Operating Instructions 03.2003 Evobus Gmbh

Operating Instructions 03.2003 EvoBus GmbH

Not to be reprinted, reproduced or translated in any form without prior permission.

Address for orders: EvoBus GmbH Service Documentation D-89077 Ulm Printed in Germany

Order no. U 02 2 00 005 02 Parts no.: Introduction

The user information that is enclosed with each bus is only intended for use by upon the contents of this user information. those persons who are qualified to operate the bus. The user information is split into the following parts: Environmental protection: EvoBus GmbH declares that it is committed to integrated environmental protection that acts upon the original aspects and incor- • The operating instructions (OI) provide answers to all important questions porates all effects resulting from production processes and products upon the on operation of chassis components. environment in its corporate decisions.

• The service manual (SM) serves as the guideline for maintaining chassis The goals are to use resources sparingly and respect the natural means of liveli- components from the technical standpoint. It includes all notes on main- hood that must be preserved to serve mankind and nature. tenance intervals and tasks as well as pages reserved for certification that service tasks have been carried out. You can also help the environment and operate the bus in an environmentally- friendly way. Please read and note the contents of the "General instructions" section in the "Overall bus 00" chapter before you take your bus into operation for the first Fuel consumption and wear and tear in the drive train (engine, clutch, transmis- time. sion, axles, brakes, tyres) are extremely dependant upon the driving technique.

Before the bus is driven please make sure that you have read and understood the We hope you enjoy driving your bus. content of these operating instructions. The contents are divided into engineering design groups. EvoBus GmbH Mercedes-Benz Omnibusse Standard chassis equipment is described in the user information. Extras are also described if they need an explanation. The bus delivered to you has been cus- tomised in accordance with your order, therefore some descriptions and diagrams may differ from the equipment on your bus. The superstructure manufacturer is responsible for describing any modifications it may have made to the chassis.

The operating instructions and service manual are important documents and must always be carried in the bus.

Our buses are the subject of ongoing development. You are therefore asked to appreciate that we reserve the right to make modifications to the form, equipment and technical features. For these reasons, no claims can be made based

OC 500 LE/03.2003 GB

Table of contents

Vehicle identification ...... 1 Towing the bus ...... 00/58 Tow start the bus ...... 00/59 00 Overall bus Chassis technical data ...... 00/60 General Information / Safety Information ...... 00/ 1 Driving preparations - daily tasks ...... 00/ 5 01 Engine Driving preparations - weekly tasks ...... 00/ 5 General Information / Safety Information ...... 01/ 1 Scheduled maintenance tasks ...... 00/ 6 Starting the engine by using the key switch on the steering column ...... 01/ 2 Running-in ...... 00/ 6 Starting the engine with a button switch (optional extra) ...... 01/ 4 Indication display unit ...... 00/ 8 Driving ...... 01/ 6 Adjusting the instrument lighting ...... 00/14 Switching off the engine ...... 01/ 6 Multi-function display (MFD): indication displays ...... 00/14 Engine technical data ...... 01/ 8 "MFD": setting the trip odometer to "0"...... 00/15 Removing the drive belt ...... 01/ 9 "MFD": adjusting the time ...... 00/16 Removing the fan drive belt ...... 01/ 9 Driver information system (DIS) display: symbols ...... 00/16 Removing the generator 2 drive belt (optional extra) ...... 01/10 "DIS" display: system codes ...... 00/34 Removing the water pump drive belt (refrigeration compressor, generator 1) 01/10 "DIS" display: retrieve information by using the function switches ...... 00/35 Removing the generator drive belt (with air-conditioning system) ...... 01/11 Instrument panel indicator lamps ...... 00/41 Fitting the drive belts (OM 457 hLA) ...... 01/12 Instrument panel switches and buttons ...... 00/42 Fitting the generator drive belt (with air-conditioning system) ...... 01/12 Light rotary switch ...... 00/48 Replacing the water pump drive belt (refrigeration compressor, generator 1) 01/13 Combination switch for lights and wiper functions ...... 00/48 Fitting the generator 2 drive belt (optional extra) ...... 01/14 Multi-function stalk for permanent brakes and tempomat (optional extra) . . . 00/49 Fitting the fan drive belt ...... 01/14 Adjustable steering column ...... 00/52 Checking the engine oil level with the dipstick ...... 01/15 Driving switch ...... 00/52 Tachograph ...... 00/53 20 Cooling Speedo module (on model without tachograph) ...... 00/54 Emergency operation of the engine cooling system fan drive ...... 20/ 1 Parking brake valve ...... 00/55 Checking the coolant level for the engine and heater systems ...... 20/ 2 3-button automatic gearbox gear-change unit ...... 00/56 6-button automatic transmission gear-change unit (optional extra)...... 00/56

OC 500 LE/03.2003 GB I Table of contents

27 Automatic transmission Anti-blocking system (ABS) ...... 42/ 7 Operation ...... 27/ 1 Traction control system (TCS) (optional extra) ...... 42/ 8 Frequent stop brake ...... 42/11 32 Suspension Automatic frequent stop brake (optional extra) ...... 42/12 General Information / Safety Information ...... 32/ 1 Brake system reservoir pressure...... 42/13 Operation of the electronic level control (NR level control) (optional extra) . . 32/ 3 Lowering the bus at the entrance side (kneeling) (optional extra) ...... 32/ 3 43 Permanent brakes Raising the bus body to the 2nd driving level (optional extra) ...... 32/ 5 Permanent brakes (wear resistant auxiliary brakes) ...... 43/ 1

40 Wheels and tyres 46 Steering General Information / Safety Information ...... 40/ 1 General Information / Safety Information ...... 46/ 1 Tyre pressure table 275/70 R 22.5 ...... 40/ 4 Adjusting the steering column ...... 46/ 2 Tyre pressure table 11 R 22.5 ...... 40/ 6 Turning the steering wheel when the bus is stationary ...... 46/ 2 Tyre pressure table 295/80 R 22.5 ...... 40/ 7 Steering hydraulic system oil level too low ...... 46/ 3 Positioning the jack ...... 40/ 8 Checking the oil level in the steering hydraulics expansion tank ...... 46/ 4 Front axle ...... 40/ 8 47 Fuel system Driven axle...... 40/ 9 General Information / Safety Information ...... 47/ 1 Removing the wheel nut cover cap ...... 40/10 Draining water from the fuel pre-filter ...... 47/ 2 Removing the wheels ...... 40/11 Changing the fuel pre-filter ...... 47/ 3 Mounting the wheels ...... 40/12 Changing the main fuel filter ...... 47/ 5 Inflating the tyres from the tyre inflation connection (optional extra) ...... 40/15 Bleeding the fuel system ...... 47/10 42 Brake chassis/component 54 Electrical equipment, instrumentation General Information / Safety Information ...... 42/ 1 General Information / Safety Information ...... 54/ 1 Braking and stopping ...... 42/ 2 Removing terminals from the bus batteries ...... 54/ 3 Applying/releasing the parking brake ...... 42/ 2 Recharging the bus batteries ...... 54/ 5 Emergency braking with both brake circuits fail ...... 42/ 5 Notes on jump starting ...... 54/ 6 Brake system (BS) ...... 42/ 5 Carrying out the jump start ...... 54/ 7 Brake assistant system (BAS) ...... 42/ 7 Handling fuses ...... 54/ 8

OC 500 LE/03.2003 GB II Table of contents

OC 500 LE/03.2003 GB III

Operating Instructions Overall bus 00

Vehicle identification Bus

C634.220

Installation location The Vehicle Identification Number (VIN) (1) is stamped on the skeleton tube in the area of the steering gear in front of the front axle on the left hand side.

On RHD buses the steering gear and the VIN are located on the right hand side.

It is very important to identify the bus exactly so that the correct "technical data" can be applied.

M00_00-0221-01

OC 500 LE/03.2003 GB 1

Operating Instructions Overall bus 00

General Information / Safety Information Bus

C634.220

Symbol usage and meaning Safety instructions and other important instructions are highlighted by symbols In addition to the content of the specified instructions, the safety and accident prevention regulations promulgat- ed by occupational health and safety authorities are to be adhered to. Additionally, instructions printed on packaging for components, organisational resources and service products are to be followed. When instructions are applied, it is always assumed that user information is aimed only at persons who are qualified to implement the necessary tasks because of their training, experience and instruction. These persons should also be able at the same time to detect and prevent risks that may arise when these activi- ties are carried out. Meaning of symbols:

Notes about important additional information

Warning notices about damage to property that may possibly occur if the notice is not heeded

Danger! Warning notices for risks to people

Notices about environmental protection measures Reference to more detailed and additional user information

Notes on bus safety We recommend that you:

- Only use original parts that have been inspected to meet the OMNIplus quality standards and have been authorised by EvoBus for the respective bus type. Such parts for conversion or accessories are to be used in order not to endanger the warranty, traffic safety and validity of the operating licence. The safety, reliability and suitability of these parts have been determined in a suitable test.

OC 500 LE/03.2003 GB 00/1 Operating Instructions Overall bus 00

You can obtain further information from any EvoBus ServicePartner.

Operating safety

- Any work or modifications that have been carried out incorrectly on the chassis may result in malfunctions.

- Intrusions into electronic components and their software may cause malfunctions. As electronic components are networked, these malfunctions may also result in faults in systems that are nor directly connected. These malfunctions may considerably endanger the bus operating safety.

- Subsequently installed electrical or electronic devices must possess type-approval pursuant to Directive 95/54/EG or ECE Directive 10/02.

- Materials that are installed in the bus as the result of installation, conversion or modification and which fall within the conditions for components that have to be fireproof must also satisfy the conditions of EU Direc- tive 95/28/EG.

- Materials and components in seats and seat fixing units that are also installed in the bus as the result of installation, conversion or modification and which fall within the conditions of components that have to be fireproof must also satisfy the following directives: 76/115/EWG in the version 96/38/EG, 74/408/EWG in the version 96/37/EG, 77/541/EWG in the version 96/36/EG

- Information in the relevant certificate must be noted when such materials and components are purchased or installed. Use of materials and components that do not possess the certificate named above can result in the operating licence being withdrawn,

- We recommend that you allow an EvoBus ServicePartner to carry out any work or modifications.

Navigation and location system Please follow the instructions below if your bus is fitted with a navigation system:

- Please devote your attention principally to the other road traffic.

- Only operate the navigation and location system when the bus is stationary. Please remember that your bus covers 14 m in each second when it is travelling at only approximately 50 kph.

OC 500 LE/03.2003 GB 00/2 Operating Instructions Overall bus 00

- The navigation system is unable to detect the maximum load for bridges or the maximum rated height for driving under underpasses. The driver has the task of checking maximum bridge loads and drive-through heights.

Operation of the radio and mobile communications equipment (e.g. telephone, radio, fax machine etc.)

Danger! Accident risk.

- Please devote your attention principally to the other road traffic.

- Only operate the display unit, radio or a mobile communication device if the traffic situation permits this. Please remember that your bus covers 14 m in each second when it is travelling at only approximately 50 kph.

- Pursuant to section 23, subsection 1 a of the German Road Traffic Regulations, the bus driver is not permit- ted to use a mobile phone or vehicle phone in the Federal Republic of Germany if it is necessary to lift up or hold the mobile phone or the handset of the vehicle phone.

Danger! Please observe the legal requirements for the operation of mobile phones or vehicle phones in each country.

Operation of mobile phones and radio equipment without an external antenna We recommend that the making of telephone calls in the bus without an external antenna should not be allowed as the operation of radio transmission equipment including radio telephones (mobile phones) may result in the malfunction of inadequately protected medical equipment (cardiac pacemakers).

If a mobile phone, radio or fax is subsequently fitted into the bus in a way that does not comply with the EvoBus installation instructions the operating licence of your bus may be withdrawn (EU directive 95/ 54/ EG).

Installed furnished parts (e.g. ticket printer, ticket-cancelling machine, direction indication display etc.), as they are called, that are continued to be used in new buses must comply with the technical requirements of EU Directive 72/245 EWG,.

Danger! Please observe the legal requirements for the operation of mobile phones or vehicle phones in

OC 500 LE/03.2003 GB 00/3 Operating Instructions Overall bus 00 each country.

Definition of the name used for sales e.g. OC 500 LE 1825h OC - Abbreviation for "Omnibus Chassis"

500 - Series designation = 500

LE - Abbreviation for "Low Entry"

18 - Rated gross weight in tons = 18 tons

25 - Approx. engine output in bhp/10 = approx. 250 bhp h - Installation position of the engine h = horizontal (lying) installation position

OC 500 LE/03.2003 GB 00/4 Operating Instructions Overall bus 00

Operation Bus

C634.220

Driving preparations - daily tasks

• Check the fuel supply for the bus driving engine Switch off the engine and auxiliary heating before and auxiliary heating you refuel.

• Insert a tachograph disc. The indicator lamp in the tachograph lights up if a disc is not fitted.

Driving preparations - weekly tasks

• Check the coolant level in the cooling system and See Chapter 20. refill if necessary. Check the concentration of the anti-corrosion antifreeze and correct if necessary whenever coolant has been topped up. • Check the oil level in the hydraulic steering system See Chapter 46. and refill if necessary. • Check the tyre pressure and tyre condition (also See Chapter 40. on the spare wheel). Check the wheel nuts are firmly seated. • Check the condition of all drive belts. • Carry out a visual check to ensure there are no leaks on the engine, transmission, driven axle, steering and the cooling system.

OC 500 LE/03.2003 GB 00/5 Operating Instructions Overall bus 00

Scheduled maintenance tasks

• Carry out tasks according to the service manual Maintenance tasks must be carried out on the chassis and the engine transmission unit at regular intervals to maintain the chassis operational safety and roadworthiness. The time intervals and the scope of the required tasks are specified in the enclosed service manual and must be adhered to.

Our sales and delivery terms do not permit us to recognise claims made under the warranty if the periodic service and maintenance tasks have not been carried out at the prescribed distances or times. Have the tasks in the service manual confirmed by an EvoBus ServicePartner.

Running-in

• It is of crucial significance for the serviceable life, Regulations for running-in the bus: Up to 2000 operating safety and economy of the bus that the en- km – run-in carefully. No higher than 3/4 of the max- gine is not run at full speed during its running-in peri- imum rpm in each gear. After 2000 km – slowly in- od. crease to full speed.

OC 500 LE/03.2003 GB 00/6 Operating Instructions Overall bus 00

For technical reasons this page is empty

OC 500 LE/03.2003 GB 00/7 Operating Instructions Overall bus 00

Overview Bus

Indication display unit C634.220

M68_00-0062-09

OC 500 LE/03.2003 GB 00/8 Operating Instructions Overall bus 00

Pos. Description Pos. Description

1 Coolant temperature display 20 Clutch fluid level indicator lamp

2 Fuel level display 21 Flame system indicator lamp

3 Turn indicator left / hazard warning light indicator lamp 22 Red warning lamp STOP

4 Road speed display 23 Not assigned

5 High beam indicator lamp 24 Not assigned

6 Parking brake indicator lamp 25 Not assigned

7 Red/yellow fault lamp 26 Not assigned

8 Driver information system (DIS) display 27 Not assigned

9 Multi-function display (MFD) 28 Not assigned

10 Frequent stop brake indicator lamp 29 Adjust clock/Increase instrument lighting brightness

11 Permanent brake indicator lamp 30 Adjust clock/Decrease instrument lighting brightness

12 Engine speed display 31 Reset trip meter to "0"/Adjust clock/Store

13 Turn indicator right / hazard warning light indicator lamp 32 Show trip meter or clock

14 Reservoir pressure display brake circuit 1 33 Menu/Exit

15 Reservoir pressure display brake circuit 2 34 Move up menu

16 Fire in engine compartment indicator lamp 35 Move down menu

17 TCS active indicator lamp 36 Enter/Select

18 Engage brake indicator lamp 37 Reset

19 Auxiliary heating indicator lamp

OC 500 LE/03.2003 GB 00/9 Operating Instructions Overall bus 00

Display instruments Bus

C634.220

Indicating instrument, overall Detailed description

After the driving switch has been switched on, the indication display unit performs a check of all indicator lamps. All indicator lamps must light up for approx. 10 seconds. Parking brake indicator lamp (6) The "parking brake" indicator lamp (6) lights up when the parking brake is applied.

See Chapter 42 for safety and operating instructions.

M54_00-0760-01

OC 500 LE/03.2003 GB 00/10 Operating Instructions Overall bus 00

Frequent stop brake indicator lamp (10) The "frequent stop brake" indicator lamp (10) lights up when the frequent stop brake is active.

See Chapter 42 for safety and operating instructions. And the superstructure manufacturer's operating instructions.

M00.00-0144-01

Permanent brake indicator lamp (11) The "permanent brake" indicator lamp (11), lights up when the permanent brake is engaged.

If the indicator lamp does not go out when the permanent brake is disengaged: do not engage the permanent brakes, have an EvoBus ServicePartner rectify the fault.

See "Chapter 43" for safety and operating instructions.

M00.00-0144-01

OC 500 LE/03.2003 GB 00/11 Operating Instructions Overall bus 00

Fire in engine compartment indicator lamp (16) The "fire in engine compartment" indicator lamp (16) lights up when a fire is detected in the engine compartment (optional extra).

Danger! Stop the bus immediately heeding the traffic situation. Request the passengers leave the bus. Ini- tiate fire fighting action.

M54_00-0760-01

TCS active indicator lamp (17) The traction control system (TCS) (optional extra) prevents the drive wheels from spinning when the bus starts to move or accelerates, regardless of the road conditions. The "TCS" indicator lamp (17) lights up when the TCS engages and for approx. 10 seconds after the driving switch has been switched on. The indicator lamp flashes if the "TCS" was switched off at the switch on the instrument panel.

Danger! Accident risk. – The TCR does not release the driver from the requirement to drive according to traffic and road conditions. – The bus could skid if the TCR is switched off and the drive wheels spin.

See Chapter 42 for safety and operating instructions.

M54_00-0760-01

OC 500 LE/03.2003 GB 00/12 Operating Instructions Overall bus 00

The "engage brake" (18), "auxiliary heater" (19), "clutch fluid level" (20) and "flame system" (21) indicator lamps are not activated in the OC 500 LE. The indication display unit is also used in other bus series.

M54_00-0760-01

Red warning lamp "STOP" (22) The red warning lamp "STOP" (22) lights up when a serious fault is detected on the bus and the operational reliability and/or bus roadworthiness is endangered.

Danger! Stop the bus immediately (heed the traffic situation) and switch off the engine. Ascertain the cause.

M00.00-0140-01

OC 500 LE/03.2003 GB 00/13 Operating Instructions Overall bus 00

Adjusting the instrument lighting The brightness of the instrument lighting can be adjusted steplessly. Keep switch (1) pressed down = instrument lighting lighter, keep switch (2) pressed down = instrument lighting darker

The driving switch must be switched on.

M00_00-0138-01

Multi-function display (MFD): indication displays The information below is displayed to the driver: gear display (1), total distance travelled (2), time or trip odometer (3).

Functional check: after the driving switch is switched on all segments in the MFD are briefly displayed.

M54_00-0696-01

OC 500 LE/03.2003 GB 00/14 Operating Instructions Overall bus 00

"MFD": displaying the trip odometer or time Press switch (4). The indication display changes from the time to the trip odometer.

When switch (4) is pressed again the indication display changes back to the time.

The time is always displayed after the driving switch is switched on.

M00_00-0138-01

"MFD": setting the trip odometer to "0". Press button (3): the trip odometer is set to "0".

Reset to "0" is only possible when the trip odometer is displayed in the MFD.

M00_00-0138-01

OC 500 LE/03.2003 GB 00/15 Operating Instructions Overall bus 00

"MFD": adjusting the time Press switch (3). The set hours flash. To adjust the hours press switch (1) or (2). Press switch (3) again. The set minutes flash. To reset the minutes press switch (1) or (2). The indication display stops flashing after approx. 5 seconds if switch (1) or (2) is not pressed. The set time is automatically stored.

Danger! The time in the tachograph display changes simultaneously. However, the clock for the tachograph record sheet holder is only adjusted if record sheets are not inserted: remove the record sheets and close the record sheet holder without it containing any record sheets.

M00_00-0138-01

Driver information system (DIS) display: symbols Operational information and warnings are automatically displayed to the driver in the DIS display (8) and the status indication display (7).

M54_00-0761-01

OC 500 LE/03.2003 GB 00/16 Operating Instructions Overall bus 00

Operational information Symbols are used to show status conditions on the DIS display (8). The status indication display (7) does not light up.

Example: "external temperature" is displayed as operational information for the basic display.

M54_00-0761-01

Several operational information displays can be shown simultaneously.

Example: 1 = the temposet function has been used to limit the maximum speed to 60 kph. 2 = the current external temperature is +18° C.

M54_00-0702-01

OC 500 LE/03.2003 GB 00/17 Operating Instructions Overall bus 00

Warnings Warnings: Symbols (1) or a system code are used to indicate those faults on the DIS display (8) that endanger the operating safety and/or roadworthiness of the bus. Simultaneously, the status indication display (7) lights up in yellow or red.

When the status indication display (7) lights up in yellow: the bus may continue to be moved with care, but the cause of the warning must be rectified as soon as is possible.

Danger! When the status indication display (7) lights up in red: the bus must be stopped immediately (if traffic conditions allow) and an EvoBus ServicePartner must be notified.

M54_00-0728-71

All pending warnings and operational information are shown in succession in the "DIS" display. The display field changes every 5 seconds. The colour of the status indication display (7) also changes in response to the fault significance.

M54_00-0728-71

OC 500 LE/03.2003 GB 00/18 Operating Instructions Overall bus 00

"DIS" display: memory field When a warning is displayed the indication display can be transferred into the memory field. To do this, press switch (6). If several warnings are pending they are display in succession when the button (6) is pressed. After all the warnings have been displayed they are moved into the memory field.

M00_00-0137-01

The warning displays change to the memory field (1). The status indication display (7) corresponding to the memory field lights up in yellow or red depending upon the fault significance. Within the memory field, all pending warning displays are shown in succession.

This is necessary so that any operational information pending on "DIS" display is continuously displayed and further information can be retrieved by using the function switches.

M54_00-0698-01

"DIS" display: symbols The following symbols can be displayed on the DIS display:

OC 500 LE/03.2003 GB 00/19 Operating Instructions Overall bus 00

External temperature The sign (+ = above 0 °C/– = below 0 °C) is shown in front of the temperature figure. The external temperature is automatically displayed after the functional check is complete. The DIS display is empty if there is a malfunction in the external temperature display.

Danger! Accident risk. When the displayed temperature is close to the freezing point the road surface may already be icy, especially in lanes and on bridges. Sudden changes in temperature (e.g. after exiting from a garage or tunnel) are displayed after a time delay.

Limiter (optional extra) Is shown when temposet is activated. The set speed is also displayed.

Activation of temposet: see "Multi-function stalk for permanent brakes and tempomat"

OC 500 LE/03.2003 GB 00/20 Operating Instructions Overall bus 00

Tempomat (optional extra) Is displayed when tempomat is in operation. The set speed is also displayed.

Tempomat operation: see "Multi-function stalk for permanent brakes and tempomat"

Coolant level Is displayed when the coolant level in the expansion tank has dropped to under the minimum capacity.

At the next stop ascertain the cause and top up with coolant to the correct coolant level. Considerable damage to the engine can be caused if the coolant level is too low.

Danger! If the status indication display simultaneously lights up red then the coolant must be topped up immediately.

See Chapter 20 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/21 Operating Instructions Overall bus 00

Top up engine oil The "Top Up Engine Oil" symbol is shown in the DIS display if the oil level in the engine has dropped to the minimum capacity. The necessary top-up amount in litres is also shown.

When the engine oil level is too low the operating safety of the engine is put at risk (damage to engine possible). Avoid high engine speeds. Top up with engine oil the correct engine oil level at the next stop. If possible, fill up with the fully recommended top-up amount (approx. 6 litre). Do not overfill under any conditions.

Danger! The engine oil must be topped up immediately if the status indication display simultaneously lights up red.

See Chapter 01 for safety and operating instructions.

Engine oil overfilled The oil level in the engine is more than 2 l above the maximum capacity if the warning "Engine Oil Overfilled" is shown in the DIS display.

Danger! The operating safety of the engine is put at risk when the engine oil level is too high (damage to engine possible). Avoid high engine speeds. Siphon off or drain off at least 2 l oil. Retrieve and correct the current engine oil level.

See Chapter 01 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/22 Operating Instructions Overall bus 00

Oil pressure The warning display "Engine oil pressure" is shown in the DIS display when the oil pressure is too low in the engine.

Danger! Stop the bus immediately (heed the traffic situation), switch off the engine then determine and rectify the cause. Considerable damage can be caused to the engine if the oil pressure is inadequate.

Power steering oil level Is displayed when the oil level in the storage tank for the power-steering pump has dropped to the minimum capacity.

Danger! Stop the bus immediately (heed the traffic situation), switch off the engine then determine and rectify the cause. There is a risk of accident if there is oil loss as this may result in heavy steering.

See Chapter 46 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/23 Operating Instructions Overall bus 00

Engine protection function information The operational information "Engine protection" is displayed when the coolant temperature reaches approx. 105 °C in whilst the bus is being driven.

The engine output is reduced automatically. Determine the cause and have it corrected, possibly by an EvoBus ServicePartner.

The cause for the coolant temperature being too high may be a too-low coolant level (see Chapter 20), a defective or badly tensioned drive belt (see Chapter 01) or a defective fan connection (see Chapter 20).

Indication display breakdown Is displayed when important operational information, warnings or events can no longer be shown in the DIS display.

Danger! Accident risk. The bus driving and braking characteristics may change. Stop the bus (heed the traffic situation) and switch off the engine. Faults that alter the bus driving and braking characteristics can no longer be displayed. Have an EvoBus ServicePartner rectify the fault.

OC 500 LE/03.2003 GB 00/24 Operating Instructions Overall bus 00

Reservoir pressure brake circuits 1-3 The reservoir pressure in brake circuits 1, 2 (under 6.8 bar) or 3 (under 5.5 bar) is too low.

Danger! Stop the bus immediately (heed the traffic situation). Have an EvoBus ServicePartner inspect the brake system. – Only continue driving after the indication display has gone out when the compressed air consumption is too high (e.g. after activating the lifting and lowering system and simultaneously manoeuvring). The fault is cancelled only when 7.2 bar is exceeded.

See Chapter 42 for safety and operating instructions.

Reservoir pressure auxiliary consumers Is displayed when the reservoir pressure in the auxiliary consumer circuit drops to under 5.5 bar.

Danger! If the warning display "Reservoir pressure auxiliary consumers" is shown in the (DIS) display this indicates that malfunctions may occur in the pneumatic suspension system, door system or clutch operation. Drive carefully. Have an EvoBus ServicePartner inspect the compressed-air system. – Only continue driving after the indication display has gone out when the compressed air consumption is too high (e.g. after activating the lifting and lowering system and simultaneously manoeuvring).

See Chapter 42 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/25 Operating Instructions Overall bus 00

Anti-blocking system information Is displayed after the driving switch is switched on. If the indication display does not extinguish no later than after the bus moves off or it lights up as the bus is being driven this indicates that the Anti-Blocking System (ABS) and the Traction Control System (TCS) are fully or partially inoperable.

Danger! The bus driving and braking characteristics may alter. Drive with care. Have the fault rectified by an EvoBus ServicePartner.

See Chapter 42 for safety and operating instructions.

Brake lining wear Is displayed when the brake lining wear is too high on one or more axles.

Danger! The bus driving and braking characteristics may alter. Drive with care. Have an EvoBus Servi- cePartner rectify the fault.

See Chapter 42 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/26 Operating Instructions Overall bus 00

Brake pressure reduced Is displayed when the brake pressure is reduced.

Danger! The bus driving and braking characteristics may alter. Drive with care. Have an EvoBus Servi- cePartner rectify the fault.

See Chapter 42 for safety and operating instructions.

Retarder temperature This is displayed if the retarder temperature (integrated in the automatic gearbox) is too high.

Danger! When the retarder temperature is too high (e.g. during a long downhill drive) the braking output of the retarder drops: slow down the bus speed by using the brake pedal.

See Chapter 42 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/27 Operating Instructions Overall bus 00

Generator 1 Is displayed when the charging voltage from generator 1 is NOK.

Danger! The driving characteristics may change, stop the bus (heed the traffic situation) and switch off the engine. Determine and rectify the cause (e.g. inspect V-belt and replace if applicable; see Chapter 01).

Battery overvoltage The warning display "Overvoltage" is shown in the (DIS) display if the voltage is too high (even briefly) whilst the bus is being driven. The cause for this may possibly be a defective generator, which overloads the batteries.

Danger! The bus driving and braking characteristics may change. Stop the bus (heed the traffic situation) and switch off the engine. Have an EvoBus ServicePartner rectify the fault.

See Chapter 54 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/28 Operating Instructions Overall bus 00

Battery undervoltage The warning display "undervoltage" is shown in the (DIS) display when the voltage drops to under approx. 22 Volt whilst the bus is being driven.

Danger! The bus driving and braking characteristics may change. Stop the bus (heed the traffic situation) and switch off the engine. Have an EvoBus ServicePartner rectify the fault.

The bus is at normal level (only on buses fitted with electronic level control) Is displayed when the bus is at normal level.

Continous display of this symbol in the normal driving can be suppressed in the "DIS" display (see Chapter 00, "DIS" display).

See Chapter 32 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/29 Operating Instructions Overall bus 00

The bus is not at the driving level (only on buses fitted with electronic level control) Is displayed when the bus body is not at one of the preset driving levels.

Danger! Drive carefully when the bus is raised or lowered. The driving characteristics may change. When the bus is raised, the changed overall height must be taken into account when driving through tunnels. When the bus is lowered, the overhang angle and ground clearance are changed.

See Chapter 32 for safety and operating instructions.

Bus lowered at entrance side (kneeling) (optional extra) Is displayed on buses fitted with electronic level control (optional extra) if the bus was lowered at the entrance side by using the switch on the instrument panel.

Danger! Danger of pinching: Make sure that persons or objects are not between the bus body and road surface. Only use the kneeling function when the bus is stationary and only use it as an entrance aid.

See Chapter 32 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/30 Operating Instructions Overall bus 00

The bus is at the 2nd driving level (optional extra) Only displayed on buses fitted with electronic level control (optional extra) if the switch on the instrument panel was actuated and the bus body has been raised to a preset, higher 2nd driving level.

Danger! Drive carefully when the bus is raised. The driving characteristics change. Take the changed overall height into account when driving through tunnels.

See Chapter 32 for safety and operating instructions.

Air filter soiled Is displayed when the air filter is soiled too much.

Service the air filter at the next opportunity.

See Chapter 01 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/31 Operating Instructions Overall bus 00

V-belt break (optional extra) Is displayed when a V-belt break is detected.

Danger! Stop the bus (heed the traffic situation) and switch off the engine. Ascertain and correct the cause.

See Chapter 01 for safety and operating instructions.

Fuel reserve (optional extra) Is displayed when the fuel tank contents have dropped down to approx. 14 %.

See Chapter 47 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/32 Operating Instructions Overall bus 00

Door open (only if connected by the superstructure manufacturer) Is displayed if one or more doors are open.

Danger! See the superstructure manufacturer's user documentation for operating and safety instructions.

Stop request (only if connected by the superstructure manufacturer) Is displayed when a passenger makes a stop request.

Danger! See the superstructure manufacturer's user documentation for operating and safety instructions.

OC 500 LE/03.2003 GB 00/33 Operating Instructions Overall bus 00

"DIS" display: system codes

M54_00-0756-71

The system codes (1) below can be shown on the DIS display as warnings:

AGN = Automatic transmission

BS = Brake control system

FR = Drive control

INS = Instrument driver's workplace

MR = Engine control

NR = Level control (optional extra)

TCO = Tachograph

Additionally, a 4-digit fault code (2) is also displayed. The fault code (2) is used by the EvoBus ServicePartner to provide detailed information upon the type and location of damage.

OC 500 LE/03.2003 GB 00/34 Operating Instructions Overall bus 00

"DIS" display: retrieve information by using the function switches Function switches (6) to (9) in the "DIS" display can be used to show various bus information and also change the settings. Press any function switch to carry this out. Switches (7) and (8) can be used to scroll within the menu. The selected menu line is visualised inversely (underlayed). The inversely visualised menu line can be selected by pressing switch (9). Press switch (6) to go back to the previous menu.

Danger! Only possible if the bus is stationary, the parking brake is applied and driving switch is ON. Never operate function switches (6) to (9) whilst the bus is in motion.

All warnings shown in the DIS display must be moved into the memory field beforehand by pressing function switch (9).

M00_00-0137-01

Main menus The main menus below can be selected in the selection menu: Fault Information

Settings

Service Information

Control Information

Equipment

Diagnostics

M54_00-0730-01

OC 500 LE/03.2003 GB 00/35 Operating Instructions Overall bus 00

Fault Information main menu In the "Fault Information" main menu, all currently present warnings and system codes (1, 2) or symbol and associated fault code can be retrieved. The associated segment (3, 4) of the status display lights up yellow or red simultaneously. Function switches (7) and (8) can be used to browse between the displayed faults.

M54_00-0701-01

Settings main menu In the "Settings" main menu a choice can be made between the "NR Permanent Display" and "Split Display" sub- menus. In the "NR Permanent Display" submenu the "Bus Normal Level" permanent display can be switched on or off.

In the "Split Display" submenu the separator between the individual displays can be switched on or off. Service Information main menu Further information cannot currently be retrieved in the "Service Information" main menu.

OC 500 LE/03.2003 GB 00/36 Operating Instructions Overall bus 00

Equipment main menu Further information cannot currently be retrieved in the "Equipment" main menu.

Control Information main menu In the Control Information main menu a choice can be made between the "Oil Pressure" and "Miscellaneous" sub- menus. The current engine oil pressure can be retrieved in the "Oil Pressure" submenu.

Further information cannot currently be retrieved in the "Miscellaneous" submenu.

M54_00-0733-01

OC 500 LE/03.2003 GB 00/37 Operating Instructions Overall bus 00

Diagnostics Information from the bus electronic systems can be shown on the DIS display in the Diagnostics main menu.

M54_00-0734-01

Bus Systems submenu All bus systems that can be diagnosed are shown in the DIS display after Diagnostics has been selected:

AGN = Automatic transmission

BS = Brake control system

FR = Drive control

INS = Instrument driver's workplace

MR = Engine control

NR = Level control (optional extra)

TCO = Tachograph M54_00-0735-71 Delete all events: All faults can be deleted in this submenu. It is only possible to delete the fault memory after the fault has been rectified.

OC 500 LE/03.2003 GB 00/38 Operating Instructions Overall bus 00

Bus System submenu Select system, DIS display changes into the submenu of the respective bus system. The following information can be retrieved: MB code number = The Mercedes-Benz code number of the respective control unit is displayed.

Events = Current existing faults are displayed.

Measure values = Actual values of individual system components can be requested.

Binary values = Digital switching states of individual system components can be requested.

Delete events = The fault memory of the respective control unit is deleted. It is only possible to delete the fault memory after the fault has been rectified.

The information listed above is used by the EvoBus ServicePartner to provide detailed information upon the M54_00-0736-01 type and location of damage in order to localise faults quickly.

Events submenu All currently existing faults in a bus system are displayed together with the fault code. All faults can be displayed after one another by toggling with the "Forward" or "Back" function switches. Additional fault information can be displayed on each fault by pressing the "Enter" function switch.

M54_00-0701-01

OC 500 LE/03.2003 GB 00/39 Operating Instructions Overall bus 00

Additional fault information The following information can be displayed:

1 = Consecutive fault number

2 = The fault currently exists

3 = Fault significance

4 = Four-digit fault code (information upon type and location of damage for workshop personnel)

Further information upon fault codes can be found in the workshop reference "On-board diagnostics".

M54_00-0737-71

Warning buzzer The indication display unit has an integral warning buzzer. Whenever a warning with "red" status is displayed the warning buzzer simultaneously sounds for a short period of time.

Danger! The bus must be stopped immediately (if traffic conditions allow) and an EvoBus ServicePartner must be notified.

A further warning buzzer is fitted in the instrument panel. This sounds when the driving switch is switched off, the frequent stop brake is activated and parking brake is not applied.

Danger! Before the drivers position is vacated the parking brake must always be applied correctly (see Chapter 42). Accident risk. The parking brake must be applied to park the bus. If required, (e.g. on upwards or downwards gradients) also secure the bus with wheel chocks to prevent it from rolling away.

OC 500 LE/03.2003 GB 00/40 Operating Instructions Overall bus 00

Control elements Bus

C634.220

Instrument panel indicator lamps

The illustrations below show the symbols found on the indicator lamps. The superstructure manufacturer decides upon the positioning of the indicator lamps.

• Red indicator lamp generator 2 fault (optional extra) Lights up after the driving switch is switched off and must go out when the engine is running.

Danger! If the indicator lamp does not go out or it lights up when the engine is running: Stop the bus (heed the traffic situation) and switch off the engine. Determine and rectify the cause (e.g. inspect V-belt and replace if applicable; see Chapter 01).

OC 500 LE/03.2003 GB 00/41 Operating Instructions Overall bus 00

• Bus outside of driving level Is displayed when the bus body is not at the preset driving level.

Instrument panel switches and buttons

The illustrations below show the symbols found on the switches. The superstructure manufacturer decides upon the positioning of the switches.

• Master safety switch (country-specific) The bus electrical system is disconnected from the batteries when the master safety switch is pressed.

Danger! The switch must only be operated in an emergency (e.g. accident, fire hazard from short-circuit). Never operate the switch when the bus is in motion as the driving and braking characteristics change.

Operation: raise the switch cover and pull up the yellow pin. Reset the switch: push in the yellow pin. Close the switch cover.

OC 500 LE/03.2003 GB 00/42 Operating Instructions Overall bus 00

• Driving switch (optional extra) All operating and display elements are supplied with voltage when the switch is engaged. All consumer units can be switched on. All electrical units as well as the engine are switched off when the switch is switched off.

To switch off the switch it is necessary to push the locking bar downwards and simultaneously push the switch upwards.

Only fitted on buses that do not have a key switch on the steering column.

• Engine start button (optional extra) Push to start the drive motor when the driving switch is switched on and the gearbox position is in neutral.

Only fitted on buses that do not have a key switch on the steering column. See Chapter 01 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/43 Operating Instructions Overall bus 00

• Hazard warning switch All the direction indicator lights on the left and right are switched on independently of the driving switch. The indicator lamps flash in the hazard-warning switch and indication display unit.

• TCS (Traction Control System) cutoff button (optional extra) The button switches off the TCR function. The function is reset by pressing the button again or switching the driving switch off and then on. When the TCS is switched off the indicator lamp flashes in the indication display unit. Danger! Accident risk. – The traction control system does not release the driver from the requirement to drive according to traffic and road conditions. – The bus could skid if the TCR is switched off and the drive wheels spin. See Chapter 42 for safety and operating instructions.

OC 500 LE/03.2003 GB 00/44 Operating Instructions Overall bus 00

• Horn changeover switch (optional extra) Switch pushed down: horn electrical. Switch pushed up: air horn. See "Multi-function stalk for light and wiper functions" for horn operation.

• Frequent stop brake switch When the bus is stationary and the switch is pressed, all the wheel brakes are braked with a pressure of 2.0 bar.

Requirement: driving switch switched on, bus is stationary.

The frequent stop brake requires less compressed air than the parking brake. Therefore, the frequent strop brake should be used at bus stops as much as possible. Only use when the bus is stationary.

OC 500 LE/03.2003 GB 00/45 Operating Instructions Overall bus 00

• Emergency stop frequent stop brake (only on buses fitted with an automatic frequent stop brake - optional extra) The active frequent stop brake can be disengaged in emergencies (e.g. technical defect - frequent stop brake does not disengage) by using the emergency release switch. This allows the bus to continue to be driven.

Operation: raise the switch cover and pull up the yellow pin. Reset the switch: push in the yellow pin. Close the switch cover.

Danger! Ensure that the doors and all luggage compartment cover are securely closed before pressing the emergency switch. Drive with care, always apply the parking brake when the bus is stationary as the frequent stop brake can no longer be engaged by the actuation switch on the instrument panel. Have an EvoBus Servi- cePartner rectify the fault as soon as possible. See Chapter 42 for safety and operating instructions.

• Kneeling button (optional extra) The bus body is lowered at the entrance side for as long as the button is pressed down in order to make it easier for passengers to enter the bus. The bus body raises again when the button is pressed up.

Danger! Lowering of the bus body may cause crush injuries to legs and feet. Make sure that persons or objects are not between the bus body and road surface when the bus is being lowered. Only use the lowering function as an entrance aid.

The kneeling function is only available when the bus is stationary. The kneeling function may be controlled in different ways (depending on the superstructure manufacturer and legislator (country-specific)).

See Chapter 32 for safety and operating instructions and also the superstructure manufacturer's operating instructions.

OC 500 LE/03.2003 GB 00/46 Operating Instructions Overall bus 00

• 2nd driving level button (optional extra) When it is pressed up, the bus body raises to a 2nd preset higher driving level. When it is pressed down, the bus body lowers to the normal level.

The 2nd driving level function is only available at speeds under 20 kph. The bus body automatically returns to the normal level when the speed increases above 20 kph.

Danger! Drive carefully when the bus is raised. The driving characteristics may change. When the bus is raised, the changed overall height must be taken into account when driving through tunnels.

Danger! Lowering of the bus body may cause crush injuries to legs and feet. Make sure that persons or objects are not between the bus body and road surface when the bus is being lowered.

See Chapter 32 for safety and operating instructions. And the superstructure manufacturer's operating instructions.

• Level control key switch (only on buses fitted with electronic level control) - Position 0 = level control switched on (driving position); - Position 1 = level control switched off (workshop position)

Danger! Whenever work is carried out under the bus and on the pneumatic suspension system: turn the key to position 1 to prevent the pneumatic suspension system from adjusting automatically.

See Chapter 32 for safety and operating instructions.

M32_00-0075-01

OC 500 LE/03.2003 GB 00/47 Operating Instructions Overall bus 00

Light rotary switch Combines the following functions:

Possible settings 0 Switched off 1 Parking light 2 Driving light Dipped beam or high beam (dependant upon the position of the multi-function stalk) when the driving switch is at position 2 (drive setting) 3 Front fog light (pull switch 1st position). In addition to the parking light, dipped beam or high beam when the driving switch is switched on 4 Rear fog light (pull switch 2nd position). In addition to the front fog lights. The indicator lamp in the light

rotary switch lights up. M54.00-0068-01 Combination switch for lights and wiper functions

Possible settings 1 Signal horn: Press button 2 Indicate left and right with automatic reset: Push the switch stalk beyond the stop until it snaps in place 3 Lane change: Push the switch stalk until it stops, hold it there and release it - the stalk returns to the cen- tre position 4 Headlight flasher: Pull the stalk upwards 5 High and dipped beams: Lever up = driving light, Lever down = high beam Move the stalk into both positions until it engages

M54.00-0081-01

OC 500 LE/03.2003 GB 00/48 Operating Instructions Overall bus 00

6 Windscreen wipers: Rotate the switch on the switch stalk: Position 0 = Off Position INT = Wipe interval Position I = Normal Position II = Fast 7 Wipe and wash: Turn the switch on the switch stalk towards the steering column. When windscreen wipers are switched on = windscreen wipe and wash Multi-function stalk for permanent brakes and tempomat (optional extra)

The functions below can be engaged with the multi-function stalk:

Operation of the permanent brakes (retarder, engine brake, constant choke)

Drive tempomat (constant speed by engine control) (optional extra)

Temposet (limitation of maximum speed) (optional extra)

Speed increase of the engine when the bus is stationary

• Permanent brakes Engage permanent brakes: The permanent brakes can only be engaged when: - the accelerator pedal is not pressed down; - a forward drive position is engaged; the road speed exceeds 3 kph. When the permanent brakes are engaged the transmission does not shift up into the next highest gear (change-up block). M54.00-0082-01

Possible settings • 2.1 - 2.2 Engine brake flap or engine brake flap and constant choke engaged.

In this switch position the engine brake or additionally also the constant choke can be engaged in response to various factors (e.g. road speed, engine speed). • 2.3 Engine brake, constant choke and retarder step 1 active. • 2.4 Engine brake, constant choke and retarder step 2 active.

OC 500 LE/03.2003 GB 00/49 Operating Instructions Overall bus 00

• 2.5 Engine brake, constant choke and retarder step 3 active.

Danger! The permanent brakes switch off and the change-up block is disengaged if the accelerator pedal is pressed when the permanent brake is active.

Danger! The retarder is automatically reduced above a specified coolant temperature characteristic. The braking output reduces.

Danger! When the ABS is operating correctly and one or both wheels on the driven axle have blocking potential then the permanent brake is automatically switched off if it was engaged. This function is not enabled if an ABS fault message is indicated - risk of skidding.

The permanent brakes can also be automatically engaged by the "permanent brake integration system" (optional extra) when the brake pedal is pressed down (see Chapter 42).

See Chapter 42 for safety and operating instructions. • Drive tempomat (optional extra) Engage drive tempomat: Precondition: Bus speed is higher than 15 kph. Service brake and permanent brake must not be engaged.

Possible settings • 1.1 Press for a short time (< 0.5 seconds) = speed currently driven is set and shown in the display. Press again briefly (< 0.5 seconds) = increase set speed by 1/2 kph. Press for a long time (> 0.5 seconds) = accelerate bus as long as switch pressed. When the multi-function stalk is released the current speed is set as the new value. • 1.2 Press for a short time (< 0.5 seconds) = speed currently driven is set and shown in the display or the last stored speed is driven (memory). Press again briefly (< 0.5 seconds) = reduce set speed by 1/2 kph. Press for a long time (> 0.5 seconds) = decelerate bus as long as switch pressed. When the multi-function stalk is released the current speed is set as the new value. M54.00-0082-01 • 1.3 The tempomat is switched off, the last stored value remains saved in the control unit.

The drive tempomat is switched off automatically as soon as the service or permanent brakes are applied.

OC 500 LE/03.2003 GB 00/50 Operating Instructions Overall bus 00

Danger! Do not use the tempomat on a slippery road surface - risk of skidding. Only use the tempomat if traffic conditions allow driving at a constant speed. The set speed may not be able to be kept constant on slopes. Take your foot off the accelerator pedal when the tempomat is switched on.

• Temposet (optional extra)

Possible settings • 1.4 Press button briefly = temposet (LIM): The current speed is set as the maximum speed. The set value is shown in the display. The driver must continue to use the accelerator. Keep button pressed: the set maximum speed is increased as long as the switch is pressed. Switch off: switch the multi-function stalk to position 1.3 or engage the tempomat.

The temposet can be engaged for speeds greater than 10 kph, between 10 and 15 kph a limit is set at 15 kph. It is possible to "overdrive" the set speed by pressing down accelerator pedal past the stop ("kick down").

• Increase engine speed Precondition: bus is stationary, engine is running. M54.00-0082-01 Possible settings • 1.1 The maximum engine speed can be increased steplessly to 750 rpm. • 1.3 Engine speed increase off, normal idle speed

OC 500 LE/03.2003 GB 00/51 Operating Instructions Overall bus 00

Adjustable steering column Button for adjusting the height and angle of the steering wheel. Move the steering column downwards into the release position by pressing the button (1).

Danger! Only make adjustments when the bus is stationary. Lock the steering column in place after you have adjusted the steering wheel to match the driver's requirements. To do this, press button (1) upwards.

Danger! After the adjustable steering column has been adjusted a check must be carried out of whether all instruments and warning lamps can be seen.

The steering column is automatically locked in place after a time of approx. 12 (+/- 5) seconds has expired after the button (1) has been released. See Operating Instructions Chapter 46 for safety and operating instructions.

M46.00-0030-01

Driving switch

Danger! Never lock the steering when the bus is rolling. Take out the key even when leaving the bus for a short time.

Possible settings 0 Parked position Insert or take out the key in this position, parking light can be switched on. 1 Steering unlocked All consumer units can be switched on. 2 Drive position 3 Start position

M54.00-0083-01

OC 500 LE/03.2003 GB 00/52 Operating Instructions Overall bus 00

Tachograph 1 Button for opening the record sheet holder Driver 1 places the labelled record sheet on the dividing plate in the record sheet holder with the front side upwards. Driver 2 places the labelled record sheet under the dividing plate in the record sheet holder with the front side upwards. The record sheets must be exchanged when the drivers change. 2 Button for adjusting the required time group for driver 1 Keep the button pressed down until the required time group is shown in the display. 3 Button for adjusting the required time group for driver 2 Keep the button pressed down until the required time group is shown in the display. 4 Menu selection button

Different selection menus are available (see manufacturer's operating instructions). M54.00-0369-01 5 Button (-): Move back within the menu 6 Button (+): Move forward within the menu 7 Display (lights up when driving switch is on) The basic screen (date, time and total odometer) is shown if there are not any error messages. When the tachograph detects a fault it is displayed by a flashing 4-digit fault code in the display. The faults below can be corrected by the operator:

8000 = driving without a record sheet

8100 = record sheet not loaded for driver 1

8200 = record sheet not loaded for driver 2

OC 500 LE/03.2003 GB 00/53 Operating Instructions Overall bus 00

8300 = the time on the record sheet holder does not correspond with the time in the display (e.g. after a power interruption or time adjustment in the MFD). Fault elimination: - remove both record sheets; - close the record sheet holder without record sheets; - the time of the display and record sheet holder is (audibly) synchro- nised; - open the record sheet holder and reload the record sheets. If other fault codes are displayed: contact the nearest EvoBus ServicePartner and have the fault corrected. Speedo module (on model without tachograph) The time in the multi-function display (MFD) can be adjusted by using the speedo module. 1 Speedo module 2 Button (-): clock setting back 3 Button (+): clock setting forward

M54_00-0845-01

OC 500 LE/03.2003 GB 00/54 Operating Instructions Overall bus 00

Parking brake valve

See Chapter 42 for safety and operating instructions.

Danger! The parking brake spring actuators require a release pressure of 5.8 to 6.4 bar. When the reservoir pressure is too low there is a risk that the brake is not fully disengaged, the linings have slight contact during driving and the brake is overheated unnecessarily. The indicator lamp in the indication display unit must go out when the parking brake is released. The emergency disengage device is combined with the parking brake valve and is operated in exactly the same way as the normal parking brake. The valve automatically switches over to the air supply for the emergency release device and the spring actuators are released.

Danger! Risk of skidding. When the parking brake is engaged the ABS is inoperative.

Possible settings

A Parking brake applied M42.20-0003-01 Danger! Check that the hand lever (1) is fully locked in place. To do this, push the hand lever towards "released" (B) without pulling the release ring (2) out of its lock position. The lever must not be able to be moved. B Parking brake released

OC 500 LE/03.2003 GB 00/55 Operating Instructions Overall bus 00

3-button automatic gearbox gear-change unit See Chapter 27 for safety and operating instructions.

D "Drive position D" Gears 1 to 5 are automatically selected. N "Drive position N" Transmission in neutral. No gear is selected. R "Drive position R" The reverse gear is selected.

M27_00-0023-01

6-button automatic transmission gear-change unit (optional extra) See Chapter 27 for safety and operating instructions.

1 "Drive position 1" Only the 1st gear is selected. 2 "Drive position 2" Gears 1 and 2 are automatically selected. 3 "Drive position 3" Gears 1 to 3 are automatically selected. D "Drive position D" Gears 1 to 5 are automatically selected. M68_00-0070-01 N "Drive position N" Transmission in neutral. No gear is selected.

OC 500 LE/03.2003 GB 00/56 Operating Instructions Overall bus 00

R "Drive position R" The reverse gear is selected.

OC 500 LE/03.2003 GB 00/57 Operating Instructions Overall bus 00

Operation Bus

C634.220

Towing the bus

Danger! Follow the superstructure manufacturer's instructions.

Danger! Only authorised skilled personnel (recovery service) may tow away broken-down buses. Country-specific regulations must be obeyed.

Danger! The driving switch on the towed bus must always be set to position 1 during towing. The steering lock must not be engaged. The steering may block if this is not carried out.

Danger! When the bus is being towed with a raised front axle the driving switch must not be switched on, otherwise the "TCS" braking control is active.

• Buses with ZF - transmission: - place the transmis- Maximum towing distance = 50 km; maximum sion in neutral (N); towing time = 2 hours; maximum towing speed = 25 kph. Over a long towing distance: remove the propeller shaft.

The propeller shaft must always be removed if it is suspected that damage may be caused to the transmission. Irreparable damage to the transmission may be caused by not doing this.

Danger! Secure the drive shaft against dropping down before removing it.

OC 500 LE/03.2003 GB 00/58 Operating Instructions Overall bus 00

• Buses with Voith - transmission: For a towing dis- Maximum towing distance = 10 km. Maximum tance up to 10 km shift the transmission into the towing speed = 30 kph. Over a long towing distance: neutral position (N). Disconnect the connector at the remove the propeller shaft. transmission control unit. The propeller shaft must always be removed if it is suspected that damage may be caused to the transmission. Irreparable damage to the transmission may be caused by not doing this.

Danger! Secure the drive shaft against dropping down before removing it.

Tow start the bus • It is not possible to start the engine by tow-starting the bus on buses fitted with automatic transmission.

OC 500 LE/03.2003 GB 00/59 Operating Instructions Overall bus 00

Chassis technical data Bus

C634.220

Name Value Rated total weight, Country-specific19,000 kg Max. rated axle load for front axle, Country-specific7,100 kg Max. rated axle load for rear axle, Country-specific12,000 kg Track width front axle, 2,101 mm Track width driven axle, 1,802 mm Track width trailing axle, 2,055 mm Tyre size, 275/70 R 22.5 mm Tyre size (optional extra), 295/80 R 22.5 mm Tyre size (optional extra), 11 R 22.5 mm

OC 500 LE/03.2003 GB 00/60 Operating Instructions Engine 01

General Information / Safety Information Bus

C634.220

Safety instructions for working in the engine compartment

Danger! Serious danger. Freely rotating parts can cause serious injuries in the vicinity of the running engine and drive train. Never leave the engine running when work is carried out in the engine compartment. Se- cure the engine against unauthorised starting. To do this, switch off and pull out the master battery switch (2).

Danger! Risk of burning. Hot components in the engine compartment may cause burning. If the engine is at its operating temperature allow it to cool down for some time.

M54_00-0806-01

OC 500 LE/03.2003 GB 01/1 Operating Instructions Engine 01

Operation Bus

C634.220

Starting the engine by using the key switch on the steering column

The parking brake must be engaged. Transmission in neutral.

• Turn the driving switch to position 2. The warning buzzer sounds and the indication display unit executes an indicator lamp check.

M54.00-0083-01

OC 500 LE/03.2003 GB 01/2 Operating Instructions Engine 01

• Then move the driving switch to position 3 without To prevent damage to the starter system, stop pressing down on the accelerator pedal. the minutes after 15 seconds and repeat after approx. 1 minute. Before the restart turn the key back until it can go no further. After you have tried to start the bus three times without success you must break off for approximately 15 minutes.

M54.00-0083-01

• Release the key after the engine starts.

• Observe the indication display unit: the "STOP" The operating safety of the engine is put at risk if light (22) must go out. The STOP light illuminates the STOP light does not go out. Switch off the engine when the engine oil pressure or oil level is too low. immediately and ascertain the cause.

Danger! An acoustic warning signal sounds when the pressure in the compressed air supply system is too low and it cuts out when the required pressure is reached. Do not disengage the parking brake until the operating pressure is at a suitable level.

M54_00-0761-01

OC 500 LE/03.2003 GB 01/3 Operating Instructions Engine 01

Starting the engine with a button switch (optional extra)

The parking brake must be engaged. Transmission in neutral.

• Press the rocker switch (1) on the instrument pan- The warning buzzer sounds and the indication display el. unit executes an indicator lamp check.

M01_00-0100-01

OC 500 LE/03.2003 GB 01/4 Operating Instructions Engine 01

• Then press the switch (2) on the instrument panel. To prevent damage to the starter system, stop the minutes after 15 seconds and repeat after approx. 1 minute. After you have tried to start the bus three times without success you must break off for approximately 15 minutes.

M01_00-0100-01

• Release the switch (2) after the engine starts. • Observe the indication display unit: the "STOP" Danger! The operating safety of the engine is light (22) must go out. The STOP light illuminates put at risk if the STOP light does not go out. Switch when the engine oil pressure or oil level is too low. off the engine immediately and ascertain the cause.

M54_00-0761-01

OC 500 LE/03.2003 GB 01/5 Operating Instructions Engine 01

Driving

Never allow the engine to run in the "hot running" state, but start driving the bus and run the engine at medium rpm.

The engine should only ever be placed under full load after it has reached the operating temperature (75 - 90 °C) depending upon operating conditions and external temperature.

Carry out a functional check on the service brake immediately after the bus has started to move.

See Chapter 27 for operation of the automatic transmission.

• Observe the tachometer whilst the bus is being Stay in the economical range (green area). Make driven sure that the engine speed does not increase into the danger zone (red area).

Switching off the engine

• Stop the bus, transmission in neutral, apply parking brake.

OC 500 LE/03.2003 GB 01/6 Operating Instructions Engine 01

• Turn driving switch back from position 2 (drive posi- Before you switch off the engine allow it to run tion) to position 1 at idle speed for approximately 1-2 minutes (if the coolant temperature is high or after driving under full engine loading (e.g. after driving uphill) so that the exhaust turbochargers can cool down).

M54.00-0083-01

• If a key switch is not installed (optional extra) To switch off the switch it is necessary to push switch off the rocker switch (1) on the instrument the locking bar downwards and simultaneously push panel. the switch upwards.

Before you switch off the engine allow it to run at idle speed for approximately 1-2 minutes (if the coolant temperature is high or after driving under full engine loading (e.g. after driving uphill) so that the exhaust turbochargers can cool down).

M01_00-0100-01

OC 500 LE/03.2003 GB 01/7 Operating Instructions Engine 01

Engine technical data Bus

C634.220

Name Value Maximum output, 185 kW at 2,000 rpm Maximum torque, 1,100 Nm at 1,100 rpm Number of cylinders, 6 Cylinder layout, in series (horizontal) Bore, 128 mm Stroke, 155 mm Engine displacement, 11,970 ccm Exhaust gas standard, Euro 3

OC 500 LE/03.2003 GB 01/8 Operating Instructions Engine 01

Removing the drive belt Bus

C634.220

Danger! Serious danger. Freely rotating parts can cause serious injuries in the vicinity of the running engine and drive train. Never leave the engine running when work is carried out in the engine compartment. Secure the engine against unauthorised starting. To do this, switch off and pull out the master battery switch.

Danger! Risk of burning. Hot components in the engine compartment may cause burning. If the engine is at its operating temperature allow it to cool down for some time.

Caution: Replacement V-belts and some of the tools described below are not part of the scope of supply for the bus. Only original Omniplus replacement V-belts may be used.

Removing the fan drive belt

Required tools: ratchet or tommy bar 1/2", extension 1/2", spanner A/F 18, open-ended spanner A/F 18, open-ended spanner A/F 19. • Slacken the fastening bolts (1.1) by approx. 1 turn. • Slacken the lock nut (1.2) on the tension bolt and unscrew it fully. • Screw in the tension bolt (1.3) until the drive belt If the tension bracket is difficult to move, push (1) can be removed manually. the drive belt firmly downwards. Slacken the fastening bolts (1.1) more if necessary.

M13_00-0052-01

OC 500 LE/03.2003 GB 01/9 Operating Instructions Engine 01

Removing the generator 2 drive belt (optional extra)

Required tools: screwdriver, tommy bar 1/2", extension 1/2", spanner A/F 19, open-ended spanner A/F 19. • Slacken the fastening bolts (2.1) (front and rear) approx. 1 rotation. • Slacken the fastening bolts (2.2) (2 bolts) for the spring-loaded spindle approx. 1 rotation. • Slacken the lock nut (2.3) on the spring-loaded spindle and unscrew the tension bolt (2.4) until the drive belt can be removed manually.

M01.00-0062-01

Removing the water pump drive belt (refrigeration compressor, generator 1)

Required tools: hexagon socket spanner 8 mm, open-ended spanner A/F 19. • Slacken the fastening bolt (3.1) for the tensioning pulley (3.2) approx. 1 rotation using the hexagon socket spanner. • Slacken the lock nut on the spring-loaded spindle (3.3) and unscrew it fully. • Slacken the clamping nut (3.4) until the drive belt If the tension bracket is difficult to move, move can be manually removed from the belt pulleys. the tensioning pulley (3.2) to the left manually.

M13_00-0051-01

OC 500 LE/03.2003 GB 01/10 Operating Instructions Engine 01

Removing the generator drive belt (with air-conditioning system)

Required tools: ring spanner straight A/F 19, open-ended spanner A/F 19, open-ended spanner A/F 17. • Slacken the fastening bolts (4.1) (front and rear) approx. 1 rotation. • Slacken the fastening bolts (4.2) (2 bolts) for the spring-loaded spindle approx. 1 rotation. • Slacken the lock nut (4.3) on the spring-loaded spindle and unscrew the tension bolt (4.4) until the drive belt can be removed manually.

M01.00-0060-01

OC 500 LE/03.2003 GB 01/11 Operating Instructions Engine 01

Fitting the drive belts (OM 457 hLA) Bus

C634.220

Caution: Do not use force (e.g. by using a tyre lever) to pull drive belts onto the belt pulley edges during assembly. This could cause hidden damage to the cord, which would considerably reduce the serviceable life.

Fitting the generator drive belt (with air-conditioning system) • Manually lay the new drive belts over the belt pulleys for the refrigeration compressor and the generator. • Tighten the tension bolt (4.4) until the required belt The drive belt tension must not be too high under tension has been reached. any conditions. You must be able to twist the drive belt by at least 90° using two fingers at the measur- ing point (4.5).

Contact the nearest EvoBus ServicePartner so that it can set the drive belt tension correctly with a gauge. • Tighten the lock nut (4.3) for the spring-loaded spindle. M01.00-0060-01 • Tighten the fastening bolts (4.2) (2 bolts) for the spring-loaded spindle. • Tighten the fastening bolts (4.1) (front and rear) for the generator.

OC 500 LE/03.2003 GB 01/12 Operating Instructions Engine 01

Replacing the water pump drive belt (refrigeration compressor, generator 1) • Manually lay the new drive belt (3) over the belt pulleys for the crankshaft, water pump and refrigeration compressor (or generator). • Lay the drive belt (3) on the tensioning pulley (3.2) (see picture). • Tighten the clamping nut (3.4) on the spring-loaded The drive belt tension must not be too high under spindle until the drive belt (3) has reached the re- any conditions. You must be able to twist the drive quired belt tension. belt by at least 90° using two fingers at the measur- ing point (3.5).

Contact the nearest EvoBus ServicePartner so that it can set the drive belt tension correctly with a gauge. M13_00-0051-01 • Tighten the lock nut (3.3) for the spring-loaded spindle. • Tighten the fastening bolt (3.1) for the tensioning pulley (3.2) using the hexagon socket spanner.

OC 500 LE/03.2003 GB 01/13 Operating Instructions Engine 01

Fitting the generator 2 drive belt (optional extra) • Manually lay the new drive belt over the belt pulleys for the crankshaft and the generator. • Tighten the tension bolt (2.4) until the correct belt The drive belt tension must not be too high under tension has been reached. any conditions. You must be able to twist the drive belt by at least 90° using two fingers at the measur- ing point (2.5).

Contact the nearest EvoBus ServicePartner so that it can set the drive belt tension correctly with a gauge. • Tighten the lock nut (2.3) for the spring-loaded spindle. M01.00-0062-01 • Tighten the fastening bolts (2.2) (2 bolts) for the spring-loaded spindle. • Tighten the fastening bolts (2.1) (front and rear) for the generator. Fitting the fan drive belt • Manually lay the new drive belts (1) over the belt pulleys for the crankshaft and the fan. • Unscrew the tension bolt (1.3) until the correct belt The drive belt tension must not be too high under tension has been reached. any conditions. You must be able to twist the drive belt by at least 90° using two fingers at the measur- ing point (1.5).

Contact the nearest EvoBus ServicePartner so that it can set the drive belt tension correctly with a gauge. • Tighten the fastening bolts (1.1). • Tighten the lock nut (1.2). M13_00-0052-01

OC 500 LE/03.2003 GB 01/14 Operating Instructions Engine 01

Maintenance Bus

C634.220

Checking the engine oil level with the dipstick

Danger! Risk of burning. Hot components in the engine compartment may cause burning. If the engine is at its operating temperature allow it to cool down for some time.

Note: The engine oil level can be retrieved in the DIS display of the indication display unit. See Chapter 00. Additionally, the bus also has a dipstick. Small differ- ences between the indication display in the DIS display and on the dipstick are normal.

• Pull out the dipstick (3) when the engine is at its The oil level must be visible between the 2 ar- operating temperature and is not running. rows on the dipstick (3).

The oil level check must be carried out when the bus is horizontal and stationary.

Wait for approximately 10 minutes after the engine has been switched off so that the oil can collect in the sump. • Top up any missing oil at the filler spout (1) in com- We recommend that topping up with engine oil pliance with the service product instructions. After- is only carried out when the oil level has dropped to wards check that the filler cap is fitted correctly and the "min" marking. Then fill up with engine oil to the firmly. "max" marking (approx. 6 litre).

Do not overfill under any conditions. Damage to M18_00-0047-01 the engine may be caused if the oil level is too high.

OC 500 LE/03.2003 GB 01/15

Operating Instructions Cooling 20

Operation Bus

C634.220

Emergency operation of the engine cooling system fan drive

Required if the electrical controller malfunctions or the electromagnetic clutch is defective.

Danger! Risk of burning. Hot components in the engine compartment may cause burning. If the engine is at its operating temperature allow it to cool down for some time.

• Disconnect the electrical plug connection (5) to the Always insert and tighten all 4 screws. The angle electromagnetic clutch. Unscrew and remove the 4 plates could break off if this is not done. emergency screws (1) from the fan shaft (2). Turn the fan blades so that the 2 angle plates (3) with The fan is now rigidly connected with the drive, runs the bore holes are over the tapped holes (4) in the permanently with it and no longer exercises any regu- fan connection. Screw in and tighten the emergency lator function for the coolant temperature. screws. Close the engine compartment cover. Switch Have the actuator and control of the electromag- on the master battery switch. Start the engine briefly in order to make the second angle plate (3) (offset by netic clutch checked and serviced at an EvoBus Servi- cePartner as soon as possible. 180°) accessible. Switch off and pull out the master battery switch. Screw in and tighten the remaining 2 emergency screws (1).

M20_00-0084-01

OC 500 LE/03.2003 GB 20/1 Operating Instructions Cooling 20

Maintenance Bus

C634.220

Checking the coolant level for the engine and heater systems

• Reading off the coolant level Danger! Hot coolant squirting out poses a risk of scalds to skin and eyes. Wear protective clothing (gloves and goggles). Open the filler cap for the coolant expansion tank only if the coolant temperature is under 50 °C. Risk of poisoning due to swallowing coolant.

Danger! Only open the filler cap fully when the cooling system is depressurised.

The coolant level on a cold engine (under 50°C) must be between the upper and lower markings (min. (1.1) and max. (1.2)) on the sight glass (1) for the expansion tank. M20.00-0037-01 • Top up the coolant: Open the filler cap slowly until Only ever top up when the engine is cold. the 1st catch in order to vent off the overpressure. Turn up to the 1st catch and remove the filler cap. Use clean and well filtered water with as low a lime content as possible (drinking water quality) mixed with anticorrosion antifreeze (comply with the service product instructions).

OC 500 LE/03.2003 GB 20/2 Operating Instructions Automatic transmission 27

Operation Bus

C634.220

Operation

Danger! Risk of accident: do not shift down on a slippery road surface (risk of skidding). Press pushbutton "N" when there is a risk of sliding and skidding.

Danger! When a switch is pressed down on the gear selection switch, the pressed-down switch illuminates. Risk of accident: there is maximum risk of transmission damage (limited system monitoring) when a pressed-down switch is flashing. Should this occur, drive to the nearest workshop with the engine under only partial load.

Danger! Secure the bus solely with the parking brake when it is parked, to prevent the bus from rolling away

• Starting the engine: shift the gear selection switch It is only possible to start the engine when the to neutral (N). transmission is in neutral (starter lock).

The picture shows the models with "3-button gear selection switch" (top) and "6-button gear selection switch" (optional extra).

M27_00-0024-01

OC 500 LE/03.2003 GB 27/1 Operating Instructions Automatic transmission 27

• Engage gear: engage the required driving mode or Conditions: bus is stationary, service brake en- direction of travel on the gear selection switch. gaged, accelerator pedal in idle position and engine speed under 900 revolutions/minute.

Never operate the gear selection switch and accelerate at the same time. • The selected gear is displayed in the multi-function display (MFD) (9).

M54_00-0761-01

• Driving away: wait for 1 -2 seconds after having selected the required driving mode. • Release the parking brake.

OC 500 LE/03.2003 GB 27/2 Operating Instructions Automatic transmission 27

• Release the service brake and accelerate. Danger! Only release the brake when the bus starts to move off. Otherwise there is a risk that the bus moves away too soon (bus creep).

Danger! Risk of accident: on upwards gradients release the brake and accelerate immediately so that the bus does not roll back.

Do not drive away at temperatures under -15°C. Allow the engine to run and warm up for approx. 5 minutes. Gear selection switch in neutral.

• Driving: Individual gears are selected automatically The engine speed during gear changes in the depending upon: – gear selection switch setting; – transmission is very dependant upon the accelerator road speed; – accelerator pedal position. pedal position. Accelerator pedal pushed down a little (low accelera- tion) = early shift up Accelerator pedal pushed down a lot (high accelera- tion) = late shift up

OC 500 LE/03.2003 GB 27/3 Operating Instructions Automatic transmission 27

Accelerator pedal stamped down over the full accel- eration position until the stop (kickdown) = at low engine speeds a gear is automatically shifted back and shift up is carried out at the engine rated speed.

Danger! Risk of accident: on long downward gradients shift down manually into switch position 1, 2 or 3 (optional extra). This limits shift ups. The smaller the selected driving mode, the better the engine braking effect. However, never allow the engine speed to increase into the red range on the tachometer. In extreme situations, (to protect the engine) the change-up block is deactivated and the gearbox shifts up, engage the service brake.

Danger! Risk of accident: if the transmission is shifted to "N" whilst the bus is being driven then the power flow between the engine and output gear is in- terrupted. This means the loss of engine and retarder braking effect, engage the service brake. • Change of direction of travel: Prior to shifting from Danger! If this rule is not adhered to a blockage a forward gear (1 - D) to reverse (R) or the other way may be caused which will result in the bus skidding. round: - bus is stationary; - engine idles speed, -gear- change unit in neutral (N). • Then select the required driving mode and direction of travel (see Engage gear). • Stopping: Short stop: Keep the switch position and stop the bus using the service brake or frequent stop brake. • Long stops and parking: Always shift the gear se- Danger! There is no direct link between axle lection switch to neutral "N". and engine: Secure the bus against rolling away; always apply the parking brake. • Gear positions during forward driving:

OC 500 LE/03.2003 GB 27/4 Operating Instructions Automatic transmission 27

• Switch position "D" Gears 1 to 5 (ZF transmission) or 1 to 4 (Voith transmission) are automatically selected in succession.

Drive setting "D" produces the ideal handling characteristics in nearly all operating situations. • Switch position "3" (only on models with "6 button Gears 1 to 3 are automatically selected in succession. gear selection switch") For driving on slight to medium upwards gradients to prevent pendulum-like gearshifting between the 3rd and 4th gears. On a downwards gradient the engine braking effect can be utilised up to the permissible maximum engine speed in 3rd gear. • Switch position "2" (only on models with "6 button Gears 1 to 2 are automatically selected in succession. gear selection switch") For driving on medium upwards gradients to prevent pendulum-like gearshifting between the 2nd and 3rd gears. On a downwards gradient the engine braking effect can be utilised up to the permissible maximum engine speed in 2nd gear. • Switch position "1" (only on models with "6 button Only the 1st gear is selected. gear selection switch") For manoeuvring the bus. On a downwards gradient the engine braking effect can be utilised up to the permissible maximum engine speed in 1st gear. • The automatic transmission has an integral retarder (wear-resistant auxiliary brake). See Chapter 43 for the retarder safety and operating instructions.

OC 500 LE/03.2003 GB 27/5

Operating Instructions Suspension 32

General Information / Safety Information Bus

C634.220

Bus manoeuvrability when the pneumatic suspension is depressurised The front chassis and transmission to the driven axle have been designed so that the bus is guaranteed to be manoeuvrable even when the air-suspension bellows are depressurised. In this condition, the whole weight of the bus lays on the stop buffers built into the front chassis and rear axle. They are not used when the suspension operates normally and only prevent the bus hitting the axle when com- pression is extreme. The stop buffers have not been designed to be operated under continuous loading and cannot be considered a replacement for the normal suspension under any circumstances, Additionally, the bodywork can be damaged (cracks etc.).

Danger! Although the bus remains manoeuvrable when the suspension is depressurised, it must only be driven at walking pace to the nearest lay-by. Notify an EvoBus ServicePartner. The body must always be secured at the correct points by using jacks and floor stands whenever work is carried out on the pneumatic suspension system as the bus body can sink relatively quickly if there is an air loss.

Danger! When working on buses fitted with electronic level control (optional extra) always also switch off the "NR level control" key switch. The is necessary to prevent the "NR level control" from automatically adjusting.

Model types of pneumatic suspension A purely pneumatically operating suspension system is installed as standard.

OC 500 LE/03.2003 GB 32/1 Operating Instructions Suspension 32

As an option. an "electronic level control" = (NR level control) can be fitted (recognisable by the "NR level control" key switch on the instrument panel. This electropneumatically functioning suspension system can allow the following functions to be installed as optional extras:

- Lower bus at entrance side (kneeling)

- Raise bus to 2nd driving level.

M32_00-0075-01

OC 500 LE/03.2003 GB 32/2 Operating Instructions Suspension 32

Operation Bus

C634.220

Operation of the electronic level control (NR level control) (optional extra)

In this section, all functions are described that are possible on buses fitted with the "NR level control". Different combinations are available to conform with customer requirements.

• Buses with "NR level control": In normal driving the Permanent display of the symbol in the "DIS" dis- "Normal level" symbol is continuously displayed in the play can be suppressed (see Chapter 00, "DIS" dis- DIS display. play).

Lowering the bus at the entrance side (kneeling) (optional extra)

Requirement Instruction Page

Driving switch on

Bus stationary

Reservoir pressure in the auxiliary consumer circuit above 6.5 bar

"NR level control" key switch in "driving position"

OC 500 LE/03.2003 GB 32/3 Operating Instructions Suspension 32

Requirement Instruction Page

Country specific and bus body manufacturer specific: doors closed.

• Press down the button on the instrument panel The bus body is automatically raised to the nor- until the bus body has fully lowered on the entrance mal level if the button is released whilst the bus low- side. ers.

The air-suspension bellows on the entrance side vent and the vehicle body lowers on the entrance side.

The "Kneeling" display is shown on the DIS display.

The "automatic frequent stop brake" may also be activated depending on the country and bus body manufacturer.

OC 500 LE/03.2003 GB 32/4 Operating Instructions Suspension 32

• Press up the button on the instrument panel. The bus body is raised to the normal level. The "Bus at normal level" display is shown in the DIS display once the normal level has been reached

Raising the bus body to the 2nd driving level (optional extra)

Requirement Instruction Page

Driving switch on

Bus stationary

Reservoir pressure in the auxiliary consumer circuit above 6.5 bar

"NR level control" key switch in "driving position"

Danger! Drive carefully when the bus is raised. The driving characteristics may change. When the bus is raised, the changed overall height must be taken into account when driving through tunnels.

Danger! Lowering of the bus body may cause crush injuries to legs and feet. Make sure that persons or objects are not between the bus body and road surface when the bus is being lowered.

OC 500 LE/03.2003 GB 32/5 Operating Instructions Suspension 32

• Press up the button and hold it pressed up. The bus body raises to a 2nd preset higher driving level. The bus body raises by 70 mm on the Australia model.

The "Bus at 2nd driving level" display is shown in the DIS display of the indication display unit.

OC 500 LE/03.2003 GB 32/6 Operating Instructions Suspension 32

• Release the button. The bus body lowers to the normal level. The "Bus at normal level" display is shown in the DIS display once the normal level has been reached The bus body automatically returns to the normal level if the bus speed exceeds 20 kph.

OC 500 LE/03.2003 GB 32/7

Operating Instructions Wheels and tyres 40

General Information / Safety Information Bus

C634.220

Important notes on tyres In § 36 STVZO "Richtlinien für die Beurteilung von Luftreifen" (section 36 of the road traffic regulations "Guide- lines for evaluating tyres") German legislators specified how tyres must be supplied for motor vehicles so that they are considered to be safe to operate and use in traffic and the condition they must be in when used. Each motor vehicle operator is responsible for adhering to these requirements. If the bus is used in countries outside of Germany then the regulations valid in the respective country must be complied with.

Tyre pressure Check the tyre pressure (including the spare wheel) when the tyres are cold. The pressure difference in the tyres on one axle must not be greater than 0.2 bar. If the pressure on tyres is too low check there are no leaks on the valves, wheel rims and tyres. Tyre pressure can increase by up to 1 bar after a fast journey or in warm weather. Do not release any air otherwise the air pressure will be too low after the tyres have cooled. Check the "tyre pressure table" published by the tyre manufacturer for details of tyres and air pressures.

Danger! When the tyre pressure is too low the driving safety and tyre running performance are reduced; the fuel consumption, tyre wear and risk of tyre damage are increased.

Important information for changing wheels Only fit tyres onto a bus that have same size, design and profile structure. Make sure you adhere to the rim and tyre size as well as maximum tyre load and speed index prescribed by the manufacturer. For twin tyres, fit tyres that have the same external diameter, otherwise the tyre that has the largest diameter will be overloaded. Tip: the simplest and most reliable measurement method is to check circumferences using a circumference tape. The maximum tolerance for twin tyres is 0.5% of the tyre diameter. The larger tyre must always be fitted to the outer position.

Danger! It is only permissible to replace aluminium wheels by steel disc wheels or steel disc wheels by aluminium wheels if other wheel nuts and other wheel bolts are used.

OC 500 LE/03.2003 GB 40/1 Operating Instructions Wheels and tyres 40

Safety measures to be taken in a breakdown or when changing a tyre Park the bus as far away as possible from flowing traffic and on firm ground. Switch on the hazard warning lights. Let all passengers disembark and take them out of the danger zone (e.g. behind the crash barrier). If necessary, set up a warning triangle or hazard warning light at a suitable distance from the bus. Comply with the laws of the country. On buses fitted with electronic level control: prior to jacking up the bus, set the "NR level control key switch" on the instrument panel to the workshop position (see Chapter 32). Only change the wheel on a level, firm and anti-skid surface. The bus or jack may slip out to the side on a soft or slippery surface (snow, ice, smooth surface etc.).

Danger! Never lie under the bus if it is raised up and is not supported by floor stands. Do not start the engine as this represents a danger to life. Safeguard the engine against it being switched on without authorisation. Take the key out of the driving switch.

OC 500 LE/03.2003 GB 40/2 Operating Instructions Wheels and tyres 40

For technical reasons this page is empty

OC 500 LE/03.2003 GB 40/3 Operating Instructions Wheels and tyres 40

Overview Bus

Tyre pressure table 275/70 R 22.5 C634.220

M40_00-0044-08

OC 500 LE/03.2003 GB 40/4 Operating Instructions Wheels and tyres 40

* Additional note for Michelin: On the front axle the tyre pressure should be that shown in the table plus 1 bar. However, the maximum value is 8.5. The numbers in the table show the respective axle load in kg. The table's first line gives the tyre pressure that is to be set in bar.

The tyre pressure table listed here must not considered to be complete and is primarily an aid to orientation. In general, the exact tyre pressure is set by the tyre manufacturer and is shown against the axle load in the manufacturer's tyre catalogue.

OC 500 LE/03.2003 GB 40/5 Operating Instructions Wheels and tyres 40

Tyre pressure table 11 R 22.5

M40_00-0045-08 * Additional note for Michelin: On the front axle the tyre pressure should be that shown in the table plus 1 bar. However, the maximum value is 8.5. The numbers in the table show the respective axle load in kg. The table's first line gives the tyre pressure that is to be set in bar.

OC 500 LE/03.2003 GB 40/6 Operating Instructions Wheels and tyres 40

Tyre pressure table 295/80 R 22.5

Reifendrucktabelle-08 * Additional note for Michelin: On the front axle the tyre pressure should be that shown in the table plus 1 bar. However, the maximum value is 8.5. The numbers in the table show the respective axle load in kg. The table's first line gives the tyre pressure that is to be set in bar.

OC 500 LE/03.2003 GB 40/7 Operating Instructions Wheels and tyres 40

Positioning the jack Bus

C634.220

Danger! Follow the jack manufacturer's instructions.

Danger! Secure the bus against rolling away (apply the parking brake). Use a wheel chock at the front axle if there is a defective wheel on the rear axle.

Front axle • Place the telescopic jack (10t) on a laminated wood Danger! Jamming hazard. If no floor stands are base and jack up the bus under the axle bracket on available you must put the spare wheel or the defec- the left or right hand sides. tive wheel at a suitable position under the bus body while you are changing a wheel as a protective measure for the event of the jack collapsing.

M00.00-0088-01

OC 500 LE/03.2003 GB 40/8 Operating Instructions Wheels and tyres 40

Driven axle • Place the telescopic jack (10t) on a laminated wood Danger! Jamming hazard. If no floor stands are base and jack up the bus at the jacking point (ar- available you must put the spare wheel or the defec- rowed). tive wheel at a suitable position under the bus body while you are changing a wheel as a protective measure for the event of the jack collapsing.

M40.00-0013-01

OC 500 LE/03.2003 GB 40/9 Operating Instructions Wheels and tyres 40

Removing the wheel nut cover cap Bus

C634.220

Danger! Secure the bus against rolling away.

• The wheel nut cover cap (1) is fastened to the wheel by two wheel nuts. Slacken and remove these two wheel nuts. • Remove the wheel nut cover cap (1).

W40_20-0057-01

OC 500 LE/03.2003 GB 40/10 Operating Instructions Wheels and tyres 40

Removing the wheels Bus

C634.220

Danger! Secure the bus against rolling away.

• Unscrew the wheel nuts (3). • Remove the wheels. When you remove the wheels, make sure that the disc wheels are not pulled over the threads on the wheel bolts. This would damage the bolt threads, make it difficult to screw on the wheel nuts and, in the worse case, the wheel nuts could seize on the damaged bolts.

M40.00-0016-01

OC 500 LE/03.2003 GB 40/11 Operating Instructions Wheels and tyres 40

Mounting the wheels Bus

C634.220

• Smear the outer circumference of centering lug (2) with "Plastilube" anti-corrosion paste to prevent the disc wheels from seizing. • Wheel bolt thread and wheel nut between the nut and disc washer (lightly oil at the arrow).

M40.00-0016-01

OC 500 LE/03.2003 GB 40/12 ***** ***** *** * * ****** ** * ***** *** *** **** ****** *************** ***** * ***** ****** * * *** ******* ******* ********* ***** * * ***** * file: C:/TEMP/GRIPS/EVO_Out.sgm position: 9949,1 (63,0) Error:document type does not allow element "SOLL" here . ***** ***** *** * * ****** ** * ***** *** *** **** ****** *************** ***** * ***** ****** * * *** ******* ******* ********* ***** * * ***** * file: C:/TEMP/GRIPS/EVO_Out.sgm position: 9951,1 (72,0) Error:end tag for "ANZWERT" which is not finished . ***** ***** *** * * ****** ** * ***** *** *** **** ****** *************** ***** * ***** ****** * * *** ******* ******* ********* ***** * * ***** * file: C:/TEMP/GRIPS/EVO_Out.sgm position: 9971,1 (63,0) Error:document type does not allow element "SOLL" here . ***** ***** *** * * ****** ** * ***** *** *** **** ****** *************** ***** * ***** ****** * * *** ******* ******* ********* ***** * * ***** * file: C:/TEMP/GRIPS/EVO_Out.sgm position: 9973,1 (72,0) Error:end tag for "ANZWERT" which is not finished . Operating Instructions Wheels and tyres 40

• Note the 2 different flat collar nuts. For steel disc wheels: flat collar nut without external marks.

For aluminium disc wheels: flat collar nut with external marks: 3 rings on the auto tensioner + "Für Alu-Räder" text on the hexagon.

Danger! Other wheel bolts and flat collar nuts are needed when the bus wheels are changed from steel wheels to aluminium wheels or vice versa. Con- tact an EvoBus ServicePartner prior to conversion.

M40.00-0033-01

• Put the wheels in place. • Put the wheel nut cover cap in place. Before placing the wheel nut cover cap in position, clean rust and dirt from the contact surfaces to the wheel nut cover cap if necessary. • Fit the wheel nuts until they are in contact with the disc wheel / wheel hub. • Raise the bus, remove the stands and lower the Follow the jacking instructions (see "Take off the bus. wheels").

OC 500 LE/03.2003 GB 40/13 Operating Instructions Wheels and tyres 40

• Tighten the wheel nuts to the specified torque, in a crosswise pattern. Danger! The wheel nuts must be retightened after the bus has been driven for 30-60 miles (approximately 50-100 km). Tightening torque Wheel nuts Nm Wheel nuts for aluminium wheels Nm

OC 500 LE/03.2003 GB 40/14 Operating Instructions Wheels and tyres 40

Maintenance Bus

C634.220

Inflating the tyres from the tyre inflation connection (optional extra)

Note: When the engine is running, a pressure up to 12 bar (pressure regulator cut-out pressure) can be drawn off. Compressed air can only be drawn of when the pressure regulator is in the fill position. If the pressure regulator is switched off (idle position - blows into the air) the pressure must be reduced by using the pedal-operated brake valve until the pressure regulator switches on.

Caution: As the pressure can be too high to fill a tyre the filling procedure should be monitored using the pressure display on the indication display unit.

• Front axle tyres: • Remove the protective cap from the tyre inflation The tyre inflating hose (2) is found in the toolkit. connection (1) in the front (installation location specified by superstructure manufacturer, normally behind bumper or nose cover) and connect the tyre inflating hose (2).

M40_00-0041-01

OC 500 LE/03.2003 GB 40/15 Operating Instructions Wheels and tyres 40

• Tyres on the rear/trailing axles: • Open the engine compartment cover. • Remove the protective cap from the tyre inflation The tyre inflating hose (2) is found in the toolkit. connection (1) (installation location: in the engine compartment on the top right) and connect the tyre inflating hose (2). • Close the engine compartment cover. Position the hose so that the engine compartment cover can be closed.

M40_00-0034-01

• Reduce the pressure in compressed-air system (by pumping the brake pedal), until the reservoir pressure in circuits 1 (14) and 2 (15) sinks to under 6.5 - 7 bar in the pressure display.

M00_00-0144-01

OC 500 LE/03.2003 GB 40/16 Operating Instructions Wheels and tyres 40

• Unscrew the protective cap from the tyre valve and place the valve connector (4) in position.

M40.00-0020-01

• Start the bus engine and fill the tyres up to the Check the display for reservoir pressure circuits 1 prescribed pressure (approximately 8.5 bar). First re- (14) and 2 (15). move the valve connector (4) from the tyre valve, then turn off the engine.

M00_00-0144-01

OC 500 LE/03.2003 GB 40/17 Operating Instructions Wheels and tyres 40

• After you have finished pumping the tyres remove Danger! Never drive the bus when the tyre in- the tyre inflating hose (2) and seal the tyre inflation flating hose is connected. connection (1) with the protective cap.

Danger! Pump up the tyres to the prescribed pressure at the next opportunity.

M40_00-0034-01

OC 500 LE/03.2003 GB 40/18 Operating Instructions Brake chassis/component 42

General Information / Safety Information Bus

C634.220

Safety precautions The bus braking behaviour may change if the indication display unit shows a yellow fault warning in the brake system. Drive with extreme care. Have the fault rectified as soon as possible at an EvoBus ServicePartner. The bus braking behaviour changes if a red fault warning is displayed. The pedal travel can increase during braking. The anti-blocking protection is switched off. Stop the bus immediately and disable it (as allowed by the traffic situation). Have an EvoBus ServicePartner rectify the fault immediately.

OC 500 LE/03.2003 GB 42/1 Operating Instructions Brake chassis/component 42

Operation Bus

C634.220

Braking and stopping

• When the bus is driven over long downhill distances Normally the service brake must only be applied you should make use of the braking effect of the en- sharply in the event of potential danger. gine by shifting into a lower gear. Use the installed permanent brakes as this removes loading from the Danger! Always apply the parking brake before service brake. you leave the bus. On uphill or downhill slopes you must also place wheel chocks at the wheels and turn the steering towards the kerbside. • Switch off the engine using the driving switch

Applying/releasing the parking brake

Requirement: operating pressure at least 5.8 bar to 6.4 bar

Danger! Only apply the parking brake when the bus is stationary. Always apply the parking brake before you leave the diver's position. On uphill or downhill slopes you must also place wheel chocks at the wheels and turn the steering towards the kerbside.

OC 500 LE/03.2003 GB 42/2 Operating Instructions Brake chassis/component 42

• Switch the lever for the parking brake (1) down in Danger! Check that the hand lever is fully the "A" position and engage it in place. locked in place. To do this, push the hand lever towards "B" without pulling the release ring (2) out of its lock position. The lever must not be able to be moved. The parking brake is applied (air venting noise can heard when it is operated).

M42.20-0003-01

The indicator lamp (6) lights up.

M54_00-0760-01

OC 500 LE/03.2003 GB 42/3 Operating Instructions Brake chassis/component 42

• Raise the locking ring (2) and swing the lever for The parking brake is released (air charging noise can the parking brake (1) upwards in the "B" position. heard).

M42.20-0003-01

The indicator lamp (6) goes out.

The reservoir pressure must be at least 6.4 bar to guarantee that the parking brake works perfectly. If the parking brake indicator lamp (6) does not go out despite there being adequate reservoir pressure there is a defect in the spring actuator or emergency release circuits. Have an EvoBus ServicePartner inspect the brake system.

A constant acoustic warning sounds if the parking brake is released and the driving switch is switched off.

M54_00-0760-01

OC 500 LE/03.2003 GB 42/4 Operating Instructions Brake chassis/component 42

Emergency braking with both brake circuits fail

• Pull the hand lever gradually towards "A" and hold Danger! The release ring must be pulled to pre- it in the required position as it otherwise automatical- vent the brake lever catching. ly returns to the release position "B". Danger! Risk of skidding. When the parking brake is engaged the ABS is inoperative.

M42.20-0003-01

Brake system (BS)

The electropneumatic brake system (BS) controls the braking of the bus. The brake assistant system (BAS), anti-blocking system (ABS), traction control system (TCR), start lock and frequent stop brake functions are integrated in the brake system (BS). The "BS" allows a faster braking effect to be achieved at the wheel brake and the braking force is distributed optimally to the individual axles. The permanent brakes (engine brakes / retarder) can be automatically switched on when the brake pedal is pressed down (permanent brake integration system).

TCS, start lock, frequent stop brake and permanent brake integration system are optional extras

OC 500 LE/03.2003 GB 42/5 Operating Instructions Brake chassis/component 42

• Fault indication: A fault in the electropneumatic Danger! The bus driving and braking charac- brake system is indicated in the (DIS) display by "BS" teristics may alter. If there is a yellow alarm: Drive (1) and a fault code (2) (see also Chapter 00, DIS). with care. Have the fault rectified by an EvoBus Ser- vicePartner. If there is a red alarm: Stop the bus as quickly as possible (heed the traffic situation), notify an EvoBus ServicePartner.

M54_00-0756-71

• Sensors which steplessly measure the brake lining When a brake lining thickness is too small it is dis- wear are fitted to each wheel. played on the DIS display (see Chapter 00).

Danger! The bus driving and braking characteristics may alter. Drive with care. Have the fault rectified by an EvoBus ServicePartner.

OC 500 LE/03.2003 GB 42/6 Operating Instructions Brake chassis/component 42

Brake assistant system (BAS)

• The brake assistant system (BAS) detects a haz- The brake assistant ensures that braking dis- ardous situation from the speed with which the brake tances are as short as possible. pedal is pressed and then immediately builds up the full braking force.

Anti-blocking system (ABS)

The anti-blocking system (ABS) prevents the wheels from blocking regardless of the road conditions and as slow as walking speed.

Danger! In the event of danger the brake pedal should therefore be pressed down fully. This guarantees that all wheels are regulated and the bus decelerates optimally. If the road surface is slippery you should also declutch so that the braking effect of the engine does not affect the action of the ABS.

Danger! The anti-blocking protection in the ABS does not release the driver from the requirement to drive according to traffic and road conditions. The bus course holding and steerability are improved when it brakes. However, the anti-blocking protection is unable to avert the consequences of driving with a too low safety distance or too high a speed in bends.

• Functional check: switch on the driving switch. The ABS indication display lights up for approx. 2 seconds in the (DIS) display.

Danger! The indication display must illuminate and go out after 2 seconds or after the bus has started to move. Anti-blocking protection (and TCS) function is not guaranteed if the indication display does not go out or if it illuminates as the bus is being driven. Drive with care. Have an EvoBus ServicePartner rectify the fault.

OC 500 LE/03.2003 GB 42/7 Operating Instructions Brake chassis/component 42

• The ABS automatically switches the permanent brakes off if they are engaged and one or both wheels block. However, the "Permanent brake" (11) indicator lamp does not go out as long as the permanent brake switch is applied.

M00_00-0144-01

Traction control system (TCS) (optional extra)

The traction control system (TCS) prevents the drive wheels from spinning when the bus starts to move or accelerates, regardless of the road conditions.

Danger! Accident risk. – The traction control system (TCS) does not release the driver from the requirement to drive according to traffic and road conditions. – The bus could skid if the TCR is switched off and the drive wheels spin.

OC 500 LE/03.2003 GB 42/8 Operating Instructions Brake chassis/component 42

• Indicator lamp check: Switch on the driving switch. The "TCS" indicator lamp (17) lights up and must go out after approx. 10 seconds.

M54_00-0760-01

• The "TCR" is automatically switched on if the drive The "TCS" indicator lamp (17) lights up. wheels on one or both sides start to spin. • If the drive wheels spin on one side they are automatically braked. • If the drive wheels spin on both sides the engine The tempomat cannot be activated (or switched output is automatically reduced. on). If the tempomat was switched on before the "TCS" intervention, it is switched off and then reac- tivated after the TCS intervention.

OC 500 LE/03.2003 GB 42/9 Operating Instructions Brake chassis/component 42

• The TCS can be switched off: Press the "TCS" Danger! – The bus could skid if the "TCR" is switch. switched off and the drive wheels spin.

The "TCS" indicator lamp (17) flashes.

• Press switch "TCS" again. Bus being driven with "TCS", the "TCS" indicator lamp (17) must go out.

The traction control system is automatically switched on again after the engine is switched off and then on.

M54_00-0760-01

OC 500 LE/03.2003 GB 42/10 Operating Instructions Brake chassis/component 42

Frequent stop brake

• The frequent stop brake is activated when the The frequent stop brake requires less switch is pressed on the instrument panel. compressed air than the parking brake. Therefore, the frequent strop brake should be used at bus stops as much as possible.

Only use when the bus is stationary.

Danger! Always correctly apply the parking brake before you leave the diver's position. Accident risk. The parking brake must be applied to park the bus. If required, (e.g. on upwards or downwards gradients) also secure the bus with wheel chocks to prevent it from rolling away.

• Reaction on the bus when the frequent stop brake The indicator lamp (10) lights up in the indication dis- is engaged: play unit. All wheel brakes are automatically braked with 2.0 bar compressed air. Engine idling speed. The engine speed cannot be increased any more.

M00_00-0144-01

Automatic frequent stop brake (optional extra)

The frequent stop brake function described above is extended by the following for the "automatic frequent stop brake" model: The frequent stop brake can not only be

OC 500 LE/03.2003 GB 42/11 Operating Instructions Brake chassis/component 42 applied by the switch on the instrument panel, but also, for instance, automatically when the passenger door is opened. (The switch-on conditions are dependant upon the superstructure manufacturer, adhere to the operating instructions of the superstructure manufacturer.)

• The automatic frequent stop brake is only switched The indicator lamp (10) must go out. off once the switch-on conditions are deactivated (e.g. the passenger doors have been closed) and then the accelerator pedal is pressed down.

M00_00-0144-01

• "Emergency stop" switch with "automatic frequent stop brake". • The "automatic frequent stop brake" can be Danger! Ensure that the doors and all luggage switched off by using the emergency release switch in compartment cover are securely closed before press- emergencies (e.g. technical defect - frequent stop ing the emergency switch. Drive with care, always brake does not switch off). This allows the bus to apply the parking brake when the bus is stationary as continue to be driven with limited functions. the frequent stop brake can no longer be engaged by the actuation switch on the instrument panel. Have an EvoBus ServicePartner rectify the fault as soon as possible. Operation: raise the switch cover and pull up the yellow pin. Reset the switch: push in the yellow pin. Close the switch cover.

OC 500 LE/03.2003 GB 42/12 Operating Instructions Brake chassis/component 42

Brake system reservoir pressure

The reservoir pressure must be adequate in the individual compressed air circuits of the brake system (10 bar) and auxiliary consumers (8.5 bar) to guarantee the operating safety of the bus. The auxiliary consumers are only charged after brake circuits 1 and 2 have been charged. The reservoir pressure required for the service brake is 10 bar.

• The reservoir pressure for brake circuits 1 (14) and 2 (15) can be read off at the manometers in the indication display unit.

M00_00-0144-01

OC 500 LE/03.2003 GB 42/13 Operating Instructions Brake chassis/component 42

The symbol below is shown on the DIS display when the reservoir pressure in brake circuit 1 or 2 drops to under 6.8 bar or to under 5.5 bar in the parking brake circuit: Danger! Stop the bus immediately (heed the traffic situation). Have an EvoBus ServicePartner inspect the brake system.

Danger! A sensor is defective if a the "STOP" display lights up in the indication display unit and no pressure can be read in the manometer. Stop the bus immediately (heed the traffic situation). Have an EvoBus ServicePartner inspect the brake system. • When the compressed air consumption is too high (e.g. after activating the lifting and lowering system and simultaneously manoeuvring), only continue driving after the indication display has gone out. The fault is cancelled only when 7.2 bar is exceeded. • The symbol below is shown on the DIS display Danger! Malfunctions may occur in the pneu- when the reservoir pressure in the auxiliary consumer matic suspension system, door system or clutch op- circuit drops to under 5.5 bar: eration. Drive carefully. Have the compressed-air system checked immediately by an EvoBus ServicePart- ner.

OC 500 LE/03.2003 GB 42/14 Operating Instructions Permanent brakes 43

Operation Bus

C634.220

Permanent brakes (wear resistant auxiliary brakes)

Permanent brakes: The bus has engine brakes and a retarder integrated in the automatic transmission. There are different methods of applying the permanent brakes.

Actuation by the "multi-function stalk for permanent brakes and tempomat" (hand lever).

Automatic actuation by the brake pedal (permanent brake integration system).

As well as a combination of both alternatives.

• Actuation by the "multi-function stalk for permanent brakes and tempomat" (hand lever). • In stalk position 2.1 - 2.5 the permanent brakes Two engine-brake steps can be controlled. (Only are switched on. In positions 2.1 and 2.2 the engine exhaust flap and also constant choke). The question brakes are switched on. In stalk positions 2.3 - 2.5 of which engine-brake step is engaged in stalk posi- the retarder is also switched on. tions 2.1 and 2.2 is dependent on different factors and is performed by the "drive control" control unit.

The effect of the engine brake is dependant upon the engine speed (high engine speed = high engine braking output). The engine brake is only effective at engine speeds above 900/min and can be used up to approx. 2300/min. Observe the best effective range of the engine brakes (yellow area) on the tachometer.

M54.00-0082-01

OC 500 LE/03.2003 GB 43/1 Operating Instructions Permanent brakes 43

• Retarder: activation is performed in three brake Requirements for retarder operation: - accelera- steps (stalk positions 2.3 - 2.5). tor pedal is not pressed down; - a forward drive position (1-D) is engaged; - the road speed exceeds 3 kph.

When the retarder is engaged the transmission does not shift up into the next highest gear (change- up block).

Danger! The permanent brakes switch off and the change-up block is disengaged if the accelerator pedal is pressed when the permanent brake is active.

M54.00-0082-01

The retarder is automatically reduced above a specified coolant temperature characteristic.

Danger! The braking efficiency reduces, brake the bus by using the service brake.

• On buses fitted with the "permanent brake integration system" the engine and retarder brake steps are automatically actuated. The question of which brake step is engaged is dependent on various factors (e.g. bus speed, brake pedal position, engine speed).

OC 500 LE/03.2003 GB 43/2 Operating Instructions Permanent brakes 43

• The "Permanent brake" (11) indicator light lights up Do not engage the permanent brakes if the "Per- when the permanent brakes are engaged. manent brake" indicator lamp illuminates in lever position "0". Have the fault checked by an EvoBus Servi- cePartner.

M00_00-0144-01

OC 500 LE/03.2003 GB 43/3

Operating Instructions Steering 46

General Information / Safety Information Bus

C634.220

Important note The size of the steering system and the mechanical steering ratio have been selected so that in the event of a malfunction in the hydraulic steering servo the force that has to be applied to the steering wheel does not ex- ceed what the legislators deemed to be the maximum reasonable amount. For vehicles over 12t this force is 450N (400N for vehicles between 3.5t and 12t) applied to the steering circumference when steering the vehicle from driving straight ahead into a circle with a 20m radius at a speed of approximately 10 kph. No more than 6 sec. are to pass from starting the turn up to reaching the 20m radius. The driver must know that if the steering servo breaks down suddenly (e.g. by pump drive malfunction) the bus can nevertheless still be steered, although considerably more force must be applied in order to steer. As such a situation occurs extremely rarely, but then often completely unexpectedly, the driver may mistakenly assume that the steering system is blocked. The driver merely has to apply the necessary force in order to steer. This important note should assist in clarifying the described interrelationship and possibly assist the driver against making a misjudgement.

Danger! If the steering servo malfunctions the bus is very difficult to steer. Have the fault rectified immediately by an EvoBus ServicePartner.

OC 500 LE/03.2003 GB 46/1 Operating Instructions Steering 46

Operation Bus

C634.220

Adjusting the steering column

• To adjust the steering column press the button (1) Danger! Only make adjustments when the bus downwards. is stationary. Lock the steering column in place after you have adjusted the steering wheel to match the driver's requirements. To do this, press button (1) upwards.

If the button (1) is not pressed again the steering column will automatically lock after approx. 12 seconds.

M46.00-0030-01

Turning the steering wheel when the bus is stationary

• Adhere to the instructions. When the steering wheel is turned and the bus is stationary without the servo (engine switched off) and without a turntable under the front wheels (tyres have direct contact with the ground) you must consider the points below to prevent damage to the steering column.

OC 500 LE/03.2003 GB 46/2 Operating Instructions Steering 46

• Slacken the steering wheel adjuster and push the Never have more than one person turn the steer- steering wheel forward and down as far as it can go. ing wheel. Do not pull the steering wheel on one side Fix the steering wheel adjuster in place. Turn the only. steering wheel using both hands at an angle of 90° to 180° to one another. We ask the workshop in particular to note this.

Steering hydraulic system oil level too low

• The adjacent warning is shown in the (DIS) display Danger! Stop the bus immediately (heed the if the oil level in the steering hydraulic system expan- traffic situation). Have an EvoBus ServicePartner sion tank has dropped to the minimum capacity. check the steering system for leaks. There is a risk of accident if there is further oil loss as the bus can only be steered with difficulty.

OC 500 LE/03.2003 GB 46/3 Operating Instructions Steering 46

Maintenance Bus

C634.220

Checking the oil level in the steering hydraulics expansion tank

• Reading the oil level When the engine is running you must be able to see the oil level lay between the min. and max. markings (2) on the expansion tank (1).

Danger! Hydraulic oil for the steering system must only be filled by an authorised specialist who adheres to the service product instructions.

M46.00-0032-01

OC 500 LE/03.2003 GB 46/4 Operating Instructions Fuel system 47

General Information / Safety Information Bus

C634.220

Refuelling Only use diesel fuels that comply with DIN EN 590 (see service product instructions). Use winter-grade diesel fuel in cold periods (down to approx. -20 °C). When external temperatures are even colder the diesel fuel can become unusable due to paraffin separation. As a preventative measure against this you may add proportionate quantities of petroleum or authorised flow im- provers dependant upon the external temperature. The engine output may reduce according to the amount of additive. Therefore pour in as little additive as possible according to the external temperature. (Maximum petroleum additive 50%). The addition of petroleum reduces the flash point of the diesel fuel. This therefore increases the risks when handling this fuel mixture. Make sure you obey the relevant safety regulations. Switch off the engine and auxiliary heating before you refuel. Park the bus on a level surface before you refuel. Ensure that cleanliness is at the utmost level when refuelling. Do not leave cotton waste or cleaning cloths in the proximity of opened filler necks.

Danger! Risk of explosion from fuel ignition, risk of poisoning from inhalation and swallowing fuel as well as risk of injury due to skin and eyes coming into contact with fuel.

Safety instructions for working in the engine compartment

Danger! Never leave the engine running when work is carried out in the engine compartment. Safeguard the engine against it being switched on without authorisation. Take the key out of the driving switch. If the engine is at its operating temperature allow it to cool down for some time - risk of burning.

OC 500 LE/03.2003 GB 47/1 Operating Instructions Fuel system 47

Maintenance Bus

C634.220

Draining water from the fuel pre-filter

Danger! Risk of explosion from fuel ignition, risk of poisoning from inhalation and swallowing fuel as well as risk of injury due to skin and eyes coming into contact with fuel.

• Place a container underneath. • Unscrew and remove the drain plug (4) at the bot- tom of the filter. • Pump off water using the fuel feed pump (1). Dispose of the water/fuel mixture in accordance with environmental protection requirements. • Replace and tighten the drain plug (4).

M47.00-0011-01

OC 500 LE/03.2003 GB 47/2 Operating Instructions Fuel system 47

Maintenance Bus

C634.220

Changing the fuel pre-filter

Danger! Risk of explosion from fuel ignition, risk of poisoning from inhalation and swallowing fuel as well as risk of injury due to skin and eyes coming into contact with fuel.

• Place a container underneath. Danger! Safeguard the engine against it being switched on. Switch off the driving switch and take out the key. • Switch off the fuel supply using the shutoff device (4) ("Fuel Off" position). • Slacken the drain plug (8) and bleed screw (3) and let the filter element run empty. Dispose of fuel in accordance with environmental protection requirements. • Remove the filter element (5) from the filter head The separation container (7) can be reused so do and disconnect the separation container (7) from the not damage it. filter element.

Dispose of the old filter element (5) in accordance with environmental protection requirements. M47_00-0015-01 • Clean the separation container (7) and sealing ring groove.

OC 500 LE/03.2003 GB 47/3 Operating Instructions Fuel system 47

• Rub the new square ring (6) with clean diesel oil or engine oil and lay it in the separation container groove. • Screw the separation container (7) finger tight onto Do not use any tools when tightening. the new filter element (5). • Grease the new sealing ring (2) with clean diesel oil or engine oil and lay it in the filter element groove (5). • Screw the filter element (5) finger tight onto the new filter head. • Tighten the drain plug (8). • Open the fuel supply using the shutoff device (4) ("Fuel On" position). • Fill the filter using the fuel feed pump (1) until fuel flows out of the opened bleed screw (3) without any M47_00-0015-01 bubbles. • Tighten the bleed screw (3). • Start the engine and check that the system does not have any leaks. Danger! Risk of injury: only carry out any tightening when the engine is switched off.

OC 500 LE/03.2003 GB 47/4 Operating Instructions Fuel system 47

Maintenance Bus

C634.220

Changing the main fuel filter

Danger! Risk of explosion from fuel ignition, risk of poisoning from inhalation and swallowing fuel as well as risk of injury due to skin and eyes coming into contact with fuel.

• Safeguard the engine against it being switched on. Switch off the driving switch and take out the key. • Open the cap on the fuel tank. The is necessary to reduce the excess pressure. • Block the fuel supply using the shutoff device (2) on the fuel pre-filter ("Fuel Off" position).

M47.00-0011-01

OC 500 LE/03.2003 GB 47/5 ***** ***** *** * * ****** ** * ***** *** *** **** ****** *************** ***** * ***** ****** * * *** ******* ******* ********* ***** * * ***** * file: C:/TEMP/GRIPS/EVO_Out.sgm position: 13058,1 (63,0) Error:document type does not allow element "SOLL" here . ***** ***** *** * * ****** ** * ***** *** *** **** ****** *************** ***** * ***** ****** * * *** ******* ******* ********* ***** * * ***** * file: C:/TEMP/GRIPS/EVO_Out.sgm position: 13060,1 (72,0) Error:end tag for "ANZWERT" which is not finished . Operating Instructions Fuel system 47

• Place a container underneath Fuel must not come into contact with drive belts or other parts that are not fuel-resistant. • Empty the fuel filter housing: slacken the hollow The fuel return line runs empty (approx. 0.5 l fu- screws (1.1) and (1.2) on the fuel filter support ("T" el). connection).

Dirty fuel will enter the engine circuit if you do not do this.

Dispose of the drained out fuel in accordance with environmental protection requirements.

M47_00-0039-03

OC 500 LE/03.2003 GB 47/6 Operating Instructions Fuel system 47

• Unscrew filter cover (1) • Remove the filter element (3) and place a new filter element in position. Dispose of the old filter element in accordance with environmental protection requirements. • Replace the O-ring (2) and screw on the filter cover Tightening torque (1). Screw cap Nm

M47_00-0010-01

OC 500 LE/03.2003 GB 47/7 Operating Instructions Fuel system 47

• Tighten the hollow screws (1.1) and (1.2) on the fuel filter support ("T" connection).

M47_00-0039-03

OC 500 LE/03.2003 GB 47/8 Operating Instructions Fuel system 47

• Open the fuel supply using the shutoff device (2) on the fuel pre-filter ("Fuel On" position). • Start the engine and check that the system does The engine fuel system is self-bleeding. Bleeding not have any leaks. can be supported by using a hand pump on the fuel pre-filter to protect the battery and starter.

M47.00-0011-01

OC 500 LE/03.2003 GB 47/9 Operating Instructions Fuel system 47

Maintenance Bus

C634.220

Bleeding the fuel system

• Open the bleed screw (3). • Start the fuel feed pump (1) and pump until fuel flows out of the bleeding vent without any bubbles. • Tighten the bleed screw (3). The bus circuit (from the petrol tank to the pre- filter) has to be bled. The engine circuit (from the pre-filter to the main filter) is self-bleeding. Howev- er, bleeding should be supported by using a hand pump on the fuel pre-filter to protect the battery and starter. • Start the engine and check the fuel system for any Stop the start-up procedure after 15 seconds if leaks. necessary and repeat after approximately 1 minute. M47.00-0011-01 After you have tried to start the bus 3 times you must break off briefly (approximately 15 minutes).

OC 500 LE/03.2003 GB 47/10 Operating Instructions Electrical equipment, instrumentation 54

General Information / Safety Information Bus

C634.220

Safety precautions The control panels and batteries are delivered preassembled and precabled, but without a precisely defined installation location on the chassis. The superstructure manufacturer is responsible for the precise installation position and access. Whenever any work is carried out on the electrical system or the batteries are connected or disconnected the following must be heeded for safety reasons: Always switch off the workshop switch (2). The driving switch must always be switched off whenever wiring harness plugs are connected or disconnected to electronic control units. Always protect the starter, generator and electrical plug connections against dampness when the engine is washed. Never bridge fuses or replace one with a fuse that has a higher amp rating.

M54_00-0806-01

OC 500 LE/03.2003 GB 54/1 Operating Instructions Electrical equipment, instrumentation 54

Safety instructions for handling batteries

Danger! Open flames and smoking are strictly forbidden whenever work is carried out to the bus batteries. Spark formation must be prevented. Wear safety goggles. Keep children away. There is a risk of caustic burns. The operating instructions must be complied with. There may be a risk of explosion.

Danger! Risk of injury/explosion. Battery acid is corrosive. Always heed the safety instructions and safety precautions when handling batteries or battery acid. Battery acid must never come into contact with skin, eyes, clothing or the bus paintwork. Keep children away. Immediately rinse off acid splashes with clean water, contact a doctor. Do not place any metal objects on batteries (risk of short circuit). Do not smoke in the proximity of batteries; prevent sparking or naked flames (risk of explosion).

M54.00-0117-01

Action to be carried out during electrical welding The safety requirements below must be adhered to in order to protect electronic control units against excess voltage during electrical welding:

- Remove the terminal from the negative pole of the battery (follow the instructions for removing terminals from the bus batteries).

- Connect the earthing cable of the electrical welder directly to the part to be welded. Make sure when doing this that there are no electrically insulated components between the earthing cable and the weld point.

- Do not allow the electronic control units and electrical cables to come into contact with the earthing cable, welding electrode or welding rod.

OC 500 LE/03.2003 GB 54/2 Operating Instructions Electrical equipment, instrumentation 54

Operation Bus

C634.220

Removing terminals from the bus batteries

• Switch off the engine The superstructure manufacturer is responsible for the exact battery locations and battery access.

M54_00-0806-01

OC 500 LE/03.2003 GB 54/3 Operating Instructions Electrical equipment, instrumentation 54

• Switch off the workshop switch (2) Danger! There is a risk of explosion due to break sparks acting on oxyhydrogen gas when terminals are removed from the batteries. The workshop switch (2) has been installed to exclude this risk of injury.

Danger! Before work is carried out on the bus electrical system, and especially on the batteries, switch the workshop switch (2) to OFF (key can be removed). The workshop switch interrupts the main cable from the positive pole of the battery to the whole bus electrical system and may therefore only be switched off when the driving switch is in the switched off position and after the auxiliary heater has carried out a delay switch-off (risk of overheating).

• Disconnect the battery minus terminal (5). The adjacent illustration shows a possible example, the superstructure manufacturer is responsible for the positioning of the batteries.

M54_00-0806-01

• Disconnect the battery plus terminal (4).

OC 500 LE/03.2003 GB 54/4 Operating Instructions Electrical equipment, instrumentation 54

• Reconnect terminals to the batteries in the reverse order

Recharging the bus batteries

Recharge any batteries that are not used once per month

• Connect the charger Danger! Risk of explosion due to formation of oxyhydrogen gas. Make sure there is good ventilation when you charge the bus batteries.

Check the charging voltage (24 or 12 V) and charging current (approximately 1/10 of the rated capacity, e.g. 200Ah battery with 20 A charging current) are correct. • Switch of the charger after charging has finished Danger! Only disconnect the connecting terminals after no more gas is released from the battery (wait a few minutes).

OC 500 LE/03.2003 GB 54/5 Operating Instructions Electrical equipment, instrumentation 54

Notes on jump starting

• Use the jump start connector (3) for jump starting if possible.

M54_00-0806-01

• If jump starting is not carried out using the jump Before you connect the jump leads check that the start connector: make sure that you obey the follow- operating voltage (24V) and polarity are the same. ing instructions. Only ever use jump leads (cable diameter approximately 70 mm2) for a jump start, never use a boost charger. Comply with the safety regulations.

Only use jump leads that have insulated terminals.

A discharged battery can freeze at temperatures below -10°C. It must be defrosted before the jump start.

Danger! Risk of caustic burns. Do not lean over the batteries during the jump start.

OC 500 LE/03.2003 GB 54/6 Operating Instructions Electrical equipment, instrumentation 54

Carrying out the jump start

• Turn the key in the driving switch back until it can go no further. • Firstly connect one end of the positive cable to the (+) pole on the discharged battery and the other end to the (+) pole on the charged battery.

M54_00-0806-01

• Connect the negative cable to the (-) pole on the As far as possible from the discharged battery. charged battery and then the other end to an earthed metal part that is bolted to the engine block. • Run the engine of the charged vehicle at an increased speed. • Start the engine of the bus to be jump started in the normal way and let it run at idle speed. • Switch off the engine of the charged vehicle.

• Fully disconnect the earth connection of the jump Before you disconnect the jump leads switch on leads then disconnect the positive cable. the larger consumer units of the jump started bus, such as the lighting, heated windows or ventilation, to prevent voltage peaks.

OC 500 LE/03.2003 GB 54/7 Operating Instructions Electrical equipment, instrumentation 54

Handling fuses

• Always carry some extra fuses in the bus for the Fuses provide protection against too-high cur- event of an emergency. rents (cables heating outside tolerances) in the electrical system. The superstructure manufacturer is responsible for the control panel installation locations. The fuse assignment (chassis-based) is vehicle- specific. The legend is printed printed on the adhe- sive label close to the control panels (only if fitted by the superstructure manufacturer).

Make sure that you correct the cause of the short circuit before you change a burnt-out fuse. Check that the connections have a good contact. • Make sure that you obey the adjacent instructions. Danger! Never bridge or repair fuses. Never change fuses for one with a higher amp rating - this would result in damage to the electrical system.

Always switch off the workshop switch before any work is carried out on the electrical system.

OC 500 LE/03.2003 GB 54/8