gear and will attempt to creep
again. Therefore, when stopping at
f.e.a. bus stop where passengers
will leave or come in, apply the
handbrake before opening the
door. Make sure that all
passengers are on board or have
left, the door is closed and the
traffic conditions are right before
releasing the handbrake and
driving off.
When the vehicle is halted for longer
periods, position N should be engaged.
Malfunctioning
When the automatic gearbox malfunctions,
the DNR switch is blinking change down to
a low gear and drive to the nearest DAF
BUS dealer under partial load.
In the event of a serious failure of the Voith
automatic gearbox a warning lamp (B1) on
the SWS panel will flash simultaneously
with the DNR switch. The vehicle must be
stopped without delay to prevent
consequential damage to its drive line.
28
DRIVING

RETARDER
The retarder is a wear-resistant,
hydraulically operated continuous brake
and is therefore extremely suitable as an
auxiliary brake and for driving downhill.
The retarder is engaged by a switch on the
instrument panel and operated by the foot
brake pedal.
When the retarder is used for continuous
braking (for example, during a long descent),
the temperature gauge of the gearbox
oil should be checked regularly. If the
pointer of the temperature gauge should
reach the 150°C mark (start of the red
segment), a warning lamp will then light up
in the gauge and a buzzer, if fitted, will
sound.
Green segment : during normal
driving
conditions.
Green-red segment : when braking
with the retarder.
Red segment : oil temperature
too high.
If the oil temperature has become too high
for a given situation, select a lower speed
program and if the temperature still remains
too high, the retarder should be
disengaged.
If the oil temperature still does not drop, the
vehicle must be stopped, the gearbox put
in the neutral position and the accelerator
pedal fully depressed. After a few seconds
the oil temperature should start dropping
now. If not, the cause will have to be
sought in a defect in the coolant circuit or
in an unduly low oil level in the gearbox.
Note: The retarder is automatically
disengaged if the brakes are applied while
at the same time the accelerator pedal is
depressed. As soon as the accelerator
pedal is released, the retarder will automatically
be engaged again.
STEERING
The steering gear is of the hydraulically
assisted type. The steering wheel should
not be forced when the road wheels are
blocked by an obstacle or when the road
wheels are at full lock as this might cause
damage to the hydraulic pump.
BRAKES
ABS (Anti lock Braking System) (if fitted)
The ABS unit prevents the wheels from
locking during emergency braking or when
braking on a slippery surface. Furthermore,
vehicles equipped with ABS retain their
good steering properties and directional
stability in these conditions.
DO NOT ADJUST YOUR DRIVING STYLE
OR BRAKING TO THE ABS!
In particular, do not brake later and harder
than you would normally do. This will only
cause accelerated wear of the tyres and
the brake system, and you may endanger
other road users who are driving behind
you and who do not have ABS on their
vehicles.
DRIVING 29

PARKING AND STOPPING THE ENGINE
Parking
Apply the parking brake by means of the
lever. Stop the engine.
Switch off the contact and remove the key
from the contact lock (if fitted). Finally
switch off the master switch.
The engine can be stopped in two
different ways:
- By means of the engine stop switch on
the instrument panel.
- By means of the stop push button on the
operating panel in the engine compartment.
Make sure that all hatches and windows
are closed. Lock all the doors.
Service brake and parking/emergency
brake. The service brake is operated by
means of the brake pedal. If the service
brake does not work because of insufficient
air pressure, the parking brake can be used
as an emergency brake. By moving the
parking brake lever slowly backwards, the
vehicle is gradually braked by the spring
brake actuators. When the parking brake
lever is then lifted somewhat and moved
further backwards, it will be locked in
position so that it acts as a parking brake.
In this position the warning lamp on the
instrument panel will come on.
NOTE: When the vehicle is parked on a
gradient, one or more of the following
precautions must also be taken:
- Chock the wheels at front and rear.
- Angle the wheels so that the vehicle
will not move into the traffic stream if it
is accidentally set in motion.
Stopping the engine
Stop the vehicle. Put the gear level in
neutral (N) and run the engine at idle for a
few minutes to let it cool down.
30
DRIVING

MAINTENANCE
GENERAL
The vehicle should be maintained in
accordance with the instructions in the DAF
maintenance manual.
After the first 2000-3000 km a special
maintenance service (2500 km service)
should be carried out. After this the vehicle
should be regularly serviced depending
upon the annual mileage of the vehicle.
This section describes a number of general
maintenance operations. For more detailed
information about maintenance operations
and service intervals please consult the
DAF BUS maintenance manual or you DAF
BUS dealer.
BEFORE THE WINTER SEASON
Cooling system
Check the antifreeze content of the coolant
and add antifreeze to the cooling system as
necessary.
Use ethylene-glycol based antifreeze and
mix in accordance with the manufacturer’s
instructions.
Draining and filling the cooling system
- Move the temperature control slide on
the heater control panel to the WARM
position.
- Remove the filler cap from the cooling
system with caution.
- Drain the cooling system via the drain
taps/plugs on the cylinder block, oil
cooler and radiator.
Do not forget to drain the heating
system (if one is fitted which uses the
engine coolant).
- Fill the cooling system with a mixture of
water and anti-freeze.
- Run the engine for a few minutes and
check the coolant level. Top-up if
required.
The cooling system must be flushed every
TWO YEARS.
The coolant MUST be RENEWED.
COOLANT or ANTI FREEZE should
satisfy the requirement of ASTM
standard D or SAE J 1034.
CORROSION INHIBITORS should satisfy
the requirements of ASTM standard D
3306 of SAE J 1034.
MAINTENANCE 31

Air drier
The operation of the air drier should be
checked regularly. Drain the air reservoirs
at regular intervals. It time and again the
amount of water escaping is excessive
renew the air drier element, but at least
once a year.
Windscreen washer reservoir
- Add screenwash antifreeze to the water
in the reservoir (DAF Part No. 610763).
(Not coolant antifreeze)
Moisture separator in fuel system
Check the moisture separator for the
presence of water or dirt and drain as
necessary by unscrewing milled nut A and
bleed screw B.
Fuel
During the winter months the oil companies
often use additives to prevent blockages
caused by wax deposits. Under extreme
conditions. or if no so-called winter fuel is
available - and if permitted by law - a
maximum of 25% kerosene may be added.
If this is prohibited by law, however a maximum
of 25% two-stroke petrol may be
added (consisting of a mixture of ordinary
grade petrol and engine oil). To prevent the
formation of ice - and if permitted by law -
a maximum of 0.5% methylated spirit may
be added .
AFTER THE WINTER SEASON
Cooling system
The antifreeze mixture may be left in the
cooling system during the summer. In
climates where the temperature never falls
below + 5°C a rust-inhibiting agent should
be added to the coolant.
Check the antifreeze content of the coolant
and add antifreeze as necessary.
Only use coolant or antifreeze which
satisfies the requirements of the specification
in accordance with DAF N 47001 or
SAE J 1034 on account of the light alloy
radiator fitted on these vehicles. Mix the
32
MAINTENANCE

antifreeze in accordance with the
manufacturer’s instructions.
Air drier
The operation of the air drier and the condition
of the filter element should be checked
regularly.
Check for the presence of water in the air
reservoirs and check the heater unit (if
fitted) and the safety valve of the air drier
for correct operation.
Windscreen washer reservoir
It is advisable to add windscreen cleaner
(DAF Part No. 610764) to the water in the
screenwash reservoir.
DAILY MAINTENANCE
Checking the engine oil level
- Pull the dipstick A from its holder.
- Wipe the dipstick clean with a non-fluff
cloth.
- Place the dipstick back in the holder
and wait a few seconds.
- Withdraw the dipstick again and check
the oil level. The oil level should always
be between the two marks on the
dipstick.
- If required, top up through filler hole B
(red). Always use oil of the same brand
and quality grade. Never over-fill with
oil!
MAINTENANCE 33

Check the coolant level
- Remove the filler cap from the
expansion tank with caution.
- Run the engine for a few minutes.
- Switch off the engine and check the
coolant level.
The coolant level should now be
between the MAX and MIN marks.
Top-up with coolant as necessary.
Air pressure in brake system
- Drain the water from the air reservoirs
by pulling the ring.
Wheels and tyres
- Remove any stones, etc. from the tread
and from between the tyres (in the case
of twin wheels).
- Check for evidence of wear and damage
and for nails or other foreign objects
embedded in the tyres.
- Check the attachment of the wheels.
Lighting and instruments
- Check the vehicle lighting, direction indicators,
brake lights and instruments for
correct operation.
- Also check the horn, windscreen wipers
and washers for correct operation.
Driver’s seat and mirrors
- Adjust the seat and mirrors to the correct
position.
34
MAINTENANCE

WEEKLY MAINTENANCE
Hydraulically assisted power steering
With the engine switched off, check
whether the fluid is approx. 2 cm above the
upper mark on the dipstick. Top up as required
with ATF. Start the engine. With the
engine running at idle, the fluid should
come up to the upper mark on the dipstick.
Avoid turning the steering wheel when the
vehicle is standing still and the engine running
because the high pressures involved
could cause damage to the steering gear.
Hydraulic fan drive gear
With the engine running at idle, check
whether the fluid level is situated in the visible
area of the plastic tube. If necessary,
top up with ATF via the filler hole.
Oil level - ZF automatic gearbox
- Stand the vehicle on level ground.
- Engage the neutral position.
- Handbrake on.
- Start the engine and run it at idle.
- Pull the dipstick from its holder and wipe
it clean with a non-fluff cloth.
- Place the dipstick back in the holder.
- Withdraw the dipstick again and check
the oil level. At operating temperature
(approx. 85°C) the oil level should be
between the two A marks. When the
gearbox is cold, the level should be
between the two B marks. Mark C
indicates the minimum level.
MAINTENANCE 35

Oil level - Voith gearboxes
- Stand the vehicle on level ground.
- Engage a gear with the selector lever.
- Handbrake on.
- Run the engine at idle.
- Pull the dipstick (a or b) from its holder
and wipe it clean with a non-fluff cloth.
- Place the dipstick back in the holder.
- Withdraw the dipstick again and check
the oil level. At operating temperature
(min. 60°C) the oil level should be between
the max. and the min. mark.
Batteries
- Check the electrolyte level: this should be
about 5 mm above the cell plates.
Top-up as required with distilled water.
- Check to ensure that the battery poles
and clamps are clean and greased If
necessary, also clean the top of the
battery casing. Coat the battery poles
with acid-free petroleum jelly (vaseline).
Windscreen washer reservoir
Check the fluid level and top-up if required.
Summer season: add a windscreen cleaner
to the water in the screenwash reservoir
(DAF Part No. 610764).
Winter season: add a special screenwash
antifreeze to the water in the screenwash,
reservoir (DAF Part No. 610763).
Tyres
- Check the tyre pressures and tread
depth.
36
MAINTENANCE

PERIODIC MAINTENANCE
Changing engine oil and renewing the
oil filter
- Stand the vehicle on level ground
- Drain the oil sump. Draining the oil
should preferably be done when the
engine is at operating temperature.
- Renew the oil filter. Never refit a used
filter, not even after cleaning!
- Fill the sump with the specified oil
through the oil filler hole.
- Run the engine for some time.
- Check that the oil filter and the oil drain
plug seal off well.
- Check the oil level and, if necessary.
top up.
- These operations must be carried out
every 20.000 km.
Air filter
- Engine off
- Remove the filter cover.
- Remove the nut.
- Take out the filter element.
- Clean the filter housing on the inside.
- Clean the filter element by blowing compressed
air (max. 2 bar) from the inside.
- Renew the filter element after it has been
cleaned two times and at least once a
year.
- The filter element has to be renewed
when it is damaged or no longer seals
off.
MAINTENANCE 37

Checking the V-belts
Check the tension and the condition of the
V-belts. It should be possible to deflect the
V-belts 12-15 mm.
For changing the V-belts see the section
EMERGENCY REPAIRS (Renewing the
V-belts).
Changing the fuel main filter This is
situated next to the oil filter and is the
smaller of the two.
Moisture separator in fuel system
Check for water and dirt and, if necessary,
drain the water with the dirt after unscrewing
the milled screw A and the bleed
screw B.
38
MAINTENANCE

Renewing the power-steering filter
Remove the cap, take out the filter element
and renew.
Renewing the filter of the hydraulic fan
drive gear
Remove the cap, take out the filter element
and renew.
Changing oil and renewing the oil filter
in ZF automatic gearboxes
- Stand the vehicle on level ground.
- Drain the oil (when at operating
temperature) through the drain orifice.
- To drain the oil contained in the gearbox
oil cooler, remove the two drain plugs.
- Unscrew the four filter cover screws and
remove the cover together with the filter.
- After renewing the filter element and the
O-ring, replace the cover.
- Fill the gearbox with oil through the filler
tube.
MAINTENANCE 39

- Check the oil level as indicated in the
section ’WEEKLY MAINTENANCE’.
- These operations should be carried out
in accordance with the maintenance
schedule.
N.B. Gearbox oil should be changed at
least once a year at every 20.000 Km or as
recommended in the maintenance
schedule.
Changing oil and renewing the oil filter
in Voith automatic gearboxes
- Stand the vehicle on level ground
- Drain the oil at operating
temperature:
* Unscrew oil sump screw Ba.
* Drain the oil.
* Unscrew screw Bb (above screw
Ba)
* Drain the oil from the torque
converter
* Refit screws Ba and Bb
- To change the filter:
* Drain the oil from the oil filter (Ad)
* Unscrew cover Ac, take out the filter
element and renew.
- Fill with oil through filler tube Ab.
- Check the oil level as indicated in the
section ’WEEKLY MAINTENANCE’
- These operations to be carried out in accordance
with the maintenance schedule.
40
MAINTENANCE

Automatic chassis lubrication (type
W.V.)
Lubrication is effected with lithium-based
grease NLGI N° 2. A sight glass (1)
enables to see whether there is still
sufficient grease. The minimum level is
indicated by a mark on the sight glass.
Refilling is effected through orifice (2).
When grease emerges at the relief valve,
this means that the maximum level has
been reached.
Differential
- CHECKING THE OIL LEVEL
- Stand the vehicle on level ground.
- Wait a few minutes to allow the oil
level to settle.
- The oil level should reach to the
edge of the filler/level hole B.
- OIL CHANGING
- Stand the vehicle on level ground.
- Drain the oil (at operating
temperature) through drain hole
A.
- Fill the differential through
filler/level hole B.
- Check the oil level.
Front wheel hubs, type N 130
- CHECKING THE OIL LEVEL:
- Stand the vehicle on level ground.
- Wait a few minutes to allow the oil
to settle.
- Rotate the wheels so that the
name DAF on the hub cap is
horizontal and the arrow is pointing
upwards.
- The oil level should reach to the
edge of hole A.
- OIL CHANGING
- Rotate the wheels so that hole A is
undermost.
- Drain the oil when still warm through hole
A.
MAINTENANCE 41

- Rotate the wheels so that the name
DAF on the hub cap is horizontal and
the arrow pointing upwards.
- Fill the hubs with oil through orifice A
until the oil level reaches to the edge.
- Check the oil levels.
Optional:
Depending on the specification grease
lubricated hubs are fitted.
Brakes
- CHECKING THE BRAKE LINING
THICKNESS
The brake lining thickness can be checked
through the inspection hole inspection in
the back plate.
* Apply the parking brake
* Measure the brake lining thickness
through the inspection hole. The min.
permissible thickness is 7 mm.
- ADJUSTING THE BRAKES
Since the vehicle is fitted with automatic
slack adjusters, the brakes need not be adjusted,
but brake chamber push rod travel
needs to be checked on each
inspection/service. Refer to workshop
manual for measurements.
Air drier
The air drier should be checked regularly
for correct operation and also the condition
of the filter element. Check the air
reservoirs for the presence of water and
check the heater unit and the air drier
safety valve for correct operation.
The filter element assembly should be
renewed at least once a year.
Tighten all from the outside accessible
bolts and nuts.
Pay special attention to the wheel nuts and
to the bolts and nuts of the propeller shafts.
Note: Check all pipelines and hoses.
42
MAINTENANCE

EMERGENCY REPAIRS
SERIOUS OIL LEAKAGE
In the case of (serious) oil leakage from
any of the drive line components, drive the
vehicle (if this is still possible) to the
nearest workshop.
BLEEDING THE FUEL SYSTEM
- Slacken the handwheel on the fuel feed
pump and operate the pump until considerable
resistance is felt.
- Retighten the handwheel immediately.
RENEWING THE V-BELTS
- Slacken the attachment and adjusting link
bolts of the alternator.
- Pivot the alternator against the engine
block.
- Renew the belts.
- After the new belts have been fitted, adjust
them to the specified tension and
retighten all bolts and nuts.
NOTE: Always renew the V-belts as a
set. Check the tension of new V-belts
after the first 50 km and 500 km and
subsequently during every service
inspection.
EMERGENCY REPAIRS 43

Mechanically
- Chock the wheels at front and rear.
- Use a ring spanner to turn the bolt
counter-clockwise as far as the stop.
- Repeat this procedure for the other
spring brake actuators.
Restore the parking brake to its normal
operating condition as soon as possible by
turning the bolts clockwise and tightening
them to a torque of 40-50 Nm.
RELEASING THE PARKING BRAKE
With compressed air
- Chock the wheels at front and rear.
- Move the parking brake lever forwards.
The spring brake actuators can be released
by connecting the tyre inflating hose to the
emergency filler connection on the foremost
part of the RH side member. Eventually,
however, the exact position is determined
by the bodybuilder and therefore you
should refer to his instructions.
Air can be obtained from one of the tyres.
- Take care that the pressure in the compressed
air system on no account exceeds
9.8 bar.
FAULTS IN THE ANTI LOCK BRAKE
SYSTEM (IF FITTED)
If the red warning lamp lights up at speeds
higher than about 7 km/h, this indicates a
defect in the Anti-lock Brake System. In
this case, check the fuses in the ABS
switchbox. On the inside of the cover there
is a sticker showing the position of the
fuses and other components. If the fault
cannot be remedied by fitting a new fuse,
the vehicle can still be driven because the
fault only affects the ABS control and the
conventional brake system is therefore still
operating normally. Faults in the Anti-lock
Brake System should always be repaired
by an authorised DAF BUS dealer.
44
EMERGENCY REPAIRS

WHEELS
Spigot-mounted wheels
DAF fits spigot-mounted wheels on its
vehicles. Spigot-mounted wheels have the
following characteristics:
- Wheels with cylindrical bolt holes.
- Wheel nuts with a loose (captive) flat
thrust washer.
- Wheel hub with cast-on letter ’C’.
Caution
USE ONLY THE WHEELS AND WHEEL
NUTS DESIGNED
SPECIFICALLY FOR
SPIGOT-MOUNTING!
Changing wheels
- Chock the wheels.
- Clean the wheel nuts and apply a drop
of oil to the screw thread. Slacken the
wheel nuts.
- Place the jack under the axle, as close
as possible to the wheel that is being
changed. Jack up the vehicle, remove
the nuts and take the wheel off the
hub.
- Before mounting the wheel, carefully
clean the mating edge of the wheel hub
and the inner edge of the spare wheel.
Remove any burrs and remnants of
paint and then apply a thin coating of
grease to the mating edge.
- Clean the wheel studs and apply a drop
of oil to the screw thread.
- Also apply a drop of oil between the
thrust washer and the wheel nut.
- Mount the wheel and gradually tighten
the nuts crosswise to the specified
torque. (see page 47).
- Retorque the wheel nuts after 100 km.
EMERGENCY REPAIRS 45

LEAKAGE IN AIR SUSPENSION SYSTEM
If one of the air suspension bellows
becomes defective, the air delivery line
leading to both bellows on the same axle
should then be disconnected. The delivery
line must also be plugged to prevent the
loss of a substantial amount of the compressed
air in the reservoirs, which is also
needed to operate the brakes.
N.B.
Never attempt to tow start the
vehicle as it has an automatic
gearbox.
INFLATING TYRES
- Remove the cap from the tyre inflating
connection.
- Connect up the tyre inflating hose.
- Inflate the tyre while the engine is running
and with maximum pressure in the
air reservoirs.
Note:
The entire compressed air system can be
filled from the outside via the tyre inflating
connection. Make sure that the pressure in
the system does not exceed 9.8 bar.
TOWING
- Turn the contact key to the position
that unlocks the steering wheel (except
when the vehicle is being towed in a
hoist tackle; see below).
- Move the selector lever to the neutral
position (N).
- Always use a towing bar. Departure
from this rule is only permitted in an
emergency; in this case the maximum
permissible speed is 20-25 km/h.
- If it is supposed that there is a defect
in the gearbox, disconnect the propeller
shaft from the gearbox.
- If there is insufficient pressure in the air
reservoirs, release the parking brake.
- In case of a defect in the differential
hoist the vehicle at the rear end and
lock the steering wheel.
46
EMERGENCY REPAIRS

REPLACING BULBS
For the replacement of bulbs, please refer
to the instructions that are usually supplied
by the bodybuilder. This applies to the interior
lighting and vehicle lighting, including
the alignment of the headlamps.
N.B. When fitting a new headlamp bulb
make sure that the projection on the bulb
holder engages the recess in the reflector.
Never touch the glass of a halogen bulb
with your bare fingers. After replacing the
bulb the headlamp alignment should always
be checked.
Tachograph
Rotate the lamp E a quarter-turn, remove
and replace.
FUSES
All the usual fuses are located on the central
panel of the electrical system. For the
location of this central panel, please refer
to the instructions that are usually supplied
by the bodybuilder.
Caution: Never replace a burnt-out fuse
with one of a higher rating!
Note: For the list of fuses, please refer to
the wiring diagram and to the possible additional
information supplied by the
bodybuilder.
EMERGENCY REPAIRS 47

SPECIFICATIONS
Unless otherwise stated, the specifications given here apply to all
variants of the SB 220 series.
No additives of any kind may be mixed with the fuel or
lubricants, except in those cases specified by DAF.
SPECIFICATION OF COMPONENTS OF THE SB 220 SERIES
Engine LT 160 C/
Later models LT 160 L (8 NOx)
Gearbox
Voith D 863/D851.3
ZF4HP500
ZF5HP500
Rear axle 2255/later models 1339
Front axle N 130
Steering gear
box ZF 8043
pump ZF 7674
ENGINES
Make
DAF
Type
LT 160 : water cooled, four-stroke
diesel engine with direct fuel injection
and piston cooling, turbo compressor
Number of cylinders 6
Bore x stroke
130 x 146 mm
Cubic capacity
11.6 litres
Compression ratio LT 160:15:1;
Idling speed
600-650 rpm
Max. no-load speed 2160-2200 rpm
Max. speed under load 2000 rpm
Thread
metric, to ISO standards
Valve clearance
0.5 mm
Lubricating system
capacity, incl. filters
and coolers
approx. 29 litres
oil sump capacity, max. level approx. 25 litres
min. level approx. 17 litres
oil pressure
at idling speed
min. 1 bar
at 2000 rpm (hot engine) max. 4.2 bar
Cooling system
capacity, excl. heater approx. 90 litres
operating temperature 79-92 ° C
coolant according to SAE J 1034
Fuel system
injection timing 22° BTDC LT 160 G/
14° BTDC LT 160 L
firing order 1-5-3-6-2-4
injection pressure
200-220 bar
Fuel
fuel tank
Tightening torques
cylinder head nuts
cylinder head bolts
injection line union nut
2x150 ltr. or 1x250 ltr. or 2x172 ltr.
215 Nm
50 Nm
max. 25 Nm
48
EMERGENCY REPAIRS

Engine oil
Viscosity
The temperature limits should be
considered as approximate. * When
using SAE-10W oil, avoid long
periods of driving at high engine
speeds and high engine loads if
the temperature rises above the
indicated values.
AUTOMATIC GEARBOXES
Type VOITH, D 863
Number of forward gears 3
Ratios
1st speed 5.50:1
2nd speed 1.36:1
3rd speed 1.00:1
reverse gear 3.66:1
Oil capacity
approx. 25 litres
Type Voith, D851.3
Number of forward gears 3
Ratios
1st speed 5.20:1
2nd speed 1.36:1
3rd speed 1.00:1
reverse gear 3.80:1
Oil capacity
approx. 23-26 litres
Specifications of engine lubricants
CCMC-D5
If CCMC-D4 engine oil is used instead of the D5 grade specified,
the maximum oil change interval will be 5.000 km, irrespective of
the sulphur content of the fuel.
Type ZF 4 or 5 HP 500
Number of forward gears 4 or 5
Ratios
1st speed 2.81: 1
2nd speed 1.84: 1
3rd speed 1.36: 1
4th speed 1.00: 1
5th speed 0.80: 1
reverse gear 3.97: 1
Oil capacity
approx. 30 litres
SPECIFICATIONS 49

SPECIFICATION OF GEARBOX LUBRICANTS
VOITH gearboxes
Refer to the list of lubricants issued by Voith, N° G 607.
ZF gearboxes
Refer to the list of lubricants issued by ZF, N° TE-ML 14.
Note: The lubricant type used in these two gearbox types is ATF
REAR AXLE
Type 2255
Ratios 4.10: 1
4.56: 1
5.14: 1
5.72: 1
Capacity
approx. 15 litres
Type 1339
Ratios 3.31:1
3.73:1
4.10:1
4.56:1
Capacity
approx. 18.5 litres
Specification of lubricants for the driven axles
FRONT AXLE
Type N 130
Camber 1 °
King pin inclination 7°30’
Caster 3°
Toe-in
0-1 mm
Max. turning angle 55°-57°
Hub capacity
0.5 litres
AIR SUSPENSION
Front axle
- Two bellows with levelling valve
- V-shaped torque rod to keep the axle in place
Rear axle
- Four bellows with two levelling valves
STEERING GEAR
Type
hydraulically assisted
Type numbers
box 8043
pump 7674
Fluid
ATF, type A, suffix A or ATF
Dexron type
Capacity
approx. 4 litres
Type Viscosity Lubricant
2255 85W140 API-GL 5
1339
50
SPECIFICATIONS

BRAKE SYSTEM
Service brake
Front wheel brakes
Rear wheel brakes
Parking brake
Reservoirs
operating pressure
min. permissible pressure
dual circuit air brakes
drums
drums
spring brake actuators on
the rear axle
9.8 bar
5 bar
ELECTRICAL SYSTEM
Starter motor
type
Bosch
output
5.5 kW
Alternator
number 1
type
Bosch
output
28V/120A
Battery
number 2
voltage
24 V
capacity
200 Ah
WHEELS AND TYRES
Tightening torque,
wheel nuts
700 Nm
Wheel sizes
22.5 x75(10studs)
Tyre size 275/70 R 22.5 or 11/70 R 22.5
Tyre pressure
Refer to the tyre pressure table of
the relevant tyre manufacturer
SPECIFICATIONS 51

LUBRICATION CHART
grease
engine oil
transmission fluid
hypoid oil
Legend
1. Front axle brake camshafts
2. Front wheel bearing
3. King pins (top and bottom)
4. Differential
5. Rear axle brake camshaft
6. Rear wheel bearings
7. Universal joints
8. Automatic gearbox
9. Hydraulic fluid reservoir,
power steering
10. Hydraulic fluid reservoir, fan
drive unit
11. Engine oil sump
brake fluid
C = check
S = symmetric
V = change/renew
automatic
transmission fluid
LUBRICATION CHART 53

54
FUSES

E000 7.5A fuse, LH end/outline marker/tail light
E001 7.5A fuse, RH end/outline marker/tail light
E004 7.5A fuse, dipped beam, driver’s side
E005 7.5A fuse, dipped beam/dipped beam warning lamp,
co-driver’s side
E006 7.5A fuse, main beam, driver’s side
E007 7.5A fuse, main beam/main beam warning lamp, co-driver’s
side
E009 7.5A fuse, fog lights
E010 7.5A fuse, rear foglamps
E013 7.5A fuse, stop lights
E016 7.5A fuse, reversing lights
E017 7.5A fuse, hazard warning system/tachograph measuring
system (A3)
E019 7,5A fuse, operation, preheating
E022 7.5A fuse, hazard warning system
E023 7,5A fuse, cold-starting switch/tachograph clockwork
(A1)/auxiliary heating timer unit (1)
E024 7.5A fuse, wipe/wash/intermittent wipe
E025 15A fuse, windscreen wiper motor/headlamp washer motor
E026 7.5A fuse, cigar lighter
E029 7.5A fuse, retarders/exhaust brake
E035 7.5A fuse, instruments and warning lamps
E040 7.5A fuse, ABS (9)
E041 7.5A fuse, ABS (1)
E042 7.5A fuse, ABS (19)
E049 7,5A fuse, central lubrication (30)
E050 7,5A fuse, central lubrication
E051 7,5A fuse, ECAS (1)+
E053 7.5A fuse, ECAS (16-pole diagnostic connector)
E055 7.5A fuse, EGAS (6/2)
E056 7.5A fuse, EGAS
E061 7,5A fuse, ECAS, bus
E065 7.5A fuse, starter interlock relay/additional operation
E084 7.5A fuse, lighting
E089 7.5A fuse, compact tachograph, VLG A1
E091 7,5A fuse, air drier heater element
E101 7.5A fuse, neutral position, Easy-shift
E107 15A fuse, central safety switch
E109 7.5A fuse, oil sump filling system/engine fuel valve
E111 25A fuse, turntable
E119 7,5A fuse, control relay, power supply unit injector
E201 15A fuse, engine compartment fan
E226 7,5A fuse, battery charge
E227 7,5A fuse, bus stop brake
E228 7,5A fuse, engine protection system
E231 Fuse oil sump filling system
E232 Fuse start relay
FUSES 55

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