VDL Workshop Manual

WORKSHOP MANUAL
Citea LLE E6 EBS-1C

Main group 5
1640 DD0855_02
Citea LLE E6 EBS-1C
Foreword
This workshop manual contains all the relevant informa-
tion to help when tracing and solving technical problems,
when making adjustments and when carrying out repair
work.
The book contains diagrams, system descriptions, fault
finding instructions and work instructions. It also contains
safety regulations, which must be strictly observed.
Experienced mechanics
The technical information and the explanations of the
repair work stated in this workshop manual have been
compiled with the utmost care.
Whilst compiling this workshop manual, it has been

assumed that the mechanic has the necessary experi-
ence and has had the required education or training to be
able to carry out the work in a responsible and safe man-
ner.
Vehicle type
The information in this manual has been updated until
the time of printing and only concerns the following
vehicle series:
- Citea LLE 120-250 ISB6.7 E6.
In this manual, this series of vehicles is referred to as:

"Citea LLE E6 EBS-1C".
ISB6.7 indicates that the contents of this manual relate to

the 6.7 litre ISB6.7 engine from Cummins.
E6 indicates that this manual contains guidelines for the

engines which meet the Euro 6 emission requirements.
"EBS-1C" indicates that this vehicle series has a 1st gen-

eration EBS brake system.
DD0855_02
5 CONTENTS
Citea LLE E6 EBS-1C
Steering column switch..................................1-10
Technical information Diagnosis .......................................................2-1 0

Diagnosis of the electrical systems .................2-1
General information...................................... 1-1
Earth connections ........................................... 1-3
Wiring harnesses ............................................ 1-4
Components.................................................... 1-6 Wiring repairs 1
Tightening torques ....................................... 2-1
Accessories and special tools .....................1-1
Connector ........................................................1-1
Contact ............................................................1-1
Diagnosis
Special tools ....................................................1-2 2
Removing and installing contacts ...............2-1
Tracing faults ................................................ 1-1 Unlocking connectors ......................................2-1
Battery fault finding table ................................ 1-1 Unlocking contacts ..........................................2-5
Lifespan .......................................................... 1-4 Removing a contact .........................................2-8
Fault finding charts.......................................... 1-5 Locking an MQS contact ...............................2-10
3
Tracing faults ................................................ 2-1 Bosch 89-pole connector ...............................2-11
Generator fault finding table............................ 2-1 39-pole connector contacts ...........................2-12
Cummins engine connectors .........................2-15
Electrical connections ..................................3-1 4
Making crimping connections ..........................3-1
Tracing electrical faults Fitting a Scat seal ............................................3-6
Fitting an electrical knock connection ..............3-7
Test equipment and points of attention...... 1-1 Earth wire: removing and installing..................3-9
Points of attention when tracing faults ............ 1-2 Repairing CAN network wiring.......................3-10 5
Locating short circuits ..................................... 1-5
Locating breaks............................................... 1-6
Locating contact resistances........................... 1-7
Locating poor earth connections..................... 1-8
Batteries
6
Safety regulations .........................................1-1
General information .........................................1-1
Measurement and diagnosis Charging the batteries .....................................1-3
equipment General information ......................................2-1
Properties ........................................................2-1 7
Devices .......................................................... 1-1
General information .........................................2-3
Calibrating the tachograph .............................. 1-1
Opening and closing the battery box ...............2-6
BOB test box................................................... 1-1
Disconnecting and connecting the battery cables2-7
Digital multimeter (FLUKE) ............................. 1-3
Removing and installing the batteries..............2-9
Diagnosis tool ................................................. 1-4
Cleaning the batteries....................................2-11 8
Measurement variables................................... 1-5
Signals ............................................................ 1-6 Charging the batteries ..................................3-1
Lead-antimony battery .....................................3-1
Sealed lead-calcium battery (SMF) .................3-4
Gel battery .......................................................3-6 9
Electrical components Storage of batteries .......................................4-1
Component description................................ 1-1 General information .........................................4-1
Inductive transmitter........................................ 1-1 Storage for less than 4 weeks .........................4-2
Storage for more than four weeks ...................4-3
Pressure sensors ............................................ 1-2
Generator........................................................ 1-3
10
Inspecting the batteries ................................5-1
Earth breaker switch ....................................... 1-4 Lead-antimony battery .....................................5-1
Temperature sensors...................................... 1-6 Sealed lead-calcium battery (SMF)/gel battery5-5
Fluid level sensors .......................................... 1-7
Vehicle speed sensor...................................... 1-9 External starting assistance .........................6-1
Starting assistance with the NATO plug ..........6-2
DD0855_02
CONTENTS 5
Citea LLE E6 EBS-1C
Starting with the aid of auxiliary batteries ....... 6-3

0 Battery charging assistance ........................ 7-1 Function diagrams
Lead-antimony battery .................................... 7-1
Sealed lead-calcium battery (SMF)/gel battery7-4 Function diagrams ........................................1-1
Antigas.............................................................1-1
Clutch air conditioning off ................................1-6
1 Air conditioning speed control .........................1-7
Electrical installation ASR switch active ............................................1-8
ASR warning symbol .......................................1-9
General information...................................... 1-1 Automatic sump filling....................................1-10
Determining the safety level............................ 1-1 CAN network .................................................1-14
2 Precautionary measures when welding .......... 1-2 Central lubrication..........................................1-15
Peak voltages ................................................. 1-3 Cruise control ................................................1-17
EMC compatibility ........................................... 1-4 EAS euro 6 ....................................................1-19
CAN network................................................... 1-5 EBS red warning symbol ...............................1-26
Overview of the network systems ................... 1-7 EBS yellow warning symbol ..........................1-27
3 Electrical installation .................................... 2-1
ECAS .............................................................1-28
Fan operation (WE) .......................................1-32
Simulating a speed signal ............................... 2-1
Coolant level..................................................1-35
Coolant temperature ......................................1-38
Air pressure gauges ......................................1-39
4 Service diagrams
Engine start/stop............................................1-42
Engine control sump refill ..............................1-46
Service diagrams .......................................... 1-1 Engine compartment temperature .................1-56
The diagram.................................................... 1-1 AdBlue tank level...........................................1-57
Oil separator ..................................................1-58
5 Oil pressure ...................................................1-60
Primary retarder.............................................1-61
Brake lining wear ...........................................1-62
Reading the service diagrams Voltage supply ...............................................1-63
General information...................................... 1-1 Steering adjustment lock ...............................1-64
6 Overview of abbreviations............................... 1-1 Automatic gearbox.........................................1-65
Engine protection valve .................................1-68
Marks on electrical wiring ............................ 2-1 Vehicle weight monitoring..............................1-69
Introduction ..................................................... 2-1
Colour code..................................................... 2-2
7 Numeric code .................................................. 2-3
Explanation and reading .............................. 3-1
Recognizing the power supply and the earth .. 3-1
Area indication ................................................ 3-2
Electric Part Code (EPC) ................................ 3-3
8
10
DD0855_02
Citea LLE E6 EBS-1C
Disclaimers
© 1640 VDL Bus & Coach bv, Valkenswaard,

The Netherlands.
In the interest of continuous product development VDL

Bus & Coach reserves the right to change specifications
or products at any time without prior notice.
No part of this publication may be reproduced and/or

published by printing, by photocopying, in digital format
or in any way whatsoever without the prior consent in
writing of VDL Bus & Coach.
This manual shall be governed by and applied in

accordance with the laws of the Netherlands.
Any dispute here under shall be referred to the decision
of the District Court of ’s-Hertogenbosch in the
Netherlands
Next remark is relevant if the text has been translated for

your convenience from the English original into an other
language.
A translation, however, can have the consequence that
differences of interpretation arise with respect to the
content and meaning of the text.
In all cases, therefore, the English version of this
document will be regarded exclusively as the single and
authentic source to establish the content and the
meaning of the text in case of a dispute.
DD0855_02
5
Citea LLE E6 EBS-1C
2-4 DD0855_02
5 TECHNICAL INFORMATION
Citea LLE E6 EBS-1C
TECHNICAL INFORMATION
0
DD0855_02
TECHNICAL INFORMATION 5
Citea LLE E6 EBS-1C
DD0855_02
Citea LLE E6 EBS-1C General information
1. GENERAL INFORMATION
0
Points of attention concerning the electrical installation
• The earth cable must always be removed from the battery
when carrying out work that does not require the vehicle to
have an electrical power source.
• Never replace a fuse with one of a higher capacity. The
correct capacity for a fuse can be found on the sticker on
the inside of the fuse box cover. The fuse capacity is also
stated on the electrical system’s diagrams.
• Do not remove the fuse from the fuse holder while the elec-
trical system still has a voltage applied to it. Sparks may be
produced when removing a fuse. The spark can burn the
fuse holder’s contact surface and a peak voltage may be
introduced in the electrical system.
• Use a BOB test box to measure the voltage on an electrical
unit. The ECU connector with connector pins will then not
be subjected to an unnecessary mechanical load.
• When measuring the voltage across a certain (in-line) con-
nector pin, it is better to take the measurement from the
rear of the connector. Repeated insertion and removal will
reduce the connector pin’s resilience, which may lead to a
new fault.
• Do not use a tester with an LED. The LED will be lit if the
circuit or component has a poor earth connection. For a
similar test, a standard test lamp will not be lit or will be
hardly lit and is, therefore, more reliable.
• Do not connect any extra current consumers to fuses which
already protect certain electrical circuits, because this may
result in a short circuit or cause a fire.
• Do not start the engine if the battery cables are not suffi-
ciently tightened.
• When replacing the wiring, always use wiring of the same diam-
eter. Otherwise, it may result in a short circuit or cause a fire.
Table 1 below gives all the plating combinations for contacts.

The contact plating can be of different materials. It is, there-
fore, NOT permitted to combine contacts whose plating is not
listed below (gold-plated, silver-plated, tin-plated).
Combinations of different platings Combination permitted or NOT permitted
Gold-plated contact with gold-plated contact. Permitted.
Silver-plated contact with silver-plated contact. Permitted.
Tin-plated contact with tin-plated contact. Permitted.
Gold-plated contact with silver-plated contact. NOT permitted because of the material properties.
Gold-plated contact with tin-plated contact. NOT permitted because of the material properties.
Silver-plated contact with tin-plated contact. NOT permitted because of the material properties.
Tabel 1
Always use gold-plated or silver-plated contacts if the current

is ≤ 5 mA.
• Use tin-plated contacts for temperatures up to 130 °C.
• Use silver-plated contacts for temperatures up to 140 °C.
• Use gold-plated contacts for temperatures up to 150 °C.
DD0855_02 1-1
General information Citea LLE E6 EBS-1C
Ring terminal symbol

0 1. Only for use inside the vehicle.
• Maximum of four flat ring terminals under an attach-
ment bolt.
ILAh1338
Ring terminal with feed tube symbol

1. For use on the engine and in the chassis.
• Maximum of two ring terminals with feed tube under an
attachment bolt.
• A (glued) shrink sleeve must be placed over the tube of
the ring terminal to protect it against moisture. The
sleeve also serves as extra insulation material.
ILAh1339
1-2 DD0855_02
1.1 EARTH CONNECTIONS

An important inspection when there is a fault in the electrical
0
system concerns the central earth connection, where the
earth connections on the chassis require special attention.
Attention must be given to the following if an earth connec-

tion has been disconnected and then reinstalled:
• The bolt, the nut, the earthing strip and the locking washers
must be cleaned (for example, with a steel brush or sand-
paper). If a component has become corroded, then it must
be replaced by a new component.
• All the dirt and paint must be cleaned from both sides of the
chassis beam at the engine/chassis earth connection, so
that bare metal can be seen.
chassis beam at the battery/chassis earth connection, so
• On the same side as the earthing strip, the cleaned area
must be larger than the earthing strip's contact surface.
• On the same side as the nut, the cleaned area must be
larger than the nut's contact surface.
• After assembly, a protective zinc primer must be applied to
both sides of the earth connection.
• Good earth connections are essential. There must be no
paint or oxidation between the contact surfaces. Apply a
conductive grease, such as Copaslip or a similar product,
to the contact surfaces before assembly. Tighten the
attachment bolt securely.
The most important earth wires go from the batteries to the

starter motor.
The earthing point on the flywheel may only be used for

earthing large current consumers which use more than 20 A
and which are not connected to the CAN network.
All the inductive and capacitive consumers must be earthed

on an earth connection ‘M’. If the earth wire for these con-
sumers is led back to the ECU (electrical unit), there must
also be a separate ‘M’ earth connection on the ECU, which is
separated from the ‘test and signal earth’.
An ECU may not have an earth connection for inductive or

capacitive consumers with a ‘test and signal earth wire’.
Earth wires must not be connected to points other than the
vehicle's earth connections points.
This will ensure that the current for the starter motor can only
pass through the battery's main earth wire.
It is also not permitted to make a direct connection with the

battery's earth connection. The only exception is connecting
the tachograph to earth when using a main switch, because
the tachograph’s earth wire may not be interrupted.
DD0855_02 1-3
1.2 WIRING HARNESSES

0 After a wiring harness has been removed or replaced, it must
be refitted and secured in the same position as it was before
it was removed.
Depending on the vehicle configuration, wiring harnesses
with a zipper may be used. The sleeve can then be opened
and closed.

Protect the wiring harness against sharp
edges. Always fit a grommet for a feed-
through.
Protect the wiring harness by placing it in

a protective hose.
Make sure the joins are watertight.
Never remove the connectors’ seals. Fit

the connectors in the correct manner.
Make sure the wiring is not too close to

hot components.
Prevent wiring harnesses from rubbing

against plastic lines.
To prevent poor connections, the pins of

connectors must always be installed and
removed using special tools.
1.2.1 WIRING HARNESS SPECIAL TOOL
There is a special tool for closing the wiring harness sleeve.
Pliers for closing the wiring harness sleeve

This tool can be used to start closing the sleeve at any posi-
tion on the wiring harness.
ILAk0027
1-4 DD0855_02
Zipper tool for closing the wiring harness sleeve 0

This tool can only be used to close the sleeve from the start
of the wiring harness.
ILAk0028
1.2.2 REPAIRING THE WIRING HARNESS
• Clean the damaged part of the wiring harness.
• Remove the insulation sleeve and check whether the wires

are damaged.
• Tape all the wiring in the wiring harness’s sleeve.
• Tape the wiring harness’s sleeve to the wiring and tape

over the tape.
• Fit the new zip sleeve so that 50 mm protrudes on the left

and right.
• Tape the zip sleeve on the main wiring harness.
ILAh1559
DD0855_02 1-5
1.3 COMPONENTS
0 Alternating current generator
Max. current 120 A
Nominal voltage 24 V
Micro relay
Maximum cut-in current for the con-
nection between points 3 en 5 10 A
Maximum cut-out current for the con-
nection between points 3 and 4 5A
ILAh0097
Mini relay
Maximum cut-in current for the con-
nection between points 30 en 87 20 A
Maximum cut-out current for the con-
nection between points 30 en 87a 10 A
ILAh0098
1-6 DD0855_02
Maxi relay 0
Nominal voltage 24 V 24 V
Resistance across the coil at 23 °C 274.5 ± 27 Ohm
Resistance across the coil between
points 85 and 86 223 ± 22 Ohm
ILAh0122
Main switch relay

Maximum switching current 300 A
Pull-in coil resistance 5.2 Ohm ± 20%
Hold-in coil resistance 120 Ohm ± 10%
ILAh0123
Engine compartment temperature sensor

Cut-in temperature 110 ± 3 °C
Type of switch Normally closed
ILAh0790
DD0855_02 1-7
1-8 DD0855_02
Citea LLE E6 EBS-1C Tightening torques
2. TIGHTENING TORQUES
0
Alternating current generator
Drive pulley 75 Nm ± 5 Nm
B+ connection 13 Nm ± 2 Nm
Battery terminal clamp
ILAh0338
A Battery terminal clampa + 12 ± 2 Nm

a
B Battery terminal clamp + 40 ± 4 Nm
a
C Battery terminal clamp - 12 ± 2 Nm
D Battery terminal clampa - 30 ± 4 Nm
a. To prevent corrosion, lubricate the outside of the connections with acid-free Vaseline.
DD0855_02 2-1
Tightening torques Citea LLE E6 EBS-1C
2-2 DD0855_02
5 DIAGNOSIS
Citea LLE E6 EBS-1C
DIAGNOSIS
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DIAGNOSIS 5
Citea LLE E6 EBS-1C
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5 DIAGNOSIS
Citea LLE E6 EBS-1C Tracing faults
1. TRACING FAULTS
1.1 BATTERY FAULT FINDING TABLE
FAULT: NEW BATTERY GETS VERY HOT DURING CHARGING

Possible cause Remedy
1
Inadequate formation because of poor conservation or Allow the battery to cool down.
long-term (damp) storage. Fully charge the battery.
Check the specific weight.
FAULT: BATTERY ACID SPILLS FROM THE PLUG HOLES

The battery acid level exceeds the maximum level. Drain battery fluid.
Overcharging. Check the charger and, if necessary, repair it.
FAULT: ELECTROLYTE LEVEL TOO LOW

The battery box leaks. Replace the battery.
Excessive gas production caused by overcharging. Check/repair the charger.
FAULT: SPECIFIC WEIGHT IS TOO LOW (< 1.240); POOR STARTING

A power consumer has been left on. Charge the battery.
Insufficient charge. Check/repair the charger.
Short circuit in the charging circuit. Check the charging circuit.
FAULT: SPECIFIC WEIGHT IS TOO HIGH (> 1.290)

Topped up with acid instead of distilled water. Drain fluid and top up with distilled water. If necessary,
repeat after mixing (charging).
FAULT: POOR STARTING, POOR STARTING TEST, POWER FAILS UNDER A LOAD
Battery is empty. Charge the battery.
Worn battery (corroded and eroded plates). Replace the battery.
Faulty battery (dead cell). Replace the battery.
Battery capacity too small. Install a battery with a larger capacity.
Battery sulphated (on inspection, plates are hard and Replace the battery.
possibly have white deposits).
DD0855_02 1-1
DIAGNOSIS 5
Tracing faults Citea LLE E6 EBS-1C
FAULT: BURNT-IN BATTERY TERMINALS

Battery terminal clamps not securely fitted or make poor Have the battery terminals repaired, securely fit the ter-
contact. minal clamps, and, if necessary, replace the clamps.
1 FAULT: EXCESSIVE BUBBLING IN 1 OR 2 CELLS DURING HIGH LOADS (STARTING OR STARTING TEST)
Faulty cells. Replace the battery.
Leaking partition. Replace the battery.
FAULT: BATTERY DISCHARGES QUICKLY (CANNOT CONTAIN ITS CHARGE)

Insufficient charge. Check the charging circuit. Is the charging time (driving
time) sufficient?
Short circuit in the charging circuit. Check the charging circuit.
Serious self-discharging, for example, due to contamina- Clean the battery.
tion.
Battery sulphated (on inspection, plates are hard and Replace the battery.
possibly have white deposits).
FAULT: SHORT BATTERY LIFE

Too many deep discharges. Intermediate charging with a rectifier.
Not recharged after deep discharge (white deposit). Always charge the battery after a deep discharge.
FAULT: BATTERY GETS HOT DURING OPERATION AND USES A LOT OF WATER
Overcharging or charging voltage too high. Check the charger (voltage regulator).
FAULT: BATTERY HAS EXPLODED

Fire or spark during or immediately after charging. Ensure proper ventilation and be careful with fire and
sparks.
Short circuit due to tools. Pay attention to where tools are placed.
Internal fault (loose connection). Replace the battery.
FAULT: THE BATTERY DOES NOT CHARGE BECAUSE OF A FAULTY GENERATOR AND/OR FAULTY
DIODES
Reversed battery polarity or incorrect charging. Discharge the battery and recharge in the proper direc-
tion. If necessary, replace the battery.
1-2 DD0855_02
5 DIAGNOSIS
FAULT: BATTERY DOES NOT DO ANYTHING (NO VOLTAGE)

Internal interruption. Replace the battery.
Battery very deeply discharged. Charge and test the battery. If necessary, replace it.
DD0855_02 1-3
DIAGNOSIS 5
1.2 LIFESPAN
The lifespan of a battery is considerably reduced by cyclic
use. This means that the batteries are often used whilst they
are not charged. This is also often the cause of the batteries
becoming faulty prematurely (within 1.5 years).
1 If the voltage measured across one battery falls below ?12.5
V, then the battery must be recharged. If the battery is not
recharged, then the "sulphating process" will begin. This pro-
cess is a chemical reaction in the battery which produces
lead sulphate. Lead sulphate sticks to the battery plates and
can cause a short circuit between the battery plates, which
reduces the battery's capacity. Most of the lead sulphate,
however, comes loose when the batteries are charged. If a
battery is used (discharged) whilst it is not recharged by the
generator, there will be a short circuit between the plates ear-
lier. This reduces the capacity and, therefore, the lifespan of
the battery.
1-4 DD0855_02
5 DIAGNOSIS
1.3 FAULT FINDING CHARTS

1.3.1 STARTING AND CHARGING SYSTEM
ILAh1561
DD0855_02 1-5
DIAGNOSIS 5
1 The engine runs slowly.

The engine does not run.
The lighting is weak.
2 Section 1: Check the battery.
1 3 The engine runs.
OK?
4 Section 3: Check the charging system.
5 End
7 End
8 The engine does not run “Click”.
10 The engine runs. OK?
12 End
13 Section 2: Check the starting system.
14 The engine runs. OK?
15 Check the crank flywheel.
16 End
17 End
18 Dry battery.
Leaking battery.
Burnt/corroded battery terminals.
21 End
1-6 DD0855_02
5 DIAGNOSIS
1.3.2 CHECKING THE BATTERY (SECTION 1)
ILAh1562
DD0855_02 1-7
DIAGNOSIS 5
1 Start
The engine does not run.
The lighting is weak.
2 Step 1:
Visual inspection of the cables:
1 - Loose connections.
- Corrosion.
- Damaged wiring.
3 Repair/replace the cables.
4 Step 2:
Visual inspection of the battery/batteries:
- Check whether the batteries are of the same make,
type, year of construction and capacity, and whether
they have the same CCA.
- Damaged battery box.
- Loose battery terminals.
- Dirty battery cover.
5 Step 3:
Check the state of charge (SOC) and test the battery.
6 Charge/recharge the battery.
Depends on the battery supplier’s specifications.
7 Step 4:
Tighten all the battery terminals according to the
specifications.
8 Test the charging/starting system.
1-8 DD0855_02
5 DIAGNOSIS
1.3.3 CHECKING THE STARTING SYSTEM (SECTION 2)
ILAh1564
DD0855_02 1-9
DIAGNOSIS 5
1 Start
2 Step 1:
Check the batteries (see 1.3.2 Checking the battery
(section 1) (1 - 7)).
1 3 Repair/replace the batteries.
4 Step 2:
Visual inspection:
- Corrosion.
- Loose connections.
- Damaged wire sleeve.
- Battery terminal clamp's tightening torques.
5 Repair/replace any faulty parts.
6 Step 3A:
Check the main battery cables.
7 Voltage drop.
8 Step 3B:
Main cable attachment.
Repair/replace the cables.
9 Does the engine start?
10 End
11 Step 4:
Starting circuit switch.
12 Starting circuit switch fault diagnosis.
13 Repeat the starting procedure.
14 Replace the starter motor.
15 End
1 - 10 DD0855_02
5 DIAGNOSIS
1.3.4 CHECKING THE CHARGING SYSTEM (SECTION 3)
ILAh1565
DD0855_02 1 - 11
DIAGNOSIS 5
1 Start
2 Step 1:
Check the batteries (see 1.3.2 Checking the battery
(section 1) (1 - 7)).
1 3 Repair/replace the batteries.
4 Step 2:
Visual inspection:
- Corrosion.
- Loose connections.
- Melted cables.
- Damaged cable insulation.
- Generator pulley's tightening torque.
5 Repair/replace any faulty parts.
6 Step 3A:
Check the main battery cables.
7 Battery voltage - generator voltage.
8 Step 3B:
Check each cable separately.
Determine which cable is faulty. Repair/replace faulty
cables.
9 Step 4A:
Check the voltage regulator.
- Start the engine.
- Turn off all the power consumers.
- Allow the voltage to stabilize.
- Measure the output voltage.
10 Generator voltage.
11 Voltage greater than 14.8 V or less than 13.8 V.
12 Replace and test the generator.
13 Step 4B:
Check the voltage regulator.
- Increase the idling speed.
- Allow the voltage to stabilize.
- Measure the output voltage.
14 Generator voltage.
15 0.5 V at idling speed.
17 Continue from step 5.
1 - 12 DD0855_02
5 DIAGNOSIS
ILAh1566
18 Step 5
19 Step 5A:
Increase the engine speed and check the output volt-
age.
20 When the batteries are subjected to a load.
Generator voltage = 13.0 - 13.5 V.
21 Generator output voltage.
22 Nominal output voltage < 90%.
24 Nominal output voltage  90%.
25 Charging system OK.
DD0855_02 1 - 13
DIAGNOSIS 5
1 - 14 DD0855_02
5 DIAGNOSIS
2. TRACING FAULTS
2.1 GENERATOR FAULT FINDING TABLE
FAULT: THE GENERATOR DOES NOT PROVIDE A VOLTAGE WHEN THE ENGINE IS IDLING
1
Interruption of connection 15 on the generator. Repair connection 15.
Earthing of connection 15 on the generator. Repair connection 15.
Internal fault. Replace the regulator.
FAULT: GENERATOR WARNING LIGHT (YELLOW)

Interruption of "S" connection. Measure the generator voltage with as many consumers
turned on as possible and a higher engine speed than
the idling speed.
Interruption of "L" connection. Check/repair the wiring.
Interruption of connection 15. Increase the engine speed to approx. 1,500 rpm. Check
connection 15 on the generator if a voltage is provided.
The voltage difference between connections “B+” and Check all the contacts between the generator and the
“S” is greater than 2.5 V. batteries (contact resistances). The internal battery
resistance is too high.
The voltage is too low: < 16 V. Check the generator drive. Check the wiring on the con-
tact resistances. Check the controlled voltage.
Faulty voltage regulator. Replace the voltage regulator.
FAULT: HIGH GENERATOR VOLTAGE (RED)

The voltage is too high: > 31 V. Measure the voltage.
Internal fault. Replace the regulator/generator.
DD0855_02 2-1
DIAGNOSIS 5
2-2 DD0855_02
5 TRACING ELECTRICAL FAULTS
Citea LLE E6 EBS-1C
TRACING ELECTRICAL FAULTS
DD0855_02
TRACING ELECTRICAL FAULTS 5
Citea LLE E6 EBS-1C
DD0855_02
Citea LLE E6 EBS-1C Test equipment and points of attention
1. TEST EQUIPMENT AND POINTS OF ATTENTION
The following test equipment and tools can be used to trace

faults.
1. The best instrument is a digital multimeter. This instru-

ment can measure the voltage, current and resistance
without making reading errors, and can be used to trace
almost every fault.
2. An inspection lamp can be used to easily trace many, but 2
not all, faults. Faults due to a poor earth connection can-
not usually be traced with this inspection lamp or a
buzzer.
3. A scopemeter is a useful aid for complex faults, although
the user must have good knowledge of the vehicle’s elec-
tronics.
The most common faults are:

a Short circuit.
b Interruption.
c Contact resistance.
d Earthing problem (poor earth connection due to cor-
rosion).
DD0855_02 1-1
Test equipment and points of attention Citea LLE E6 EBS-1C
1.1 POINTS OF ATTENTION WHEN TRACING

FAULTS
Besides basic knowledge of electrical systems, solving prob-
lems with the electrical or electronic systems also requires
knowledge of the tools that are used, such as a multimeter
and diagnosis equipment, as well as knowledge of how to
use them.
Never replace a fuse with one of a higher rating. The correct

2 capacity for a fuse is given in the electrical circuit diagram
and on the sticker on the inside of the central box’s cover.
ILAh0086
Do not remove the fuse from the fuse holder whilst the elec-
trical installation still has a voltage. If the fuse is removed, the
fuse holder’s contact surface may be burnt by sparks and a
peak voltage may be induced in the electrical installation.
ILAh0087
When measuring the voltage on a certain (in-line) connector

pin, it is better to take the measurement from the rear of the
connector. The repeated insertion and removal will reduce
the connector pin’s resilience, which may lead to a new fault.
ILAh0088
1-2 DD0855_02
Make sure not to damage a wire's insulation when checking

whether a wire is live.
ILAh0089
It is better to cut through a wire and make a watertight join

once the measurement has been taken.
ILAh0090
DD0855_02 1-3
Do not use a tester with an LED indicator. The LED will be lit
even if the circuit or component has a poor earth connection.
For a similar test, a standard inspection lamp will not be lit, or
will be hardly lit and is, therefore, more reliable.
ILAh0091
The use of a multimeter and/or a VDL Bus & Coach diagno-

sis tool is required to solve faults with the electronic control
systems.
Error codes can be read with the VDL Bus & Coach diagno-
sis tool. Signals can also be measured with a (digital) multim-
eter.
• An electronic system can also be part of a network of vari-
ous electronic systems. This means that a fault in one sys-
tem can lead to an error message in another system.
• Give special attention to earth connections and connector
wire connections.
ILAk0049
1-4 DD0855_02
1.2 LOCATING SHORT CIRCUITS
Method for locating a short circuit

When there is a short circuit, a positive wire has become
earthed somewhere in the circuit. The fuse will then usually
be blown. An inspection lamp of approx. 70 W is used to
trace this type of fault.
• First, look on the circuit diagram to see which devices are

connected to the fuse concerned and turn them all off.
• Remove the fuse and put an inspection lamp in its place. 2
• Next, turn the devices on and off one by one. When the
lamp is lit brightly when turning on a device, then it is
almost certain that the fault is in the wiring of that device.
• Next, look at the circuit diagram to see which connectors
are connected to the device. Disconnect the first plug con-
nection (as viewed from the fuse).
If the lamp remains brightly lit, then the fault is somewhere
between the fuse and the plug connection. ILAh0092
If the lamp goes out, then the fault is further along the wiring.
Next, reconnect the plug connection and disconnect the next
plug connection. If the lamp remains brightly lit, then the fault
is between the two plug connections. If the lamp goes out,
then the search must be continued in the same way. In this
way, the section where the fault is located can be localized.
DD0855_02 1-5
1.3 LOCATING BREAKS

Method for locating a break
If a component does not work, the fault may be in the com-
ponent, but it may also be that the wiring is broken.
• First, turn on the component and use the inspection lamp

(or a multimeter) to test whether the component receives a
voltage.
• If this is not the case, then first check whether the fuse is
still intact.
2 • If there is a voltage across the fuse, then the wire from the
ILAh0093
fuse to the component must be investigated. A measure-
ment must then be made at every plug connection. If there
is no voltage across one of the plug connections, the break
in the wiring is located somewhere between the last and
the previous plug connection.
• If there is a voltage across the component, then it is possi-
ble that the negative (earth) wire is broken. An inspection
lamp must be used to check this. Make sure that the circuit
concerned is turned on.
• Connect one end of the inspection lamp to the earth con-
nection and the other end to the negative connection of the
component to be measured. If the inspection lamp is lit,
then the earth connection of the component concerned is
broken. If the inspection lamp is not lit, then, in most cases,
the earth connection is still a good connection.
• If both the positive and negative connections are in good ILAh0094
working condition, the component concerned must be
replaced.
1-6 DD0855_02
1.4 LOCATING CONTACT RESISTANCES

Method for locating a contact resistance
Voltage loss
A loss of voltage due to a high contact resistance is mainly
due to a poor connector connection or a poor earth connec-
tion. A loss of voltage is often noticeable by the reduced per-
formance of a component.
A resistance measurement of a wire easily gives a distorted

(and, therefore, incorrect) measurement. For a resistance 2
measurement, a very low load is placed on a wire or a con-
nection. A resistance measurement will give a positive result
even if there is only one intact wire in the cable or a poor con-
nection.
If an electrical load is placed on the wire or the poor connec-

tion, the conductivity will be too low and the poor cable or
connection will then function as a large resistance, creating
a loss of voltage.
Loss of voltage measurement

The loss of voltage in the circuit can be checked with the aid
of a voltmeter.
• If there is no loss of voltage in the circuit, the voltage that
is measured across the battery (V1) will be the same as the
voltage that is measured across the component (V2).
• If there is a contact resistance in the positive circuit, then a
voltage will be measured with V3.
• If there is a contact resistance in the earth circuit, then a
voltage will be measured with V4.
Comment
For a circuit that functions correctly, there will always be a
limited loss of voltage in the positive and negative circuits.
This depends on the length of the electrical wiring.
ILAh0095
DD0855_02 1-7
1.5 LOCATING POOR EARTH

CONNECTIONS
Method for locating a poor earth connection
Poor earth connection

Earth connection problems are usually caused by corrosion
between the contact areas of the earth connections. A poor
earth connection can be traced, preferably using a digital
multimeter.
2
Checking an earth connection by a loss of voltage meas-
urement
The following method can be used to check whether a certain
earth point makes a good earth connection.
• Connect the voltmeter between the battery’s earth and the
earth connection to be checked.
• Turn on as many power consumers as possible (lights,
heater fan, beam, etc.). The current through the battery
cable must be between 20 A and 40 A.
• If there is a good earth connection, the loss of voltage must
be less than 0.5 Volt.
If the voltage loss is higher, the earth connection should be

thoroughly checked. In this way, the earth connections of all
the electrical consumers can be checked and measured.
ILAh0096
1-8 DD0855_02
5 MEASUREMENT AND DIAGNOSIS EQUIPMENT
Citea LLE E6 EBS-1C
MEASUREMENT AND DIAGNOSIS EQUIPMENT
DD0855_02
MEASUREMENT AND DIAGNOSIS EQUIPMENT 5
Citea LLE E6 EBS-1C
DD0855_02
Citea LLE E6 EBS-1C Devices
1. DEVICES
1.1 CALIBRATING THE TACHOGRAPH

A roller test stand can be used to calibrate the tachograph
(for example, after changing the type of tyres used on the
vehicle).
1.2 BOB TEST BOX

BOB is an abbreviation of Break Out Box. This box is like an
intermediate connector where each connector pin protrudes
outwards and is connected to a test socket. The BOB test
box must be used together with a BOB wiring harness. A
BOB wiring harness is only available for complex systems. 3
The BOB test box can also be used to activate components.
A template indicates the connector pins on the electronic unit

when it has been connected to a test socket in accordance
with the location of the pin in the connector. (Pin A1 of the
electronic unit is pin A1 on the template, pin A2 of the elec-
tronic unit is pin A2 on the template, etc.)
ILAk0029
Measuring the voltage and signals

The connector (3) which normally goes to the electronic unit
(1) is fitted to one of the connectors of the BOB wiring har-
ness (4). The other connector of the BOB wiring harness (2)
makes the connection with the electronic unit (1). It is possi-
ble to measure the voltage and/or signals via the sockets on
the BOB test box. The value concerned can be compared
with the measurement tables which are included in the sys-
tem’s technical information.
ILAk0030
DD0855_02 1-1
Devices Citea LLE E6 EBS-1C
Measuring resistances and activating components

The connector (3) which normally goes to the electronic unit
(1) is fitted to one of the connectors of the BOB wiring har-
ness (4). The other connector of the BOB wiring harness (2)
may NOT be connected to the electronic unit (1). The BOB
test box can now be used to measure resistances and to acti-
vate components.

The electronic unit’s connectors must be
disconnected when measuring
resistances or activating components.
Comment
When the electronic unit’s connectors are disconnected and
the vehicle’s contact switch is turned on, it is possible that an
error message will be saved in the electronic unit for a certain
3 system which is connected to other systems via the CAN net- ILAk0031
work.
1-2 DD0855_02
1.3 DIGITAL MULTIMETER (FLUKE)

A multimeter can be used to rectify faults in the electrical and/
or electronic systems. The Fluke 87 multimeter allows differ-
ent measurement methods to be selected, such as a current
measurement, a voltage measurement, a resistance meas-
urement and a frequency measurement. The measurement
choices are selected by using the rotary button and the cor-
rect connection socket.
ILAk0032
DD0855_02 1-3
1.4 DIAGNOSIS TOOL
The VDL Bus & Coach diagnosis tool (TEXA) can be used to
diagnose various vehicle systems. The VDL Bus & Coach
diagnosis tool is also used to read the electronic systems. In
the case of an error message, it is possible to select a guided
diagnosis in order to trace the problem by means of meas-
urement steps.
See the instructions for a detailed description and the options
available with the VDL Bus & Coach diagnosis tool.
ILAk0049
1-4 DD0855_02
1.5 MEASUREMENT VARIABLES

Measurement units are often displayed on the measurement
and diagnosis tool by symbols.
The following symbols are used:
1 Direct voltage
2 Alternating voltage
3 Direct current
4 Alternating current
5 Resistance
6 Duty cycle
7 Frequency
ILAh0082
DD0855_02 1-5
1.6 SIGNALS
1.6.1 SINUSOIDAL SIGNAL (ALTERNATING VOLTAGE)
This signal regularly changes polarity with regard to the “0”

line.
Frequency
The frequency is indicated in Hertz (Hz). The number of com-
plete sine waves per second is equal to the frequency of the
signal (if t in the diagram is 1 second, then the frequency is 3
Hz).
3
Voltage
If the number of cycles per second increases, then not only
does the frequency increase, but so does the voltage.
Measuring a sinusoidal signal

A sinusoidal signal can be measured as follows using a mul-
timeter:
• With the multimeter in the frequency (Hz) setting. The num-
ber of complete cycles per second are measured. ILAh0083
• With the multimeter in the alternating voltage position. That
way, the average direct voltage is measured.
Sinusoidal signals in the vehicle

Examples of sinusoidal signals in a vehicle are:
• Wheel speed sensor output signal.
• Crankshaft position sensor output signal.
• Camshaft position sensor output signal.
1-6 DD0855_02
1.6.2 SQUARE-WAVE SIGNAL
Square-wave signals only have two voltage levels which, in

principle, each have the same duration (t1 is equal to t2).
If the duration of one level is different to that of the other (t1

is not equal to t2), then there is a pulse wave.
ILAh0084
Duty cycle
The duty cycle is the ratio between both signal levels
expressed as a percentage.
A / B x 100%
The voltage level ratio can vary for a pulse wave (for exam-
ple, for an increase in vehicle speed). If the number of pulses
per time unit increases, then the duty cycle value increases.
Voltage
If the number of pulses per time unit increases, then not only
does the duty cycle increase, but so does the average volt-
age.
Measuring a square-wave signal

A square-wave signal can be measured as follows using a
multimeter:
• With the multimeter in the duty cycle (%) setting.
That way, the voltage level ratio is measured.
• With the multimeter in the direct voltage setting.
ILAh0085
That way, the average direct voltage is measured.
Square-wave signals in the vehicle

• Speed sensor output signal.
• Speed signal to the electronic units.
DD0855_02 1-7
1-8 DD0855_02
5 ELECTRICAL COMPONENTS
Citea LLE E6 EBS-1C
ELECTRICAL COMPONENTS
DD0855_02
ELECTRICAL COMPONENTS 5
Citea LLE E6 EBS-1C
DD0855_02
Citea LLE E6 EBS-1C Component description
1. COMPONENT DESCRIPTION
1.1 INDUCTIVE TRANSMITTER

Inductive transmitters in the vehicle include:
• Wheel speed sensor
• Engine speed sensor
• Camshaft sensor
Engine speed registration

The engine speed is registered via the crank shaft position
sensor. The output signal from the crank shaft position sen-
sor is a sine wave with a frequency that corresponds to the
number of holes in the pulse disc and the crank shaft's fre-
quency of rotation. This signal is converted in the electrical
unit into a message which is sent via the CAN network. The ILAh0099
VFC sends this message to the ICM, which operates the rev
counter.
Operating principle of the engine speed sensor 4

The inductive transmitter consists of a permanent magnet
(1), a core (2) and a coil (3). When the inductive transmitter
is located between two teeth, the magnetic field’s lines of
force run from the north pole of the magnet to the south pole
of the magnet via the housing.
When a tooth approaches the inductive transmitter, the mag-

netic field lines run from the north pole of the magnet to the
south pole of the magnet via the housing, the teeth of the
gear and the core. Since more lines of force now run through
the core, a stronger magnetic field is produced. Changing the
magnetic field produces an alternating voltage in the coil.
The value of the alternating current which is produced

depends on the rotational speed of the gear and the air gap
between the transmitter (core) and the tooth.
ILAh0100
DD0855_02 1-1
Component description Citea LLE E6 EBS-1C
1.2 PRESSURE SENSORS

The pressure sensors in the vehicle include:
• A pressure sensor for registering the bellows pressure for
ECAS.
• A pressure sensor for registering the filling pressure.
1.2.1 ECAS PRESSURE SENSOR
There is a membrane in the pressure sensor which is made

from a semi-conducting material (silicon). If pressure is
exerted on the membrane, then it will bend. The bending of
the membrane causes the resistance of the semi-conducting
material to change.
The membrane is a part of a bridge connection. If the mem-

brane bends, then the bridge connection is no longer bal-
anced causing the output signal to vary. The output voltage
is directly proportional to the applied pressure (bending of the
membrane).
4 Inspect.
The output voltage can be inspected using a multimeter that
has been set to the direct current range.
ILAh0161
1.2.2 PRESSURE SENSOR TO CHECK THE BOOST

PRESSURE
A piezo pressure sensor is used to check the boost pressure.

This sensor consists of an electronic switch and a pressure
recording element. The pressure recording element registers
pressure changes, which are converted into an electrical
voltage. The electronic circuit enhances this voltage to pro-
duce a useable output signal.
Inspect.
The output voltage can be inspected using a multimeter that
has been set to the direct current range.
ILAh0104
1-2 DD0855_02
1.3 GENERATOR
The compact generator is lightweight and has two internal
cooling fans. The electronic regulator also controls the gen-
erator’s pre-excitation. The function of the field diodes has
also been taken over by the regulator. The generator pro-
vides a large current in the low engine speed region.
B Connection with clamp 30 of the starter motor.

15 Power supply after the contact switch has been turned on.
S Sensor connection for the regulator.
L Connection to IOU A011.
“B” connection
The generator has two B+ connections which are internally
connected to each other. B+1 is connected to clamp 30 of the
ILAh0105
starter motor.
B+2 is NOT connected. B- (earth connection) is connected to
the generator's housing.
4
Port 15
The generator receives a voltage via connection 15 after the
contact switch has been turned on. The regulator uses this
voltage to activate the pre-excitation (self-excitation). If this
connection is disconnected, the generator will not provide
any power until the generator has an approximate speed of
5,000 rpm. This corresponds to an approximate engine
speed of 1,500 rpm. Once this speed is reached, the gener-
ator will excite itself.
Sensor connection
The sensor connection can be used to compensate for voltage
losses in B+. There are voltage differences between the genera-
tor and the battery. By checking these voltage variations, the pre-
set voltage that is produced can be improved. The sensor
connection is connected to clamp 30 of the starter motor.
“L” connection ILAh0162

The L connection is connected to the VFC via an IOU by means
of the CAN system and indicates whether the generator supplies
a current and, therefore, whether the battery is charged.
This signal must be high when the engine is running and low
when the engine is not running.
If this is not the case, then the VFC sends an error message
to the main display.
The following faults can be recognized via the “L” connection.

• A too low voltage (< 16 V).
• Break in connection 15.
• Interruption of the "S" connection.
• Interruption of the "L" connection.
A too high voltage is recognized by a too high supply voltage

(> 31 V) across IOU A011.
DD0855_02 1-3
1.4 EARTH BREAKER SWITCH
The earth breaker switch's function is to disconnect the elec-

trical installation from the power supply when the vehicle is
not used for a long period of time (maximum of 2 weeks).
The earth breaker switch is located at the front on the left-

hand side behind the service hatch.

The DTCO tachograph saves an error
code if the earth breaker switch is turned
off. In some countries, the error code is
interpreted as a breach of the law. Place a
DTCO workshop card in the unit to
prevent it from saving an error code.
If an error code is saved, contact a
recognized DTCO service dealer to
calibrate the DTCO and to delete the
code.
4

Wait 5 minutes after turning off the
contact switch and the main switch
before turning off the earth breaker
switch, so that the vehicle’s electronic
systems can complete their tasks.
ILAh0743
Turning off the earth breaker switch

Do not turn off if:
- The engine is running.
- The water heater is still in operation.
- Other electrical consumers are still
turned on.
The electronic installation, the electronic

units and the generators may be
damaged if you do so.
1. Turn off the contact switch and the main switch.

2. Wait 5 minutes after turning off the contact switch and the
main switch.
3. Open the front left-hand service hatch.
4. Rotate the earth breaker switch anticlockwise to the “Off”
position.
The entire electronic installation, including the tacho-
graph and the warning lights, is now turned off.
5. Close the service hatch.
1-4 DD0855_02
Turning on the earth breaker switch

3. Rotate the earth breaker switch clockwise to the “On”
position.
4. The electronic installation will be reconnected to the bat-
teries.

Some electronic appliances must be
reset.
DD0855_02 1-5
1.5 TEMPERATURE SENSORS

The temperature sensors in the vehicle include:
• Coolant temperature sensor.
• Intake air temperature sensor.
• Fuel temperature sensor.
• Outside air temperature sensor.
These sensors are temperature-sensitive resistances. These

types of sensor have a high change in resistance for an
increase or decrease in temperature.
There are two different types of sensor, namely:

• N.T.C. resistance (Negative Temperature Coefficient). ILAh0103
• P.T.C. resistance (Positive Temperature Coefficient).
N.T.C. resistance
For an N.T.C. resistance, the resistance value falls when the
temperature increases.
4 Use:
• Measuring the coolant temperature.
ILAh0125
P.T.C. resistance
For a P.T.C. resistance, the resistance value increases when
the temperature increases.
In contrast to the N.T.C. resistance, the P.T.C. resistance

experiences a large change in resistance for a small change
in temperature.
Inspect.
The temperature sensors can be checked using a multimeter
which is set to the resistance setting.
ILAh0126
1-6 DD0855_02
1.6 FLUID LEVEL SENSORS

1.6.1 HYDRAULIC OIL LEVEL SENSOR
The sensor is, in fact, a condenser and uses the change in

capacity which occurs when the sensor changes from being
surrounded by hydraulic oil to being surrounded by air, or
vice versa. If the sensor comes to the surface at the minimum
level or if the sensor is submerged at the maximum level,
then the signal output is transmitted. However, this signal is
transmitted with a delay so as to avoid it constantly switching
on and off due to sloshing liquid. The electronics which are
necessary for this measurement are included in the sensor.
ILAh0127
Inspect.
Conditions
• Supply voltage (+24 V) connected to the +ve and –ve con-
nections.
• Inspection lamp (max. 2 W) connected to the S connection.
Hang the sensor in the fluid concerned and connect the sen-
sor as shown in the diagram. Once the sensor is removed 4
from the fluid, the inspection lamp must be lit or extinguished
(depending on whether it is a minimum or a maximum level
sensor) after a fixed delay (approx. 7 sec.).
1.6.2 COOLANT LEVEL SENSOR
The coolant level sensor consists of micro switches (reed

switches) that are connected in parallel with the two resis-
tors. These micro switches are influenced by a magnetic field
that is located outside of the sensor. If the coolant level falls,
a float that floats on the coolant and which has a permanent
magnet ensures that the micro switches are closed.
ILAj0422
DD0855_02 1-7
The “Level too low” switch detects that the coolant level is too
low and short-circuits the resistor that is switched in parallel.
The “Level low” switch detects that the coolant level must be
topped up and short-circuits the resistor that is switched in
parallel.
The resistance values are used by the VFC to detect the sta-
tus of the micro switches.
The VFC activates the instrument panel based on this.
ILAj0427
1-8 DD0855_02
1.7 VEHICLE SPEED SENSOR

The vehicle speed sensor has two connections for outgoing
signals. The real time speed signal, which is activated by a
Hall IC, is sent via one of the connections. A data signal (a
bidirectional signal) is sent via the other connection, where
an exchange of information takes place between the tacho-
graph and the speed sensor. The tachograph requests data
from the sensor.
The sensor sends sequential, coded data to the tachograph,
which checks whether this data is correct.
The coded signal consists of the following data:
• Sensor serial number.
• “Master key" (the same as the tachograph).
• Coded speed-distance signal
The coded speed signal is compared to the real time speed

signal in the tachograph. The tachograph sends requests
and data to the sensor at 10 second intervals.
ILAh0101
Speed signal duty cycle 4

The speed signal that goes to the tachograph via the vehicle
speed sensor is processed in the tachograph and sent as a
message via the CAN network. The speed signal is also con-
verted into a duty cycle signal. This duty cycle signal is used
by the electrical units that receive the message via the CAN
network.
The diagram opposite shows the linear characteristic of the

duty cycle (%) with regard to the vehicle speed (V). This
graph applies to every vehicle model.
Inspect.
The duty cycle signal (square wave voltage) can be checked
using a scopemeter or a multimeter that has been set to the
direct voltage or the duty cycle range.
ILAh0102
DD0855_02 1-9
1.8 STEERING COLUMN SWITCH

The Citea LLE E6 EBS-1C vehicle series has the steering
column switches shown below.
The advantages of the switches are:

• The switches do not short-circuit.
• They have a longer lifespan because of the use of reed
switches.
• The cruise control function is integrated in the right-hand
switch (optional).
ILAh0106
The functions of the left-hand switch are as follows:

• Left/right indicators.
• Main beam/dipped beam.
• Horn.
• Windscreen wiper speed/interval/wash.
The function of the right-hand switch (optional) is:

• Accelerate/slow down/memory cruise control function
1 - 10 DD0855_02
Citea LLE E6 EBS-1C Diagnosis
2. DIAGNOSIS
2.1 DIAGNOSIS OF THE ELECTRICAL

SYSTEMS
The table below shows which diagnosis tool can be used to
diagnose a certain system.
Please refer to the manufacturer’s instruction manual for

instructions on how to use the diagnosis tool.
System Diagnosis tool

Climate system Thermo King/Heavac
ZF EST146 VDL Bus & Coach diagnosis tool ZF-Testman Pro diagnosis software
Voith Diwa.6 VDL Bus & Coach diagnosis tool Voith ALADIN diagnosis software
EBS VDL Bus & Coach diagnosis tool Wabco diagnosis software
Cummins ECM Cummins Insite diagnosis software
ECAS-CAN 2 VDL Bus & Coach diagnosis tool Wabco diagnosis software 4
MTS door system VDL Bus & Coach diagnosis tool
ICM VDL Bus & Coach diagnosis tool
CAN bus VDL Bus & Coach diagnosis tool
Preheater (Webasto) VDL Bus & Coach diagnosis tool
For more information, contact your local VDL Bus & Coach
service organization.
DD0855_02 2-1
Diagnosis Citea LLE E6 EBS-1C
2-2 DD0855_02
5 WIRING REPAIRS
Citea LLE E6 EBS-1C
WIRING REPAIRS
DD0855_02
WIRING REPAIRS 5
Citea LLE E6 EBS-1C
DD0855_02
5 WIRING REPAIRS
Citea LLE E6 EBS-1C Accessories and special tools
1. ACCESSORIES AND SPECIAL TOOLS
• As a result of the increasing amount of electronics in vehi-

cles, an increasing number of connectors, contacts and
wiring is used. It is very important that attention is given to
this fact when carrying out repairs, so that unnecessary
faults can be prevented.
• For the repair of engine-related connectors, please refer to
https://quickserve.cummins.com.
1.1 CONNECTOR
A connector is a connection between two or more electrical
wires or components that can be disconnected. The female
connectors are on one side and the male connectors are on
the other side. This makes it possible to connect and discon-
nect them. The connector’s tasks are to protect the contacts
against undesirable electrical connections and the influence
of the surroundings, as well as to guarantee that the correct
contacts are joined together correctly.
1.2 CONTACT
A connector contains one or more contacts. These contacts 5
are available in different sizes and designs. However, they all
have the same construction:
The fitting part (1) makes the electrical connection between

the contacts possible. The contact press part (2) is the elec-
trical connection between the stripped part of the wire and
the contact. The relief part (3), also called the pull relief,
relieves the contact press part of mechanical wear The insu-
lation relief is placed over the insulating sleeve of the wire
and/or the SCAT.
ILAh0107
Three dimensions are important for a contact: the diameter

(1) of the wire to be connected, the corresponding size of the
contact press part (2) and the size of the fitting part (3).
ILAh0108
DD0855_02 1-1
WIRING REPAIRS 5
Accessories and special tools Citea LLE E6 EBS-1C
1.3 SPECIAL TOOLS

1.3.1 CONTACT BOX A
Contact box A
Contact box A (VDL Bus & Coach no. 40694960) is available
for the contacts, with the exception of the contacts with single
wire seals (SCAT contacts) and the microtimer contacts.
A sticker has been stuck inside the box to make it easier to

choose the right contact, contact shrinkage pliers and
removal tool.
ILAh0109
The number of the contact shown on the sticker is stated at

the top of the sticker. Below the picture, the Roman numeral
indicates which contact shrinkage pliers must be used (I or
II). After this number, it is stated, either by a number or a let-
ter, in which recess of the contact shrinkage pliers the con-
tact must be placed. Below this, Roman numerals indicate
which removal tool must be used to remove the contact from
the connector (III to VII). Finally, the sticker states for which
wire diameter the contact is suitable.
Contact box B
An extension to the contact shrinkage pliers and the removal
tool is necessary for the contacts with single wire seals
(SCAT contacts) and for the microtimer contacts. Contact
box B (VDL Bus & Coach no. 41240065) is used for these
ILAh0110
contacts. A sticker has been stuck inside the box to make it
1-2 DD0855_02
5 WIRING REPAIRS
easier to choose the right contact, contact shrinkage pliers

and removal tool. This sticker can be used in the same way
as the sticker in contact box A.
The number of the contact shown on the sticker is stated at

the top of the sticker. Below the picture, the Roman numeral
indicates which contact shrinkage pliers must be used (I or
II).
After this number, it is stated, either by a number or a letter,
in which recess of the contact shrinkage pliers the contact
must be placed. Below this, Roman numerals indicate which
removal tool must be used to remove the contact from the
connector (III to VII).
Finally, the sticker states for which wire diameter the contact
is suitable.
ILAk0068
Removal tool (4.0 mm)
VDL Bus & Coach no. 40694954
(Part of contact box A 40694960)
5
ILAk0069
Contact timer removal tool
ILAk0070
AMP removal tool
DD0855_02 1-3
WIRING REPAIRS 5
ILAk0071
Shrinkage pliers
ILAk0072
Shrinkage pliers
5
ILAk0073
Canon removal tool
ILAk0074
Removal tool (1.5 mm)
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ILAk0075
Contact timer removal tool
DD0855_02 1-5
WIRING REPAIRS 5
1.3.2 CONTACT BOX B
An extension to the contact crimping pliers and the squeez-

ing tool is necessary for the contacts with single wire seals
(SCAT contacts) and for the microtimer contacts. Contact
box B (VDL Bus & Coach no. 41240065) is used for these
contacts.
A sticker has been stuck inside the box to make it easier to
choose the right contact, contact shrinkage pliers and
removal tool. This sticker can be used in the same way as the
sticker in contact box A.
ILAk0076
ILAk0077 ILAk0078
Shrinkage pliers Shrinkage tool
5 VDL Bus & Coach no. 41240058 VDL Bus & Coach no. 41240059
(Part of contact box B 41240065) (Part of contact box B 41240065)
ILAk0079 ILAk0080
Shrinkage tool SCAT removal tool (4.0 mm)
VDL Bus & Coach no. 41240060 VDL Bus & Coach no. 41240061
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ILAk0081 ILAk0082
Microtimer removal tool SCAT removal tool (1.5 mm)
ILAk0083
5
Minitimer removal tool
(Part of contact box B 41240065)
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WIRING REPAIRS 5
1.3.3 OTHER SPECIAL TOOLS
ILAk0084
Removal tool
ILAk0085 ILAk0087
Removal tool Minitimer removal tool
Bosch Cummins no. 3164093
ILAk0086 ILAk0088
Removal tool ABS contact removal tool
Bosch Cummins no. 3164091
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ILAk0089 ILAk0090
OBD connector contact removal tool OBD connector contact shrinkage pliers
Adaptor set for Fluke ScopeMeter

ILAk0091
Current clamp
ILAk0092 5
ILAk0093 ILAk0154
Universal Break Out Box VDO CTC 2 tachograph and speed limiter calibra-
VDL Bus & Coach no. 41961301 tion tool
VDO art. no. 1420.0040 (CTC 2 kit)
VDO art. no. 1422.0000 (extension kit for roller test
stand)
DD0855_02 1-9
WIRING REPAIRS 5
ILAk0155
VDO Download Terminal DLT Pro
VDO no. 2910.0000.6840.0
ILAk0123
Repair set for CM2350 ECM connector, VDL Bus & Coach
no. 30117083.
For instructions on how to use the repair set, see procedure

019-505 in section 19 (see https://quickserve.cum-
mins.com).

For other special tools for the engine, see
the Cummins Service Tools Bulletins.
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Citea LLE E6 EBS-1C Removing and installing contacts
2. REMOVING AND INSTALLING CONTACTS
2.1 UNLOCKING CONNECTORS

Installing on the coupling section and locking it
The connectors described in these specifications have three
safety features.
• Checking the coding and the polarization: the correct polar-
ization and coding must be chosen for the coupling section.
• Position check of the secondary locking mechanism. If the
secondary locking mechanism is not (fully) locked, the
housings cannot be fitted in the coupling section or only by
pushing very hard. Make sure to check whether the posi-
tion of the contacts is correct. The connection is only per-
mitted if the secondary locking mechanism is completely
locked.
• Position check of the connecting part of the coupling sec-
tion. The connectors of the connecting part have a slide
that must be used for connecting and disconnecting. This
slide is pre-locked on delivery.
The slide is pre-locked by means of hooks. The slide cannot

be activated without the coupling section. After the connector
has been fitted to the coupling section, the slide is unlocked
against the force of the seal. The slide can now be activated
and the connection is fully closed. 5
Disconnecting the coupling section
To disconnect the connector, the slide must returned to the
pre-locked position. Use a simple tool, such as a screw
driver. A mechanical stop and a soft clicking sound indicate
that the slide is back in the pre-locked position. If the connec-
tion is very dirty, clean it with pressurized water (preferably
max. 80 bar/80 °C). Do not aim the jet at the connector’s con-
tacts.
ILAh1572
DD0855_02 2-1
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Removing and installing contacts Citea LLE E6 EBS-1C
Fitting the housings with contacts

The contacts can only be fitted if a secondary locking mech-
anism is locked in advance. Make sure the contacts are
inserted in the position as shown in the diagram below. If the
position is different, the contacts cannot be inserted further
than the secondary locking mechanism and the entire shrink
connection protrudes from the housing. If the position is cor-
rect, the locking is indicated by a stop and a metallic clicking
sound. The example shows a contact being fitted in a 7-pole
connector.
ILAh1573
ILAh1574
2-2 DD0855_02
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The connectors can often be locked together or to a compo-

nent. The types of lock can be divided into:
A Active lock
This means that the lock must be made active. Often,
the lock must be pressed to be released.
B Passive lock
This lock opens if the parts are pulled apart with a cer-
tain force.
ILAh0067
Two connectors in one housing

This type of connector consists of two separate connectors.
5
In order to remove the contacts, the connectors must first be
removed from the connector housing. To do this, the locking
lips must be pushed sideways. The connector can then be
slid out of the connector housing.
ILAh0068
DD0855_02 2-3
WIRING REPAIRS 5
Fitting plugs
Empty cavities must be sealed with plugs. The plug can be
fitted by hand or using a tool. The specified insertion depth of
1+3 mm must be observed. Make sure the sealing lips do not
become damaged when fitting the plug.
ILAh1575
Assembly options for housings with a lip

Depending on the model, the housings with a lip are intended
for the following assembly types:
• Housings without a flange: assembly with a clip or cable tie
(see the diagram).
5 • Housings with a flange for in a casing or scuttle panel feed-
through: assembly in a wall recess with rails.
ILAh1576
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2.2 UNLOCKING CONTACTS

Contact lock
There are different types of contact lock. A few examples are
given below. If a lock is used for each individual contact, then
this is called a primary lock. An extra, general lock for a num-
ber of contacts in a connector is called a secondary lock.
Primary contact lock

In order to keep an individual contact in place in a connector,
a contact often has one or more locking tongues. This is
called a primary lock. It is very important that these locking
tongues do not become damaged, because they are needed
to insert and remove the contact.
ILAh0069
Secondary contact lock

This type of lock is usually used for 2-row and 3-row connec- 5
tors. For connectors (1) with a locking lip (2), the locking lip
must first be removed before the contacts can be removed.
This is called a secondary lock. The locking lip is located on
the side of the connector and can usually be recognized by
the fact that it is of a different colour to the connector. The
entire locking lip must be removed. The contacts can then be
removed using the correct removal tool by unlocking the pri-
mary lock.
ILAh0070
DD0855_02 2-5
WIRING REPAIRS 5
It is also possible that the bottom part of the connector acts

as a secondary lock for the contacts. By moving this bottom
part out of the way, the contacts can be removed using the
correct removal tool by unlocking the primary lock.
This type of lock is only used for contacts with 3 connectors
in a row.
5 ILAh0071
Another type of secondary lock is formed by two slidable

parts of the connector. The top half (on the wire input side)
and the bottom half form the extra contact lock.
To unlock this type of secondary contact lock, the top half of

the connector must be pushed slightly in the direction of the
arrows (shown on the connector housing). The contacts can
then be removed from the connector using the correct
removal tool.
After fitting wires with contacts, the connector must be

pushed back into the lock, otherwise it will not fit in the other
part.
ILAh0072
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Locking and unlocking HDSC connectors
The HDSC connectors have two locking mechanisms:

• Primary lock (A): to lock both connector parts to each other.
• Secondary lock (B): to lock the contacts.
The connectors are delivered with the secondary lock in the

unlocked (pre-locked) position (B). Each connector part has
its own secondary lock.
The contacts can be fitted when the locks are in this position.
ILAh1577
Next, the secondary lock must be moved to the definite posi- 5

tion by hand (connector with a lip) or with the aid of a tool (for
example, a screw driver).
An audible “click” indicates when the end position is reached.
The connection can only be closed if both secondary locks
(of each connector part) are in the end position.
The secondary lock (yellow) is in the pre-locked position (B).
ILAh1578
To unlock the secondary lock, a suitable screw driver must

be inserted in the opening.
Carefully push the lock to move it to the pre-locked position.
ILAh1579
DD0855_02 2-7
WIRING REPAIRS 5
2.3 REMOVING A CONTACT

It is possible to replace a contact or to add another contact in
order to repair or add wiring. A contact can be removed from
the connector without damaging the contact using a special
removal tool.
The secondary lock must be in the pre-locked position before

the contacts can be removed. To unlock the contact, the
tool’s pins must be inserted, all the way to the stop, in the two
slots on the connecting side of the relevant contact (see the
diagram). The tool remains in this position and the contact
can now be removed by pulling the cable.

Do not pull the cable before the contact is
unlocked; the unlocking procedure is
made easier by carefully pushing the
cable in the opposite direction to which it
comes out.
ILAh1580
5 Removing contact locking tongues at the front

1. Push the wire forwards together with the contact (1). The
locking tongue (2) will now not be touching the connector
(3).
2. Push the correct removal tool (4) into the front of the con-
nector. This will push the locking tongue (2) downwards.
3. The contact can then be removed by carefully pulling the
wire.

If the wire is pulled before the removal
tool has pushed the locking tongue
downwards, the contact will only become
more stuck in the connector.
ILAh0073
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Removing contact locking tongues at the back
There are also contacts where the locking tongue (2) is

located at the rear of the connector (3).
1. Pull the wire backwards together with the contact (1).
The locking tongue (2) will now not be touching the con-
nector (3).
2. Push the correct removal tool (4) into the rear of the
connector. This will push the locking tongue (2) upwards.
3. The contact can then be removed by carefully pushing

the wire forwards.

Here, the locking tongue works the other
way round compared to the usual
connectors.
The removal tool to be used depends on
the type of contact.
ILAh0074
DD0855_02 2-9
WIRING REPAIRS 5
2.4 LOCKING AN MQS CONTACT

Locking an MQS contact
Before the contact can be removed, a pin must be used to

unlock the lock.
1. First, push in the lock at the end of the connector (1). At
the same time, carefully pull the wire (2) until a resistance
is felt.
2. Next, push in the second lock (3) and carefully pull the
wire (2) again.
3. The contact will now come out of the connector.

This type of contact is locked twice and
must, therefore, also be unlocked twice.
ILAh1581
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2.5 BOSCH 89-POLE CONNECTOR

The following must be carried out to remove a contact from
this type of connector:
Removing a Bosch 89-pole connector

1. Fold the protective cover that encloses the wiring har-
ness downwards by pushing the lock outwards.
2. Next, push the two outer halves of the protective cover
outwards and then upwards. The protective cover can
now be removed.
3. The pink secondary contact lock (1) must be slid to the
middle of the connector in order to remove the contacts.
4. The contacts can now be removed using the correct
removal tool.
Comment
The large contacts are locked using four locking tongues.
The small contacts are locked using two locking tongues.
The lock must also always be unlocked when inserting new
contacts. ILAh0111
Installing a Bosch 89-pole connector

Once the protective cover has been replaced, attention must
be given to make sure the lever and the slide are both in the
unlocked position. If they are not, the connector will not be 5
locked correctly to the electrical unit. There is then a chance
that there will be a poor contact between the connector and
the electrical unit.
ILAh0112
DD0855_02 2 - 11
WIRING REPAIRS 5
2.6 39-POLE CONNECTOR CONTACTS

Removing a contact from a 39-pole connector
1. Unscrew the cap nut G.
2. Slide the thrust ring H and the seal K back slightly over
the wire.
3. Use the special removal tool from contact box A or B to
remove the contacts from the connector housing F.
ILAh0113
Fitting a contact to a 39-pole connector

1. Fit cap nut G and thrust ring H over the wire.
2. Use the correct tool to fit new contacts to the wires.
3. Insert the wires and the contacts through seal K.
4. Press the contacts into their definite position in connector
housing F.
5. Slide seal K against connector housing F.
6. Position the thrust ring H so that the two cams in the side
of connector housing F fall into the recesses in the thrust
ring.
7. Tighten the cap nut G by hand.
Comment
• Thrust ring H has contact numbers on it (they serve to
determine the correct position of the contacts). These con-
tact numbers must be aligned with the contact numbers on
the connector housing.
• A wire that has been fitted incorrectly will cause a leak in
the seal when it is removed. If the wire is not replaced by a
new one, then a seal plug must be fitted.
2 - 12 DD0855_02
5 WIRING REPAIRS
Removing a contact from a 39-pole connector coupling section

1. Unscrew the end cap A and adaptor cap B and slide them
back as far as possible over the insulation sleeve.
2. Slide thrust ring H and the seal K back as far as possible
over the wiring harness.
3. Slide cap nut E back over the wiring harness.
4. Carefully remove the seal (2).
5. Carefully unlock the locks (3) in the connector housing F.
6. Remove the centring sleeve D from the connector hous-
ing.
7. Use the special removal tool from contact box A or B to
remove the contacts from the connector housing C.
ILAh0114
DD0855_02 2 - 13
WIRING REPAIRS 5
Fitting a contact to a 39-pole connector coupling section

1. Slide the end cap A and the adaptor cap B as far as pos-
sible back over the insulation sleeve.
2. Fit the centring sleeve D in the connector housing C so
that all the openings are opposite each other.
3. Check whether all the locking clips (3) are in the locking
openings (1).
4. Insert the wires, without the contacts, through the thrust
ring H and the seal K.
5. Use the correct tool to fit new contacts to the wires.
6. Feed the wiring harness through adaptor cap B.
7. Slide seal K against the connector housing C.
8. Position the thrust ring H so that the two cams in the side
of the connector housing C fall into the recesses in the
thrust ring.
9. Press the connector pins into the correct position in the
connector housing C.
10. Fit the seal (2) around the centring sleeve D and push it
as far as the stop in the connector housing C.
Comment
• For the last two steps, it is important that the wiring harness
5 is not twisted, because this can cause serious damage
(chance of a wire breaking).
• Tighten the respective cap nuts by hand.
Do not use any tools (pliers) to do this.
11. Screw the adaptor cap D on to the connector housing C.
12. Screw the end cap A (with the insulation sleeve) on to the
adaptor cap B.
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5 WIRING REPAIRS
2.7 CUMMINS ENGINE CONNECTORS

See “Connector Repair Procedures” on Quickserve online
for the repair procedures for the engine’s connectors (see
https://quickserve.cummins.com).
ILAh1558 5
DD0855_02 2 - 15
WIRING REPAIRS 5
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Citea LLE E6 EBS-1C Electrical connections
3. ELECTRICAL CONNECTIONS
3.1 MAKING CRIMPING CONNECTIONS

General information
As a result of the increasing amount of electronics in vehi-
cles, an increasing number of connectors, contacts and wires
are used. This means that more attention must be given to
connections that have to be made or repaired. When doing
so, the following must be taken into consideration:
Fitting a contact to an electrical wire

1. Wire with a reduced thickness of insulation, whilst retain-
ing the mechanical properties, for a cross-sectional area
of 0.5 to 2.5 mm2.
2. Wire with normal insulation thickness for a cross-sec-
tional area of 4 to 120 mm2.
3. Wire with different temperature ranges. T1: from 40 °C to
+70 °C (in bodywork and chassis). T2: from 40 °C to
+100 °C (in the engine compartment and the gearbox).
Comment
In view of the mechanical strength, the minimum cross-sec-
tional surface area of the wire is 1 mm2, with the exception
of the cabin wiring. This can be 0.5 mm2 in certain places. In
order to guarantee the reliability of the systems and the con- 5
nections, the following points must be taken into considera-
tion when repairing or lengthening the wiring.
Always choose:
1. The correct type of contact.
2. The correct wire diameter for that contact.
3. The correct type of material for the contact (tin-plated, sil-
ver-plated or gold-plated).
4. Use the correct tools. The ends of the wires must always
be clamped to a contact. Special pliers have been devel-
oped for this task.
Comment
A reliable connection is only made when using these pliers
and when placing the contact in the correct opening.
5. Strip the wires to the correct length. Always use wire
strippers. Rule of thumb: stripping length = crimp sleeve
length + 1 mm. The copper must not be damaged when
stripping the wire, otherwise problems may arise at a
later date.
Comment
A good connection is created if points 1 to 5 are observed.
This means that both the copper and the insulation must be
well clamped.
DD0855_02 3-1
WIRING REPAIRS 5
Electrical connections Citea LLE E6 EBS-1C
Crimping a wire on to a contact
Select the correct crimping tool and place the contact in the
correct recess.
The contact must not be twisted, be at an angle or be moved

(X) when in the press clamp recess.
1. Place the wire into the contact.
5 ILAh0115
2. The stripped part of the wire, the copper conductor, must

be placed in the contact press part (1). The wire's insula-
tion must be in the relief part (2).
3. Check again whether the wire is in the correct position in
the contact (1 and 2) and press the contact press part (3
and 4) together.
4. Do not stop the contact pressing before the tool has been
completely pressed into the end position. The tool can
only be opened once the contact pressing has been com-
pleted.
ILAh0116
3-2 DD0855_02
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Copper connection
1A
1B The contact can crack and there is a risk that the
copper conductors will not be clamped securely
enough in the contact.
2A The copper conductors are not clamped securely
enough in the contact. The wire will come loose
from the contact.
2B This will damage the contact. There is a chance that
the contact will eventually crack and the wire will
then come loose from the contact.
3A The contact will become damaged and the copper
and conductors are not all securely clamped in the con-
3B tact. It is possible that the wire will then come loose.
The height of any bulging of the contact may not be
any greater than the thickness of the material. The
width of this bulge may not be greater than half of
the thickness of the material.
5
ILAh0076
1A Wire is too thick.
1B The wire is too thin.
2A The crimping height is too high (the hole used in
the crimping pliers is too large).
2B The crimping height is too low (the hole used in
the crimping pliers is too small).
3A Asymmetric crimping.
3B Symmetric shrinkage.
4 Good contact crimping
S = Thickness of the material.
X = Cracks.
DD0855_02 3-3
WIRING REPAIRS 5
Insulation connection
Different types of crimping are permitted:
A With a good insulation connection, the wire is
clamped in the relief part with the correct force and
the insulation is not broken.
B A too high contact pressing force may lead to bro-
ken insulation, which may cause a short circuit.
This can be caused by:
- Using the wrong crimping tool.
- Using a too small recess in the crimping tool.
- A fault in the crimping tool so that the contact
pressing is stopped too late.
C If the contact pressing pressure is too small, there
is a change that the insulation will not be clamped
and the wire will come loose, resulting in the elec-
trical connection being broken, but also with the
risk of a short circuit. This can be caused by:
- Using a too large recess in the crimping tool.
- The contact pressing being stopped too soon. ILAh0077
1 Normal crimping: the two sides of the relief part
clasp all of the insulation.
2 Double crimping: two wires are clamped into one
5 contact.
3 Overlap crimping: the two sides of the relief part
slightly overlap each other.
4 Double overlap crimping: two wires are clamped
in one contact, so that the two sides of the relief
part slightly overlap each other.
The thinnest wire must always be the bottom
wire in the case of double crimping.
A connection can be checked by carefully pulling the wire

after the contact has been inserted into the connector. It must
then be possible to feel the lock created by the locking
tongue in the connector.
ILAh0078
3-4 DD0855_02
5 WIRING REPAIRS
Examples of wire-contact connections

A. The wire has not been slid far enough forwards.
The wire has not been slid far enough forwards to guar-
antee a good current transfer and pull relief.
B. Not enough of the wire has been stripped.
The stripped part of the wire is too short to guarantee a
good current transfer whilst part of the insulation is
clamped under the contact press part.
C. The wire has been stripped too far.
If the stripped part of the wire is too long and the wire is
positioned correctly in relation to the contact press part,
the pull relief will not enclose a large enough part of the
wire.
D. The wire has been stripped too far.
If the stripped part of the wire is too long and the wire is
positioned correctly in relation to the pull relief, the cop-
per conductors at the front will protrude too far past the
contact press part.
E. The copper conductors are not clamped.
Copper conductors which have not been clamped can
cause a short circuit to neighbouring wires.
F. This is a correct connection.
ILAh0079
DD0855_02 3-5
WIRING REPAIRS 5
3.2 FITTING A SCAT SEAL

Scats (Sealed Cable Automatic Termination) are used in
places where wires are exposed to tough conditions (the
environment or the vehicle use) and where there is, there-
fore, a risk of water getting into the connector.
The Scat seal, which is made from silicone, prevents corro-

sion within the connector and maintains the sealing proper-
ties under changing temperatures.
The Scat seal is pressed around the wire together with the
contact pull relief.
ILAh1571
Scats are available in different colours and sizes

1. Select the correct Scat for the wire, contact and connec-
tor concerned.
2. Slide the Scat on to an unstripped wire (A).
3. Slide the Scat far enough on to the wire and strip the wire
to the correct length (B).
4. Slide the Scat to the end of the stripped wire, so that the
copper still protrudes from the Scat (C).
5 5. Place the contact correctly (D) around the Scat (2) and
the stripped part of the wire (1).
6. The correct crimping tool must now be used to crimp the
contact and the Scat around the wire.
ILAh0117
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3.3 FITTING AN ELECTRICAL KNOCK

CONNECTION
A knock connection is made if at least the ends of two wires
must be connected to each other. This may be necessary
because of a wire repair or if an extra wire must be added to
a connection.

If a new wire is connected to an existing
wire, then this wire must be of the same
thickness as the existing wire. If a piece
of the existing wire must be removed, try
to make sure that the wire number is still
easily visible on the wire.
The contact crimping part (1) is the electrical connection with

the stripped part of the wire. The middle stop (2) is a bound-
ary, so that the wire to be connected cannot be inserted too
far. The insulation is a crimp insulation housing with a layer
of glue (3) which, after being heated with a hair dryer, forms
a protective layer against undesired electrical contact and
corrosion.
There are three different types of knock connection:

red, blue and yellow. The colour to be used depends on the
thickness of wire to be connection (and maybe also the
amount of wires to be connected). 5
• Red: cross-sectional area of 0.25 - 0.75 mm2
• Blue: cross-sectional area of 1.0 - 2.5 mm2
• Yellow: cross-sectional area of 4.0 - 6.0 mm2.

It is not recommended to connect more
than two wires together. The crimp
insulation's layer of glue is then not ILAh1582
enough to seal all the cracks that appear.
This is, therefore, not permitted,
particularly not on the outside of the
vehicle.
It is very important that the contact crimping is carried out

correctly in order to prevent electrical faults. Contact crimp-
ing pliers are necessary in order to produce a cold crimp.
These pliers produce a cold crimp between the wire and the
butt connector.
ILAk1583
DD0855_02 3-7
WIRING REPAIRS 5
Installing a contact crimping connection

1. Select the correct knock connection for the wires to be
connected.

If there is reason to connect three wires
of similar diameter together, select a butt
connector that has a diameter that is
equal to that of two wires. The single wire
on the other side must be stripped twice
the normal length and the wire must then
be folded double. This must also be done
if a wire of double the thickness of the
other wire is used on one side.
2. Strip 4 to 5 mm of the wire.

ILAh0118

The stripped end of the wire must not be
twisted.
3. Select the correct knock connection for the wires to be

connected.
4. Push the contact crimping tool together. Do not stop the
contact crimping before the tool has been completely
pressed into the end position. The tool will only be
opened once the final contact crimping position has been
5 reached.

The wire insulation must not be slid into
the contact part of the butt connector.
ILAh0119
5. Repeat this for the other ends of the butt connector.
6. Check whether the contact crimping is damaged and pull

the wires to make sure they are secure.

Poor contact crimping will result in a
poor contact, which can lead to faults.

Avoid inhaling the vapours that are
released when heating the crimping
insulation.
7. Heat the crimping insulation so that it barely touches the

wire insulation. Make sure the insulation does not burn.
If it burns, the insulation will become brittle and it then ILAh0120
easily breaks or cracks.
3-8 DD0855_02
5 WIRING REPAIRS
3.4 EARTH WIRE: REMOVING AND

INSTALLING
An important inspection when there is a fault in the electrical
system is the inspection of the earth connection, where the
earth connection on the chassis requires special attention.
Points of attention when checking the chassis’ earth

connection
Attention must be given to the following if an earth connec-
tion has been disconnected and then reinstalled:
• The bolt, the nut, the earthing strip and the locking washers
must be cleaned (for example, with a steel brush or sand-
paper). If a component has become corroded, then it must
be replaced by a new component.
chassis beam at the engine/chassis earth connection, so
chassis beam at the battery/chassis earth connection, so
• On the same side as the earthing strip, the cleaned area
must be larger than the earthing strip's contact surface.
• On the same side as the nut, the cleaned area must be
larger than the nut's contact surface.
ILAh0121
• After assembly, a protective zinc primer must be applied to 5
both sides of the earth connection.
DD0855_02 3-9
WIRING REPAIRS 5
3.5 REPAIRING CAN NETWORK WIRING

When replacing/repairing the CAN wiring, the originally
wound wire lengths and wire diameters must be taken into
consideration, with a 10% tolerance for the wound wire
length. Winding density is 40 -50 windings/m.
When repairing the wire, the wiring density must be main-

tained, where it is permitted for the wiring to be unwound
around the location of the repair for a maximum distance of
60 mm. In the case of a repair, the wire must be clasped by
a wire binder in the middle and at the end.
ILAh0081
Replacing a CAN wire

1. Measure the length of the original wire when it is
unwound.
2. Measure the thickness of the original wire. Always use a
wire of the same thickness or, if that thickness is not
available, a wire of the next larger size.
5
3. Preferably choose a wire that is the same colour as the
original wire.
4. Follow the path of the original wire and attach the wire in
the same way.
3 - 10 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C
BATTERIES
DD0855_02
BATTERIES 5
Citea LLE E6 EBS-1C
DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C Safety regulations
1. SAFETY REGULATIONS
1.1 GENERAL INFORMATION

1.1.1 LEAD-ANTIMONY BATTERIES
• Always remove the earth cable before working on the bat-

teries. When reconnecting battery cables, always connect
the earth cable last.
• Always handle batteries with care and keep them horizon-
tal.
• If the battery box is broken, the spilt fluid must immediately
be removed with (soapy) water. The acid must be neutral-
ized with a substance such as soda.
• The sulphuric acid in batteries is an aggressive and toxic
liquid. When working on batteries, wear protective clothing,
gloves and safety goggles. If it comes into contact with
clothes, skin or eyes, rinse immediately with plenty of
water. In the event of contact with eyes or skin, always
seek medical assistance.
Do not wear nylon clothes because of the generation of
static electricity.
• When topping up batteries, never allow the electrolyte level
to rise more than 10 mm above the plates or up to the level
indicator.
• Never place tools or other materials which could acciden-
tally cause the battery terminals to short-circuit on or close
to the batteries. Short-circuited battery terminals may
cause the battery to explode.
• Use insulated tools.
• Secure the batteries after completing the work, but do not 6
secure them too tightly.
• Preferably change the batteries at the same time.
1.1.2 SEALED LEAD-CALCIUM BATTERIES

• Always handle batteries with care and keep them horizon-
tal.
static electricity.
DD0855_02 1-1
BATTERIES 5
Safety regulations Citea LLE E6 EBS-1C
to the batteries. Short-circuited battery terminals may

• Secure the batteries after completing the work, but do not
• A battery may only be opened for warranty assessments.
Never add acid or distilled water! The pressure relief valves
act as a seal and must never be opened.
1.1.3 GEL BATTERIES

• Always handle batteries with care.
static electricity.
6 to the batteries. Short-circuited battery terminals may
• Secure the batteries after completing the work, but do not
• The battery must never be opened. Never add acid or dis-
tilled water! The pressure relief valves act as a seal and
must never be opened.
1-2 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C Safety regulations
1.2 CHARGING THE BATTERIES

• An explosive gas mixture may be released when batteries

are being charged. Always ensure there is suitable ventila-
tion when charging batteries. Smoking, naked flames and
sparks are strictly forbidden.
• Thaw frozen batteries before charging them.
• Switch off the battery charger before disconnecting the
cables to the battery.
• Never use a quick-charging device to start the vehicle.
• A (small quantity of) explosive gas mixture may be

released when batteries are being charged. Always ensure
there is suitable ventilation when charging batteries. Smok-
ing, naked flames and sparks are strictly forbidden.
• Thaw frozen batteries before charging them.
1.2.3 GEL BATTERIES
• Only charge gel batteries using a battery charger with an

IU or IU0U1 charging profile. 6
• A (very small quantity of) explosive gas mixture may be
released when batteries are being charged. Always ensure
there is suitable ventilation when charging batteries. Smok-
ing, naked flames and sparks are strictly forbidden.
• Never charge frozen batteries or batteries that are warmer
than 45 °C.
DD0855_02 1-3
BATTERIES 5
Safety regulations Citea LLE E6 EBS-1C
1-4 DD0855_02
5 BATTERIES
2.1 PROPERTIES
Properties of lead-antimony batteries are:

• Water consumption: the battery is low maintenance, but
not maintenance free.
• Higher gassing and self-discharging than a maintenance-
free battery.
• Resistant to deep discharge.
• Excellent cold-start properties.
• Longer service life.
Lead-antimony batteries can be recognized by the cell seal-

ing caps protruding from the cover.
ILAh1585

6
Properties of sealed lead-calcium batteries are:
• Little water consumption, which makes them low mainte-
nance.
• Little gassing.
• Longer standing time thanks to small self-discharge.
• Not resistant to heavy cyclic use, which shortens the ser-
vice life.
Maintenance-free gel batteries can be recognized by the

sunken cell sealing caps with a cross on them.
It is only permitted to remove cell sealing caps from mainte-
nance-free batteries for warranty assessment purposes.
The cell sealing caps may not be removed for any other rea-
son.
ILAh1584
DD0855_02 2-1
BATTERIES 5
2.1.3 GEL BATTERIES
Properties of gel batteries are:

• Maintenance free.
• Absolutely acid proof.
• Vibration resistant.
• No gassing.
• Resistant to cyclic use (this means that the service life of a
gel battery is much longer than that of a normal lead battery
under similar use).
• Can be installed at an angle of up to 180°.
• Resistant to deep discharging.
• Charges with a special charging curve.
Maintenance-free gel batteries can be recognized by the

sunken hexagonal cell sealing caps.
It is only permitted to remove cell sealing caps from mainte-
nance-free batteries for warranty assessment purposes.
The cell sealing caps may not be removed for any other rea-
son.

A maintenance-free gel battery may never
be opened. If opened, the battery is
damaged by oxidation.
ILAh1148
2-2 DD0855_02
5 BATTERIES

2.2.1 LEAD-ANTIMONY AND SEALED LEAD-CALCIUM
BATTERIES
• The more often a battery is discharged, the shorter its

lifespan will become.
• The lifespan of the batteries is determined by various fac-
tors, including the driving conditions and the climate.
Through time, the batteries will lose starting capacity and
must, therefore, be recharged if the vehicle is not driven or
only driven for short distances for a longer period of time.
The starting capacity is also reduced as a result of freezing
weather conditions.
• To ensure the maximum lifespan of the batteries, they must
always remain fully charged.
• If the vehicle is mainly used for short journeys or is not
used for a longer period of time, then the charging condi-
tion of the batteries must be checked at regular intervals or
the batteries must be kept constantly charged with a trickle
charger.

Turn off the earth breaker switch if the
vehicle is not going to be used for a longer
period of time (see 4 - 1.4 Earth breaker
switch (1 - 4)).
DD0855_02 2-3
BATTERIES 5
2.2.2 GEL BATTERIES
ILAh1587
1 Plate
2 Positive plate
6 3 Isolator
4 Negative plate
5 Isolator
6 Positive cell connector
7 Internal cell connector electrolyte clamp
8 Positive plate group
9 Pole bridge
10 Negative cell connector
11 Negative plate group
12 Safety plug
13 Cover
• During the entire service life of a (maintenance-free) gel

battery, it is not necessary to check the acid level, to
grease the battery terminals or to top the battery up with
distilled water.
This is because the battery’s construction is fully sealed.
• Gel batteries can only be fully charged using a battery
charger with an IU or IU0U1 charging profile.
• To ensure the maximum service life of the batteries, they
must be regularly fully charged.

It is possible to combine a newer and an
older gel battery if the difference in
production date is not more than 1 year.
2-4 DD0855_02
5 BATTERIES

Turn off the earth breaker switch if the
vehicle is not going to be used for a longer
period of time (see 4 - 1.4 Earth breaker
switch (1 - 4)).
ILAh1586
1 Charging voltage (V)
2 Current (A)
3 Charging time (hours)
DD0855_02 2-5
BATTERIES 5
2.3 OPENING AND CLOSING THE BATTERY

BOX
Opening the battery box
1. Turn off the contact switch and the main switch and wait
5 minutes.
3. Remove the lock pin (1) and use the handle (2) to unlock
the battery box.
4. Move the battery box outwards.
ILAh0771
Closing the battery box

1. Close the battery box and lock it.
2. Check whether the hook (3) is correctly fitted. Use the
6 lock pin (1) to lock the handle (2).
2-6 DD0855_02
5 BATTERIES
2.4 DISCONNECTING AND CONNECTING

THE BATTERY CABLES

There is a risk of a short circuit if the
battery’s positive cable comes into
contact with parts of the vehicle. An
explosive gas (oxyhydrogen) may be
released if there is a short circuit.

Do not place metal objects or tools on the
batteries.
When removing the battery terminal

clamps, always remove the black
negative (-) cable before the red positive
(+) cable.
When connecting the battery terminal

clamps, always connect the red positive
(+) cable before the black negative (-)
cable.

The DTCO tachograph saves an error
code if the battery terminal clamps are
disconnected. In some countries, the
error code is interpreted as a breach of
the law. To prevent the unit from saving
an error code when disconnecting the
battery cables, place a DTCO workshop
card in the unit whilst the battery is
disconnected.
6
Disconnecting the battery terminal clamps
1. Turn off all the electricity consumers.
If applicable, remove the contact key.
3. Wait 5 minutes after turning off the contact switch and the
main switch.
5. Open the battery box (see 6 - 2.3 Opening and closing
the battery box (2 - 6)).
6. Disconnect the negative cable first and then the positive
cable from both batteries.
ILAh0770
DD0855_02 2-7
BATTERIES 5
Connecting the battery terminal clamps

1. Check whether the contact switch and the main switch
are turned off.
If applicable, remove the contact key.
2. Check whether all the electricity consumers are turned
off.
3. Make sure the battery terminals and the battery terminal
clamps are clean and well lubricated with Vaseline. If
necessary, lubricate them with acid-free Vaseline.
4. Connect the positive cable first and then the negative
cable to both batteries.
5. Close the battery box (see 6 - 2.3 Opening and closing
2-8 DD0855_02
5 BATTERIES
2.5 REMOVING AND INSTALLING THE

BATTERIES
2.5.1 GENERAL INFORMATION
Lead-antimony and sealed lead-calcium batteries

Each battery weighs approximately 60 kg.
Use suitable lifting equipment.

If one battery must be replaced, it is
important that the other battery is also
replaced at the same time. If only one
battery is replaced, then the lifespan of
both batteries will be reduced.

Return old batteries for environmentally-
friendly processing.
Gel batteries

Each gel battery weighs approximately 70
kg. Use suitable lifting equipment.

It is recommend to change gel batteries
all at the same time.
It is possible to combine a newer and an
older gel battery if the difference in
production date is not more than 1 year.
6

Never connect batteries with different
capacities in series. This results in the
polarity of the smallest battery changing.

Return old batteries for environmentally-
friendly processing.
DD0855_02 2-9
BATTERIES 5
2.5.2 REMOVAL
5 minutes.
3. Open the battery box (see 6 - 2.3 Opening and closing
4. Disconnect the battery cables (see 6 - 2.4 Disconnecting
and connecting the battery cables (2 - 7)).
5. Disconnect the attachment straps (5) and remove the
assembly beam (6).
6. Remove the batteries one at a time.
ILAh0771
6
2.5.3 INSTALLATION
1. Fit the batteries in the battery box.

2. Fit the assembly beam (6) and the attachment straps (5).
3. Connect the battery cables (see 6 - 2.4 Disconnecting
2 - 10 DD0855_02
5 BATTERIES
2.6 CLEANING THE BATTERIES

The condition of the batteries must be regularly checked.

Dirty battery terminal clamps and dirty
batteries may result in a current leak and
a voltage reduction. Therefore, make sure
the battery terminal clamps, the battery
terminals and the battery cover are clean
and dry.
• Only clean the batteries when the filler caps are closed.
• Clean the cover with warm water and soap. Do not use a
solvent.
• Use an anti-static, slightly damp cloth to prevent electro-
static sparks.
• Make sure the terminals and terminal clamps are lightly
lubricated with Vaseline or a similar product.
• Deposits on the terminals can be removed with a copper
brush and lukewarm water.
• Check the bleed opening of the filler caps (only for lead-
antimony batteries). If necessary, remove the filler cap and
unblock the bleed opening.
DD0855_02 2 - 11
BATTERIES 5
2 - 12 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C Charging the batteries
3. CHARGING THE BATTERIES
There are a number of different battery chargers:

• Linear chargers.
• High-frequency chargers.
• Multi-phase chargers.
• Traction chargers.
• Hybrid chargers.
• Trickle chargers.
Before use, check whether the type of charger is suitable for

the type of battery in the vehicle and for the way it is used
within your company.
We recommend using a voltage-controlled battery charger,
preferably one which has an IUoU charging profile.
3.1 LEAD-ANTIMONY BATTERY

• Never charge a frozen battery or a battery whose temper-

ature exceeds 45 ˚C.
• A battery may only be charged using direct current. Con-
nect the battery’s positive terminal to the charger’s positive
connection (+ve) and connect the battery’s negative termi-
nal to the charger’s negative connection (-ve).
The cell sealing plugs may be left on the battery whilst
charging (except during quick-charging). The cell voltage
will rise whilst charging. This voltage rise will depend on the
charging current applied and the temperature. During nor-
mal charging, the cell voltage will rise from approx. 2 Volt/ 6
cell to approx. 2.65 Volt/cell. Exceeding the charge voltage
by approx. 2.35 to 2.4 Volt/cell (approx. 14.2 Volt in a 12 V
battery) will result in the development of gas. As a result of
the rising voltage during charging, the charge current will
tend to gradually fall. Overcharging will reduce the lifespan
of a battery.
• NEVER overcharge the battery. Overcharging and also
charging with a charging current of more than 20% of the
capacity (Ah/20 h) will cause high water usage and reduce
the battery’s lifespan.
Corrosion (damage) to the grids of the positive battery
plates is caused by unnecessarily continuing to charge a
battery (even with a low current) once it has been fully
charged. This form of wear results in the premature failure
of the battery. Depending on the charger’s power, the nor-
mal charging time is between 8 and 15 hours. If, during
charging, the temperature of the battery acid exceeds 55
°C, charging should be stopped. High temperatures reduce
the lifespan of a battery.
• Always check the electrolyte’s specific weight after charg-
ing.
A battery should be considered charged when the charge
voltage has not risen for 2 hours and the acid density (spe-
cific weight) has reached the nominal value (1.280 kg/dm3
for battery acid and 1.240 kg/dm3 for tropical acid) and
rises no further.
DD0855_02 3-1
BATTERIES 5
Charging the batteries Citea LLE E6 EBS-1C
• A charged battery must be used immediately. If this is not

possible, maintain the battery as described in "Storage of
batteries" (see 6 - 4. Storage of batteries (4 - 1)).
• A discharged battery should be charged as soon as possi-
ble. If a discharged battery is not recharged, the battery
plates may become sulphated (i.e. the battery plates
become hard), leading to a permanent loss of capacity.
• To prevent damage to electronic components, never dis-
connect the battery terminal clamps when the engine is
running.
• First connect the battery charger’s positive clamp (+) to the
battery’s positive terminal (+) and then the negative clamp
(-) to the negative terminal (-).
Only then insert the plug in the plug socket, because that
prevents sparking.
• After the battery has been charged, turn off the charger and
remove the plug from the plug socket. Leave the battery for
two hours before removing the clamps.
• To disconnect, first release the negative terminal (-) and
then the positive terminal (+).
• Always observe the charger’s instructions.
3.1.2 CHARGING METHODS

Always remove the battery clamps before
charging.
Normal charging
6 • Normal charging is used to return a fully or partially dis-
charged battery to 100% capacity. In general, a charging
current of 1/20 to 1/10 of the capacity is used.
• It is important that the charging current is reduced if gas is
produced and that the current is switched off once the bat-
tery has been fully charged.
Quick-charging
• For this charging method, multiples of the normal charge
current (approx. 3 to 5 times) are used in order to achieve
an acceptable charge in the shortest possible time.
• Before quick-charging, remove the battery cables to avoid
damage to the electronic components.
• Remove the cell sealing plugs to allow the gases produced
to escape more effectively.
• To prevent overcharging, switch to a reduced charge cur-
rent upon reaching the gas charge (2.35 to 2.4 Volt/cell).

Avoid quick-charging. Quick-charging
may only be used when absolutely
necessary. Quick-charging will overload
the battery, which will reduce the
battery’s lifespan.
3-2 DD0855_02
5 BATTERIES
Buffer charging
• With this charging method, the power consumer and the
charger are both connected to the battery. The charger
delivers sufficient current to ensure that the battery
remains practically full. The battery provides peak currents
to the power consumer.
• Buffer charging is best carried out at a constant (stabilized)
voltage.
Trickle charging
• If the battery is full, but is not used immediately, self-dis-
charge will occur. This can be between 0.1% and 1% per
day. Trickle charging compensates for this self-discharge.
• The charge current for trickle charging should be approx.
0.1 A per 100 Ah.
DD0855_02 3-3
BATTERIES 5
3.2 SEALED LEAD-CALCIUM BATTERY (SMF)


• A battery may only be charged using direct current. Con-
nect the battery’s positive terminal to the charger’s positive
connection (+ve) and connect the battery’s negative termi-
nal to the charger’s negative connection (-ve).
The cell sealing plugs may be left on the battery whilst charging
(except during quick-charging). The cell voltage will rise whilst
charging. This voltage rise will depend on the charging current
applied and the temperature. During normal charging, the cell
voltage will rise from approx. 2 Volt/cell to approx. 2.65 Volt/cell.
Exceeding the charge voltage by approx. 2.35 to 2.4 Volt/cell
(approx. 14.2 Volt in a 12 V battery) will result in the develop-
ment of gas. As a result of the rising voltage during charging,
the charge current will tend to gradually fall. Overcharging will
reduce the lifespan of a battery.
• NEVER overcharge the battery. Overcharging and also
charging with a charging current of more than 20% of the
capacity (Ah/20 h) will cause high water usage and reduce
the battery’s lifespan.
of the battery. Depending on the charger’s power, the nor-
charging, the temperature of the battery acid exceeds 55
6 °C, charging should be stopped. High temperatures reduce
the lifespan of a battery.
• A charged battery must be used immediately. If this is not
possible, maintain the battery as described in "Storage of
batteries" (see 6 - 4. Storage of batteries (4 - 1)).
• To prevent damage to electronic components, never discon-
nect the battery terminal clamps when the engine is running.
prevents sparking.
• Always observe the instructions for the charger and the
battery.

Under no circumstances may the
pressure-relief valves be removed nor
may the battery be topped up with water.
3-4 DD0855_02
5 BATTERIES

charging.
Normal charging
• Normal charging is used to return a fully or partially dis-
charged battery to 100% capacity. In general, a charging
current of 1/20 to 1/10 of the capacity is used.
• It is important that the charging current is reduced if gas is
produced and that the current is switched off once the bat-
tery has been fully charged.
Quick-charging
• For this charging method, multiples of the normal charge
current (approx. 3 to 5 times) are used in order to achieve
an acceptable charge in the shortest possible time.
• Remove the cell sealing plugs to allow the gases produced
to escape more effectively.
• To prevent overcharging, switch to a reduced charge cur-
rent upon reaching the gas charge (2.35 to 2.4 Volt/cell).

Avoid quick-charging. Quick-charging may
only be used when absolutely necessary.
Quick-charging will overload the battery,
which will reduce the battery’s lifespan.
Buffer charging
• With this charging method, the power consumer and the
charger are both connected to the battery. The charger 6
delivers sufficient current to ensure that the battery
remains practically full. The battery provides peak currents
to the power consumer.
• Buffer charging is best carried out at a constant (stabilized)
voltage.
Trickle charging
• The charge current for trickle charging should be approx.
0.1 A per 100 Ah.
Equalizing charge
• If batteries are used for traction purposes, the load is cyclic,
or in other words, the battery charges and discharges.
• If these batteries are charged with controlled chargers, it is
important for fluid-electrolyte batteries that the batteries
are fully charged as least four times a year using a charger
which exceeds the gassing voltage.
• The objective of this charge is to allow the acid to properly
circulate in the battery so that there is no stratification of the
acid, i.e. no heavy acid at the bottom and light acid at the
top.
• This charge ensures a uniform specific density in the cells.
Stratification may result in the permanent break-down of
active material.
DD0855_02 3-5
BATTERIES 5
3.3 GEL BATTERY


• Only use automatically controlled direct current (DC) chargers.
Observe the charger’s instructions.
• Gel batteries can only be fully charged using a battery
charger with an IU or IU0U1 charging profile.
If a charger is used which is not suitable for gel batteries,
the batteries sulphate. This results in a shorter service life.
• The battery must be recharged if the voltage falls below 12.4 V
(50% charge) as described in Normal charging (3 - 7).
• First, connect the positive cable to the positive terminal clamp
and then, the negative cable to the negative terminal clamp,
before inserting the charger’s plug into the plug socket.
• Turn off the charger before disconnecting the positive and
negative clamps.
• The cell voltage will rise whilst charging. This voltage rise
will depend on the charging current applied and the tem-
perature. As a result of the rising voltage during charging,
the charge current will tend to gradually fall. Overcharging
will reduce the lifespan of a battery.
• NEVER overcharge the battery. Overcharging and charg-
ing with a charging current of more than 50% of the nomi-
nal capacity reduce the battery’s service life.
6 of the battery. Depending on the charger’s power, the nor-
charging, the temperature of the battery acid exceeds
50°C, charging should be stopped. High temperatures
reduce the lifespan of a battery.
• To prevent damage to electronic components, never discon-
nect the battery terminal clamps when the engine is running.
prevents sparking.
• Always observe the instructions for the charger and the
battery.

Under no circumstances may the
pressure-relief valves be removed nor
may the battery be topped up with water.
3-6 DD0855_02
5 BATTERIES

charging.
Normal charging
• During the I-phase, the battery is charged with a current of
at least 10% of the capacity.
• When the voltage is 14-14.4 V, the charger must switch to
the U-phase (main charging phase). The voltage must
remain at 14-14.4 V for at least 12 hours, even if the battery
was only partially discharged.
• After the U-phase, the charger can be turned off (IU) or it
can switch to a float charge with a very small current
(IU0U 1).
The voltage given above applies to a 12 V system. In the

case of a 24 V system, the values must be doubled.
Quick-charging
• Use a current of no more than 50% of the nominal capacity
for a period of no more than 1 hour.
In any case, the voltage must remain below 15 V.

Never quick-charge deeply discharged
batteries.
6

Avoid quick-charging. Quick-charging may
only be used when absolutely necessary.
Quick-charging will overload the battery,
which will reduce the battery’s lifespan.
Restoring from a deep discharge

• If the voltage has dropped below 12.1 V, use a charge as
described in Normal charging (3 - 7), but ensure that
the total charging period of step 1 and step 2 is at least 48
hours.
During the entire charging phase, the temperature must
not exceed 50 °C.
Trickle charging
• Use a trickle charge voltage of 13.8 V during the entire
charging period and consider a monthly IUi charge.

Never trickle-charge deeply discharged
batteries.
DD0855_02 3-7
BATTERIES 5
3-8 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C Storage of batteries
4. STORAGE OF BATTERIES

Carry out the following before storing batteries:
Procedure
1. Disconnect the battery clamps.
2. Clean the battery terminals and the top of the batteries.
3. Apply Vaseline to the battery terminals.
4. Check the battery charge and, if necessary, recharge the
batteries (see 6 - 5.2 Sealed lead-calcium battery (SMF)/
gel battery (5 - 5)).
5. Make sure the battery is fully charged when stored.
6. Place a protective cap on at least one of the terminals to
prevent short-circuiting.
7. Protect the batteries against being knocked.
8. Check the electrolyte level. The electrolyte level must be
approx. 10 mm above the plates or, if present, up to the
level indicator.
If necessary, top up the batteries with distilled water.
4.1.2 LEAD-CALCIUM/GEL BATTERIES

6
Procedure
1. Disconnect the battery clamps.
2. Clean the battery terminals and the top of the batteries.
3. Apply Vaseline to the battery terminals.
4. Check the batteries’ state of charge and, if necessary,
recharge the batteries.
5. Make sure the battery is fully charged when stored.
6. Place a protective cap on at least one of the terminals to
prevent short-circuiting.
7. Protect the batteries against being knocked.
8. Store batteries in a cool, dry and well ventilated location.
Avoid storing them in places were sparks may occur.
DD0855_02 4-1
BATTERIES 5
Storage of batteries Citea LLE E6 EBS-1C
4.2 STORAGE FOR LESS THAN 4 WEEKS

The following measures must be taken if the batteries (dis-
connected or in a vehicle) are not going to be used for a
longer period of time (up to 4 weeks).
Measures
1. See 6 - 4.1 General information (4 - 1).
2. Regularly check the battery charge, particularly when
stored at low temperatures (see 6 - 5.2 Sealed lead-cal-
cium battery (SMF)/gel battery (5 - 5)). If the voltage
falls below 12.54 V or the specific weight of the electro-
lyte in one or more cells is less than 1.250 kg/dm3 (1.240
for batteries with tropical acid), the battery must be
charged.

The lower the specific weight of the
electrolyte, the more likely the battery is
to freeze.

All types of battery can be connected to a
trickle charger for a longer period of time
without any problems.
Measures
6 1. See 6 - 4.1 General information (4 - 1).
2. Regularly check the batteries’ state of charge, particu-
larly when stored at low temperatures. If the voltage falls
below 12.4 Volt, the battery must be charged.

4-2 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C Storage of batteries
4.3 STORAGE FOR MORE THAN FOUR

WEEKS
The following measures must be taken if the batteries are not
going to be used for more than 4 weeks.
Measures
2. Remove the batteries from the vehicle and store them in
a frost-free, dry, cool and well ventilated location.
3. Regularly check the battery charge, at least every 4
weeks (see 6 - 5.2 Sealed lead-calcium battery (SMF)/
gel battery (5 - 5)). If the voltage falls below 12.54 V or
the specific weight of the electrolyte in one or more cells
is less than 1.250 kg/dm3 (1.240 for batteries with tropi-
cal acid), the battery must be charged.

4. Limit storage to a maximum of six months. The longer a

battery is stored, the greater the permanent loss of
capacity.
The following measures must be taken if the batteries are not 6

going to be used for more than 4 weeks.
Measures
2. Remove the batteries from the vehicle and store them in
a frost-free, dry, cool and well ventilated location.
3. Regularly check the batteries’ state of charge.Do so at
least every 4 weeks. If the voltage falls below 12.4 Volt,
the battery must be charged.
4. Recharge the battery at least once a month.

5. Limit storage to a maximum of twelve months. The longer

a battery is stored, the greater the permanent loss of
capacity.
DD0855_02 4-3
BATTERIES 5
Storage of batteries Citea LLE E6 EBS-1C
4-4 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C Inspecting the batteries
5. INSPECTING THE BATTERIES

5.1.1 VISUAL INSPECTION
• A visible white dividing line at 1/3 of the plate height (visible

through a transparent battery casing) indicates that a bat-
tery has been left standing in a highly discharged condition.
• If the electrolyte is brown in colour and the battery con-
sumes a large amount of water, the battery has been over-
charged.
• If the electrolyte is murky or milky and the cells have a
white deposit, the battery has been damaged by insuffi-
cient charging (highly discharged).
DD0855_02 5-1
BATTERIES 5
Inspecting the batteries Citea LLE E6 EBS-1C
5.1.2 BATTERY FLUID LEVEL: CHECKING

Avoid sparks and naked flames near the
batteries.
Battery acid is an aggressive liquid.
In the event of skin contact: neutralize the

skin immediately with sodium carbonate
or soapsuds and rinse with plenty of
water. Contact a doctor if the affected
area remains red or painful. Remove
affected clothing, neutralize with sodium
carbonate or soapsuds and rinse with
plenty of water.
In the event of contact with the eyes:
wash with clean, flowing water for at least
15 minutes and contact a doctor.
If swallowed: do NOT induce vomiting.
Rinse your mouth, drink plenty of water
and contact a doctor.
If inhaled: get some fresh air, take a rest
1. Check the electrolyte level of all six cells. If it is below the

MIN mark on the battery box or below the indicator visible
in the filling hole (white cross), top up the batteries with
distilled water.
2. Check the battery housing for leaks. Clean and dry the
battery cover.
6
ILAh0001
Checking the charge

1. Check the battery charge if there are any doubts regard-
ing the charge condition (see 6 - 5.2 Sealed lead-cal-
cium battery (SMF)/gel battery (5 - 5)).
5-2 DD0855_02
5 BATTERIES
5.1.3 BATTERY CHARGE: CHECKING
Specific weight
• Charging and discharging the battery causes a chemical
reaction to occur in the battery involving sulphuric acid. The
concentration of the sulphuric acid falls the more the bat-
tery becomes discharged. The concentration, measured as
the specific weight (kg/dm3), is a useful yardstick for deter-
mining the battery charge.
• The battery charge can be checked using an acidometer.
Specific weight at 27 °C in kg/dm3.
Charged battery : 1.28
Half-charged battery : 1.20
Discharged battery : 1.10
• Measurement corrections are necessary for strongly devi-

ating temperatures. For each 7 °C lower, 0.005 points must
be deducted from the measured reading. For each 7 °C
higher, 0.005 points must be added to the measured read-
ing. When a battery is in a good condition, the specific
weight will be the same in all the cells. The maximum dif-
ference between the highest and lowest specific weight is
0.03 kg/dm3.

If the specific weight in a single cell is
considerably lower than the rest, the
cause may be cell closure. If the specific
weight of two adjacent cells is
considerably lower than the rest of the
battery, there could be a leak in the
partition. In both cases, the battery must 6
be replaced.
Relationship between charging condition, acid density

and clamp voltage
The electrolyte’s acid density depends on the temperature.
At temperatures below 20 °C, the acid is “thicker” as a result
of shrinkage and a higher value will, therefore, be read.
At temperatures above 20 °C, the opposite happens. A rule
of thumb is that for every 7 °C below 20 °C, the acid density
increases by 0.005 and for every 7 °C above 20 °C, the acid
density reduces by 0.005.
ILAh0160
1. Charging condition
2. Acid strength
DD0855_02 5-3
BATTERIES 5
3. Clamp voltage
Temperature (°C) Measured acid density (kg x l-1) Corrected acid density (kg x /-1) at 20 °C
6 1.290 1.280
13 1.285 1.280
20 1.280 1.280
27 1.275 1.280
34 1.270 1.280
Voltage
• The battery charge can also be measured using a sensi-
tive, preferably digital, voltmeter. This method can only be
used 1 to 2 hours after the termination of charging or dis-
charging. This method measures the absolute rest voltage
(the positive and negative clamps must have been discon-
nected from the battery).
The battery charge can be calculated using the following
formula: voltage per cell = specific weight (kg/dm3) + 0.84.
Example
For a fully charged battery, the specific weight per cell is 1.28
kg/dm3.
The voltage per cell is, therefore, 1.28 + 0.84 = 2.12 V.
A 12 V battery has 6 cells. The total voltage of a charged bat-
tery is, therefore, 6 x 2.12 = 12.72 V. The voltage of a battery
that is only half charged is approx. 12.24 V. The voltage of a
discharged battery is approx. 11.75 V.
6
5.1.4 CHECKING USING A BATTERY TESTER
• A battery tester can be used to get a quick, rough measure-

ment of the condition of the battery. In this test, the battery
is subjected to a load, after which the discharge voltage
across the battery terminals is measured. The load placed
on the battery must be at least three times the capacity of
the battery.
• The test can only be carried out if the battery is sufficiently
charged (specific weight 1.25 - 1.28 kg/dm3). At a normal
temperature (10 °C - 20 °C), the load voltage of a well-
charged battery should be 10 V after 10 seconds. For a
partially-discharged battery (specific weight 1.25 kg/dm3),
at least 9 V must be measured. It is important that the volt-
age is measured directly across the battery terminals.
5-4 DD0855_02
5 BATTERIES
5.2 SEALED LEAD-CALCIUM BATTERY

(SMF)/GEL BATTERY
5.2.1 INSPECT.

Avoid sparks and naked flames near the
batteries.
Battery acid is an aggressive liquid.
In the event of skin contact: neutralize the

skin immediately with sodium carbonate
or soapsuds and rinse with plenty of
water. Contact a doctor if the affected
area remains red or painful. Remove
affected clothing, neutralize with sodium
carbonate or soapsuds and rinse with
plenty of water.
In the event of contact with the eyes:
wash with clean, flowing water for at least
15 minutes and contact a doctor.
If swallowed: do NOT induce vomiting.
Rinse your mouth, drink plenty of water
If inhaled: get some fresh air, take a rest
Checking the housing

1. Check the battery housing for leaks. Clean and dry the
battery cover.
Checking the charge

1. Check the battery charge if there are any doubts regard- 6
ing the charge condition (see 6 - 5.2 Sealed lead-cal-
cium battery (SMF)/gel battery (5 - 5)).
DD0855_02 5-5
BATTERIES 5
5.2.2 CHECKING THE STATE OF CHARGE

The terminal voltage may only be
measured at least 24 hours after the
battery has been charged. During the
measurement, no current may be
consumed.
• The battery's state of charge can also be measured using

a digital voltmeter. This method must not be used sooner
than 24 hours after charging or discharging has finished.
This method measures the absolute rest voltage (the pos-
itive and negative clamps must have been disconnected
from the battery).
Rest voltage State of charge

Larger than 12.80 V 100%
Approx. 12.55 V 75%
Approx. 12.32 V 50%
Approx. 12.18 V 25%
Less than 12.00 V 0%
5.2.3 POSSIBLE CAUSES OF EARLY BREAK-DOWN

OF GEL BATTERIES
A negative charge balance, loss of capacity

1. Insufficient charging time (less than 12 hours).
6 2. A faulty charger.
3. A charger which is not suitable for gel batteries.
4. A negative energy balance.
Deep discharge
1. Certain consumers are not turned off.

In contrast to normal batteries, gel
batteries can be exposed to a state of
deep discharge for up to 4 weeks without
showing signs of faults.
After 4 weeks, gel batteries must be
charged for at least 48 hours at a voltage
of 14.1-14.4 V to allow them to be fully
charged again.
5-6 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C External starting assistance
6. EXTERNAL STARTING ASSISTANCE

Both systems must have the same
battery voltage (24 V).

Do not cause sparks, because that may
cause the batteries to explode.
Do not touch the terminal clamps when
starting.

Use thick start cables (at least 25 mm2)
with insulated terminal clamps.

Jump starting may only be performed
with the aid of batteries. An auxiliary
starting device may produce a too high
voltage, which will damage the vehicle’s
electrical system.

NEVER start a vehicle using a quick-
charging device.

Prevent both vehicles from touching
each other.
If the vehicle is started with a separate
battery (approx. 24 V) or with the aid of
another vehicle whose engine is running
(approx. 28 V), then the battery cables
must not be disconnected. 6
DD0855_02 6-1
BATTERIES 5
External starting assistance Citea LLE E6 EBS-1C
6.1 STARTING ASSISTANCE WITH THE

NATO PLUG
The NATO plug is located at the front on the left-hand side
behind the service hatch. The exact position of the NATO
plug differs for each vehicle.

When starting the vehicle with the aid of
starting assistance, the battery cables
must not be disconnected during the
process.
1. Turn off the contact switch and the main switch of both
vehicles.
3. Check whether the auxiliary starting aid has the correct
voltage (24 V).
4. Unscrew the cover of the NATO plug and move it to the
side.
5. Insert the start cable with the NATO contra plug into the
NATO plug of the vehicle with the flat battery (current
receiver).
6. Connect the start cables/NATO plug to the battery of the
assisting vehicle.
7. Start the engine of the assisting vehicle (current sup-
plier).
Allow the engine to run for 1 minute at an increased
6 engine speed.
8. Start the vehicle which has flat batteries. ILAh0774
Carry out the following when the engine is running and the batteries have been charged for at least 5 minutes.
1. Turn on as many power consumers as possible (for
example, the headlights, fog lights, heating, fans, etc.).
2. Remove the NATO plug/start cables from the vehicle
with the flat battery first and then from the assisting vehi-
cle.
When removing the cables, remove the cable connected
to the negative (-) terminal clamps first before removing
the cable connected to the positive (+) terminal clamps.

When the battery has been fully discharged, it
is important not to immediately remove the
NATO plug/start cables once the engine is
running. To prevent damage to the electrical
system as a result of voltage peaks, the
engine must have been running for at least 5
minutes before the NATO plug/start cables is/
are removed.
3. Then, turn the power consumers off again.

4. Refit the NATO plug’s cover.
6-2 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C External starting assistance
6.2 STARTING WITH THE AID OF AUXILIARY

BATTERIES

When starting the vehicle with the aid of
starting assistance, the battery cables
must not be disconnected during the
process.

2. Open the battery box (see 2.3 Opening and closing the
battery box (2 - 6)).
3. Check whether the auxiliary battery (B) has the correct
voltage (24 V).
4. Turn off the contact switch and the main switch of both
vehicles.
5. Connect the start cables to the positive (+) battery termi-
nal clamps first and then to the negative (-) battery termi-
nal clamps (see the diagram). To prevent sparks, the
terminal clamps must be securely attached.
6. Start the engine of the auxiliary battery. Allow the engine
to run for 1 minute at an increased engine speed.
7. Start the vehicle which has flat batteries.
Carry out the following when the engine is running and the
batteries have been charged for at least 5 minutes. ILAh0772
A. Batteries with a low voltage
B. Fully charged battery
6
1. Turn on as many power consumers as possible (for
example, the headlights, fog lights, heating, fans, etc.).
2. Disconnect the start cables. The engine may only idle
when doing so.
3. When removing the cables, remove the cable connected
to the negative (-) terminal clamps first before removing
the cable connected to the positive (+) terminal clamps.

If the battery is fully discharged and the
engine is running, it is important that the
start cables are not removed
immediately. To prevent damage to the
electrical system as a result of voltage
peaks, the engine must have been
running for at least 5 minutes before the
start cables are removed.
4. Then, turn the power consumers off again.

DD0855_02 6-3
BATTERIES 5
External starting assistance Citea LLE E6 EBS-1C
6-4 DD0855_02
5 BATTERIES
Citea LLE E6 EBS-1C Battery charging assistance
7. BATTERY CHARGING ASSISTANCE


Never disconnect the battery terminal
clamps whilst the engine is running!

When charging the batteries with a
battery charger, make sure there is good
ventilation and avoid sparks and an open
fire, because there is a risk of an
explosion.

NEVER overcharge the battery.
Overcharging and also charging with a
charging current of more than 20% of the
capacity (Ah/20 h) will cause high water
usage and reduce the battery’s lifespan.

Always disconnect the battery’s earth
cable when working on the electrical
system.

Never place tools on a battery. This could
short-circuit the battery or may even
6

Thaw frozen batteries before charging
them. Remove all the filler caps when
charging the battery.
DD0855_02 7-1
BATTERIES 5
Battery charging assistance Citea LLE E6 EBS-1C
7.1.2 CHARGING VIA THE BATTERY TERMINALS

The explanation given below for charging
a battery is for information purposes
only.
Always follow the instructions provided
by the manufacturer of the charging
device.
• Charge the battery slowly with a low amperage for approx-

imately 24 hours. If the battery is charged for longer, there
is a risk that the battery will be damaged.
• Only use a quick-charger in a situation of extreme emer-
gency. Batteries are subjected to an extremely heavy load
when being quick-charged and this can have a negative
effect on a battery’s lifespan.
• When quick-charging, both of the battery cables MUST be
disconnected in order to prevent damage to the vehicle’s
electronics.
1. Remove the battery (see 6 - 2.5 Removing and installing
the batteries (2 - 9)) or disconnect the battery's nega-
tive terminal clamp (-) (see 6 - 2.4 Disconnecting and
connecting the battery cables (2 - 7)).
2. Connect the battery charger’s positive clamp (+) to the
battery’s positive (+) clamp.
3. Connect the battery charger’s negative clamp (-) to the
battery’s negative (-) clamp.
4. The charging device must be suitable for the voltage: 12
V for a single battery and 24 V for batteries in series (2 x
12 V).
5. Turn on the battery charger.
6. Turn the battery charger off once the battery has been
6 charged.
7. Disconnect the negative (-) clamp first.
8. Next, disconnect the positive (+) clamp.
9. Check the electrolyte level (see 6 - 5.1 Lead-antimony
battery (5 - 1)).
10. Install the battery (see 6 - 2.5 Removing and installing
the batteries (2 - 9)) or disconnect the negative termi-
nal clamp (-) from the battery (see 6 - 2.4 Disconnecting
7-2 DD0855_02
5 BATTERIES
7.1.3 CHARGING USING THE NATO PLUG

only.
device.
• Charge the battery slowly with a low amperage for approx-

imately 24 hours. If the battery is charged for longer, there
is a risk that the battery will be damaged.
• Only use a quick-charger in a situation of extreme emer-
gency. Batteries are subjected to an extremely heavy load
when being quick-charged and this can have a negative
effect on a battery’s lifespan.
• When quick-charging, both of the battery cables MUST be
disconnected in order to prevent damage to the vehicle’s
electronics.
5 minutes.
side.
4. Connect the charging equipment to the NATO plug.
The charging device must be suitable for 24 V.
5. Turn on the charging device.
6. Once the battery has been recharged, turn off the charg-
ing device first before disconnecting the NATO plug.
8. Check the electrolyte level (see 6 - 5.1 Lead-antimony
battery (5 - 1)).
6
ILAh0774
DD0855_02 7-3
BATTERIES 5
7.2 SEALED LEAD-CALCIUM BATTERY

(SMF)/GEL BATTERY

Never disconnect the battery terminal
clamps whilst the engine is running!

When charging the batteries with a
battery charger, make sure there is good
ventilation and avoid sparks and an open
fire, because there is a risk of an
explosion.

Always disconnect the battery’s earth
cable when working on the electrical
system.

Never place tools on a battery. This could
short-circuit the battery or may even

Never charge frozen batteries or batteries
that are warmer than 45 °C.
Interrupt the charging if the battery
becomes warmer than 45 °C.
7.2.2 CHARGING VIA THE BATTERY TERMINALS

6

The explanation given below for charging a
battery is for information purposes only.
Always follow the instructions provided by
the manufacturer of the charging device.
• See 6 - 7.2 Sealed lead-calcium battery (SMF)/gel

battery (7 - 4) for instructions on how to charge batter-
ies.
1. Remove the battery (see 6 - 2.5 Removing and installing
the batteries (2 - 9)) or disconnect the battery's nega-
tive terminal clamp (-) (see 6 - 2.4 Disconnecting and
connecting the battery cables (2 - 7)).
2. Connect the battery charger’s positive clamp (+) to the
battery’s positive (+) clamp.
3. Connect the battery charger’s negative clamp (-) to the
battery’s negative (-) clamp.
4. The charging device must be suitable for the voltage: 12
V for a single battery and 24 V for batteries in series (2 x
12 V).
5. Turn on the battery charger.
6. Turn the battery charger off once the battery has been
charged.
7. Disconnect the negative (-) clamp first.
8. Next, disconnect the positive (+) clamp.
7-4 DD0855_02
5 BATTERIES
9. Install the battery (see 6 - 2.5 Removing and installing

the batteries (2 - 9)) or disconnect the negative termi-
nal clamp (-) from the battery (see 6 - 2.4 Disconnecting
7.2.3 CHARGING USING THE NATO PLUG

only.
device.
• See 6 - 7.2 Sealed lead-calcium battery (SMF)/gel

battery (7 - 4) for instructions on how to charge batter-
ies.
5 minutes.
side.
4. Connect the charging equipment to the NATO plug.
The charging device must be suitable for 24 V.
5. Turn on the charging device.
6. Once the battery has been recharged, turn off the charg-
ing device first before disconnecting the NATO plug.
8. Close the service hatch. 6
ILAh0774
DD0855_02 7-5
BATTERIES 5
7-6 DD0855_02
5 ELECTRICAL INSTALLATION
Citea LLE E6 EBS-1C
ELECTRICAL INSTALLATION
DD0855_02
ELECTRICAL INSTALLATION 5
Citea LLE E6 EBS-1C
DD0855_02
1.1 DETERMINING THE SAFETY LEVEL

Electrical systems that are retrofitted to the vehicle's electri-
cal installation must not behave in such a way that they have
a negative influence on the vehicle's standard system or the
general safety.

Always disconnect the battery’s positive
terminal (+) before working on the
electrical installation.
If carrying out welding work, read the instructions given in

7 - 1.2 Precautionary measures when welding (1 - 2).
DD0855_02 1-1
1.2 PRECAUTIONARY MEASURES WHEN

WELDING

It is not permitted to carry out welding
work on the vehicle without special
written permission from VDL Bus &
Coach,

Failure to observe the instructions below
may damage the electronic components.
Precautionary measures concernig the electrical instal-

lation
• Turn off the main switch and the contact switch.
Remove the key from the contact lock.
• Disconnect the positive and negative terminals from the
batteries before starting the welding work.
• Disconnect the connectors for the central electrical box,
the alternators, the electrical components, the electronic
units, the CMU, the ECU, the IOU, the ABS/EBS unit, the
dashboard and the ECM.
• When performing welding work on the bodywork or the
chassis frame, disconnect the connectors from all the elec-
tronic devices (including the sensors and actuators) that
are located within a distance of 1 metre from the welding
point or that are within a distance of 1 metre from the earth
clamp.
• Attach the welding set’s earth clamp as close as possible
to the area on the vehicle where the welding work is to be
carried out and ensure that it makes good contact with the
area being welded.
• Never attach the earth clamp to vehicle components, such
as the engine, axles, etc. It is also not permitted to carry out
7 welding work on these components. This may cause seri-
ous damage.
• Protect plastic lines, rubber components, wiring har-
nesses, operating cables, plastic components, piston rods
of hydraulic cylinders and air bellows against grinding
sparks and welding splashes. These components must not
be exposed to temperatures greater than 70 °C.
1-2 DD0855_02
1.3 PEAK VOLTAGES

All the power consumers to be added must be protected
against inductive peak voltages. A diode safety device may
be fitted.
Inductive peak voltages must not be greater than 40 V at a
minimum of 50 Hz, otherwise the electrical installation may
be damaged. The safety diode must be placed as close as
possible to the power consumer.
DD0855_02 1-3
1.4 EMC COMPATIBILITY

Electromagnetic compatibility (EMC) is understood to mean
the degree of insensitivity of electrical systems to electro-
magnetic interference. These forms of interference are
called electromagnetic interference (EMI) and are classified
as follows:
Forms of interference
1. Interference caused by magnetic fields which, in princi-
ple, are close to all electrical components. Large sources
of interference include transmission masts (such as for
radio, television and mobile telephones) and electricity
pylons.
2. Electromagnetic radiation which is caused by compo-
nents in the vehicle. Large sources of interference are
the generator, electromagnets, motors for things such as
the electric windows and electronic units.
3. The influence that the systems have on each other
caused by switching signals.
In order to minimize the electromagnetic interference, the

bodybuilder must take the following into consideration:
• Electronic systems that are added to the VDL Bus & Coach
chassis must be certified in accordance with the EMI legis-
lation 95/54/EC.
• Every system must have its own power cable and earth
connection. Only use the power supply points and earthing
points shown in the circuit diagram.
• The wiring must be as close as possible to the VDL Bus &
Coach wiring harness in the bodywork and in the chassis.
The wiring harness must always be on the inside of the
chassis in order to prevent electromagnetic fields as much
as possible.
• The wiring of the components that are sensitive to EMI
7 (contact the supplier) must be twisted.
• Wires that are too long must be shortened and the use of
loops must be avoided. Tying the wiring harnesses up may
reduce the sensitivity.
Mobile telephones or transmitters without an exterior aerial

may not be used in the vehicle. The extremely high field
strengths that these items produce in the vehicle can cause
faults or can cause electrical equipment to fail. The strong
electromagnetic fields may also cause a health risk. The
installation of such devices must, therefore, be carried out by
recognized installation fitting stations, where the correct con-
nection for the exterior aerial must be verified.
The use of mobile telephones a short distance from a vehicle
for which the contact switch has been turned on must be
avoided.
The same applies for 27 MC and satellite communication
equipment as for mobile telephones.
1-4 DD0855_02
1.5 CAN NETWORK

The CAN network (CAN databus) is, in principle, a distribu-
tion network of different electronic signals.
The digital pulse signals form coded messages. They can be
sent, received and processed by all the systems connected
to this network.
Each system takes the information it needs from the network.
For example, a signal that is created by one system can also
be used by other systems.
The CAN network works according to the SAE J1939 CAN
protocol.
The following components are part of the CAN network:

• Central Vehicle Module (CVM) or Gateway.
• Vehicle Function Controller (VFC).
• Input and Output Units (IOUs).
• Instrument panel (ICM)
• Controller Area Network (CAN databus).
• Engine management of ISB6.7 engines (EMC).
CVM
An important part of the CAN network is the CVM (Central
Vehicle Module), also called “Gateway”. It is used to reduce
the bus load on P_CAN.
This is achieved by splitting up the P_CAN into three other
CAN buses (V_CAN_1, V_CAN_2 & V_CAN_3).
The CP (Central Processor of the CVM) checks the presence
of the different ECUs that are connected to the various CAN
buses. It also checks the modules that are present on the
K_CAN (bodywork CAN bus, e.g. air conditioning and MTS).
VFC
The VFC (ZR32) is the central processing unit and mainly
uses the CAN network to communicate. The vehicle-specific
software runs on this ECU. One of the functions of the VFC
is to receive information from the vehicle’s systems, 7
switches, sensors, etc. and convert it into protocols for the
various vehicle systems, and then to send it as a coded mes-
sage.
For example, this is how all the information is exchanged with
the instrument panel (ICM). The protocols are used to send
the messages to the CAN network (CAN databus) in order of
priority. Two CAN networks are used with VDL Bus & Coach
vehicles, namely the CAN multibus and the CAN-J1939.
The VFC is connected to the vehicle systems and the ICM by
means of the CAN multibus. The driveline (gearbox (TCM),
engine (ECM) and the ABS) communicates with its individual
components via CAN J1939. The J1939 messages from the
driveline are read by the ICM.
DD0855_02 1-5
IOU
Another important part of the CAN network is the IOUs.
Via IOUs (nodes), sensors and actuators are connected to
the CAN bus, which sends the signal across the network as
a CAN message.
They can translate a CAN message into an analogue or dig-
ital output and vice versa.
Sensors without CAN functionality can still transfer their
information via the CAN bus by means of the I/O.
ICM
The ICM (DMUX), i.e. the instrument panel, gets most of its
information from the CAN network.
The instrument panel can translate CAN messages into a
visual output in the form of a symbol or text.
This tells the driver whether something is wrong with the
vehicle or if there is an important status.
The instrument panel can also be used for on-board diagnosis.
CAN bus
The CAN databus is, in principle, a distribution network of dif-
ferent electronic signals. The digital pulse signals form coded
messages. They can be sent, received and processed by all
the systems connected to this network.
Each system takes the information that it requires from the
network. For example, a signal that is created by one system
can also be used by other systems.
Furthermore, each system consists of two lines: CAN-H
(high) and CAN-L (low).
The wires for these two lines are twisted (without protection) in
order to prevent external magnetic interference. CAN wiring can
always be recognized by both the twists (entwining) and the col-
our (see 9 - 2. Marks on electrical wiring (2 - 1)).
A worldwide standard has been chosen by the Automotive

7 Industry for the communication (coded messages) between
electrical systems:
• SAE J1939/21 (Society of Automotive Engineers) wiring +
network.
• SAE J1939/71 (Society of Automotive Engineers) mes-
sages + protocol processing.
ISO 11898 is the European equivalent for the SAE J1939

standard. VDL Bus & Coach has chosen to use the extended
CAN 2.0B protocol.
VDL Bus & Coach also uses these international agreements. The
bodybuilder has the possibility to use the existing CAN network via
the "bodybuilder connectors", the interface panels or the CAN
interface provided that the bodywork's electrical system works with
the same message structure and CAN communication.
It is not permitted to alter the vehicle's existing wiring har-

nesses other than as given in the Bodybuilder's Guidelines.
There is a chance that the CAN network will be weakened or
disrupted, so that a possibly unsafe, but definitely unreliable,
situation may be created.
1-6 DD0855_02
1.6 OVERVIEW OF THE NETWORK

SYSTEMS
Vehicle control systems E6 with MOKI3 dashboard

Number of IOUs 4
VFC
- Hardware 5-channel ZR32-A
- Software KIBES-32
- Download / diagnosis tool logiCAD / TEXA
ICM
- Hardware DMUX
- Software Cavtan
- Download / diagnosis tool Cavtan / TEXA
Network
- Vehicle multiplex network M1-can/M2-can (multibus)
- ICM I-can (J1939)
- Drive line V-can1+2+3
- Bodybuilder interface K-can (J1939)
ILAh0919
DD0855_02 1-7
1-8 DD0855_02
Citea LLE E6 EBS-1C Electrical installation
2. ELECTRICAL INSTALLATION
2.1 SIMULATING A SPEED SIGNAL

The speed signal can be simulated in a number of different
ways. It may, for example, be necessary to simulate the
speed signal when carrying out a soot measurement.
2.1.1 WITH THE AID OF A WORKSHOP CARD (ONLY

DTCO) + A TACHOGRAPH TESTER.
An error is saved in the tachograph. This error can be deleted

with the VDL Bus & Coach diagnosis equipment, but must
remain "visible" for inspection institutes (remains registered
in the tachograph's internal memory).
The tachograph must also be re-calibrated.

Pay attention to the fact that the doors
will close automatically when simulating
the speed!
2.1.2 WITH THE AID OF A TACHOGRAPH TESTER

WITH A SPEED SIMULATION FUNCTION (FOR
EXAMPLE, VDO CTC 2)
Method
1. Connect the tachograph tester to the tachograph as indi-
cated in the manufacturer’s instructions.
2. Turn on the main switch and the contact switch and start
the engine.
3. Set a vehicle speed (e.g. 10 km/h).

will close automatically when simulating 7
the speed!
DD0855_02 2-1
Electrical installation Citea LLE E6 EBS-1C
2.1.3 WITH THE MTCO
1. Turn off the main switch and the contact switch.

2. Press the M button and, whilst keeping it pressed, turn on
the main switch and the contact switch. This procedure
must be carried out within 3 seconds.

Only the driver mode will be activated
(menus 2 - 6 will be blocked) when the
contact switch is turned on and off.
3. Release the M button once the contact switch has been

turned on.
4. Start the engine and increase the engine speed.
5. Use the M button to select menu 6 (simulate V signal).
ILAh0129
7 6. Set the speed signal between 75 km/h and 120 km/h
using the + and – buttons (the selected speed will be dis-
played by the speedometer on the dashboard).
7. The service mode will be turned off automatically when
the contact switch is turned off.
ILAh0130
2-2 DD0855_02
Citea LLE E6 EBS-1C Electrical installation
2.1.4 DYNAMICALLY, WITH THE AID OF A ROLLER

TEST STAND.

will close automatically when simulating
the speed!
DD0855_02 2-3
Electrical installation Citea LLE E6 EBS-1C
2-4 DD0855_02
5 SERVICE DIAGRAMS
Citea LLE E6 EBS-1C
SERVICE DIAGRAMS
DD0855_02
SERVICE DIAGRAMS 5
Citea LLE E6 EBS-1C
DD0855_02
5 SERVICE DIAGRAMS
Citea LLE E6 EBS-1C Service diagrams
1. SERVICE DIAGRAMS
1.1 THE DIAGRAM

For more information, see the vehicle documentation on the
VDL Bus & Coach Documentation Portal (http://sdp.vdlbus-
coach.com).
DD0855_02 1-1
SERVICE DIAGRAMS 5
Service diagrams Citea LLE E6 EBS-1C
1-2 DD0855_02
5 READING THE SERVICE DIAGRAMS
Citea LLE E6 EBS-1C
READING THE SERVICE DIAGRAMS
DD0855_02
READING THE SERVICE DIAGRAMS 5
Citea LLE E6 EBS-1C
DD0855_02
1.1 OVERVIEW OF ABBREVIATIONS
Abbreviation Meaning Translation

ABS Anti-lock Braking System AntiBlokkeerSysteem
AIRCO Airconditioning Airconditioning
ANS Automatische Neutralstellung bei Stillstand Automatische neutraal-schakeling bij stil-
stand
ASR Anti Slip Regeling Antislipregeling
CAN Controller Area Network Controller Area Network
CCTV Closed Circuit TeleVision Gesloten camera bewaking systeem
CMU Central Management Unit Centraal managementsysteem
CP Central Processor Centraalprocessor
DMUX Display MUltipleXer (display) Display MUltipleXer (display)
DTCO Digital Tachograph Digitale tachograaf
EBS Electronic Brake System Elektronisch gestuurd remsysteem
ECAS Electronically Controlled Air Suspension Elektronisch geregeld luchtveersysteem
ECM Engine Control Module Motormanagementsysteem
EPC Electric Part Code Codering elektrisch onderdeel
ESC Electronic Stability Control Elektronische stabiliteits controle
FAP Fahrer Arbeits Plats (drivers working place) Fahrer Arbeits Plats (chauffeurs werkplaats)
HVAC Heating Ventilation AirConditioning Verwarming, ventilatie en airconditioning
ION Input Output Node In- en uitgangs knooppunt
ICM Instrument Control Module Instrumentenpaneel
LED Light-Emitting Diode Lichtuitstralende diode
MOKI MOdul Kombi Instrument (instr.panel) MOdul Kombi Instrument (instr.paneel)
MTCO Modular TaChOgraph Modulaire Tachograaf
NBS Neutral by standstil Neutraal bij stilstand
OBD On Board Diagnose Diagnose in het voertuig
TFT Thin-Film Transistor TFT scherm
TCM Transmission Control Module Controle unit versnellingsbak
TSU Tachograph Simulator Unit Tachograaf Simulatie Unit
DD0855_02 1-1
1-2 DD0855_02
Citea LLE E6 EBS-1C Marks on electrical wiring
2. MARKS ON ELECTRICAL WIRING
2.1 INTRODUCTION
The marking system for the wiring consists of a colour code
and a numeric coding system to make it easy to classify the
wiring.
This way, connection and manufacturing errors are avoided
as much as possible.
DD0855_02 2-1
Marks on electrical wiring Citea LLE E6 EBS-1C
2.2 COLOUR CODE

All the wring is of one of the colours given below.
Wire colours
Earth wire 0.5 mm2 - 6 mm2 Brown

>6 mm2 Black with white identification
Supply voltage for subgroup 1 Connected to a physical fuse with Red

On/Off option, Ubat +30, +15
Other Yellow
General supply voltage wiring 0.5 mm2 - 50 mm2 Red

> 50 mm2 Black with white identification
Other functions, no supply voltage 0.5 mm2 - 6 mm2 Yellow

>6 mm2 Red
Twisted wiring, CAN acc. J1939 CAN Low Green

CAN High Yellow
Twisted wiring, M-CAN / I-CAN / K-CAN CAN Low Blue

CAN High Yellow
Sensors with 2 connections Power supply Green

Signal Blue
Sensors with 2 connections Earth White

Signal Blue
Sensors with 3 connections Power supply Green

Earth White
Signal Blue
2-2 DD0855_02
Citea LLE E6 EBS-1C Marks on electrical wiring
2.3 NUMERIC CODE

The numeric code consists of five digits, where the first two digits refer to the main group.
The print is always in a contrasting colour and is repeated every 20 cm.
• Main groups, 1st and 2nd digit of the 5-digit code

Main Name Main Name
group group
11 Fuel system, (facility for) auxiliary heating 61 Cooling installation
13 Fire protection system, fire detection system 62 Audio system, video system
14 Safety system, emergency operation 63 Loudspeakers
15 Supply voltage, +15 (after the contact switch) 64 Navigation system
16 Tacho, tacho simulator 66 Loudspeakers
17 Windscreen wiper installation 6 Intercom
18 Windscreen washer installation 68 Stop request, hostess call, alarm buttons
19 Engine management 69 Interior lighting
20 Pre-glow installation 70 Electronic pneumatic suspension
21 Pre-heating/auxiliary heating 72 Electronic brake system, brake wear
22 Defrosting/front box 74 Brake system
23 Heating system 75 Fri
24 Air conditioning system 76 Instrument panel
25 Ventilation system, bleeding vehicle 79 CAN connections
26 Heated wing mirrors 80 Door operation, general, door group 1
27 Electrically operated screens, windows 81 Door operation, door group 2, rear
30 Supply voltage, +30 (after main switch) 82 Door operation, door group 3
31 Earth connections 83 Door operation, door group 4
32 Central processor supply voltage, wake-up 84 Doors, other
35 Payment system 85 Central release, luggage hatches, detection system
36 Diagnosis, test system 86 Burglary system, theft prevention system
37 Plugs, plug sockets 87 Lift system, entrance aid system
39 Toilet, sleeping cabin 88 Personal safety system
40 Gearbox system 89 Chassis wiring
41 Gearbox 91 Hydraulic systems
45 Escape route signs 92 Curve safety system
46 (Interior) monitoring system 93 Kitchen sign
47 Reversing warning system 94 Supply voltage other than 24 VDC
49 Indicators 95 Filter systems 9
50 Start, stop 96 Pneumatic systems
51 Mirrors 98 Spare wiring
52 Horn 99 Extra installations
53 24 V battery booster, external charging system
56 Exterior lighting
58 Parking lights, +58
59 Hazard warning lights
DD0855_02 2-3
Marks on electrical wiring Citea LLE E6 EBS-1C
• Subgroup, 3rd digit of the 5-digit code

Subgroup Name
1 Power supply
2 Sensors (group 76 - inputs on instrument panel)
3 Loads (group 76 - outputs on instrument panel)
4 Diagnosis
5 Other
6 Communication
7 Fri
8 Fri
9 Earth
• Serial number, 4th and 5th digit of the 5-digit code

Digit 4 + Serial numbers
+5
Exception for subgroup 1

Digit 1 + 2 Digit 3 Digit 4 + +5 Description
** 1 00 - 29 Ubat (direct +)
30 - 49 30 (after main switch)
50 - 99 15 (after contact switch)

When looping wires, the numeric code of
every wire is respected.
Earth connections
There is a difference in the earth connections for the elec-
tronic systems. There are two types of earth connection:
• Power earth
• Test and signal earth
The power earth is the earth which should normally be used

for earthing electrical devices.
The test and signal earth is only used for electronic systems.
They are the earth connections from subgroup 9.
9

NEVER use the test and signal earth
when assembling electrical components.
If that is done, there is a chance that the electronic compo-

nents will become faulty. If an electronic component must be
connected, then the earth for this system must be connected
to one of the vehicle’s central earth connections.
2-4 DD0855_02
Citea LLE E6 EBS-1C Explanation and reading
3. EXPLANATION AND READING
3.1 RECOGNIZING THE POWER SUPPLY

AND THE EARTH
There are a number of different types of 24 V power supply,

classified by the moment that they are turned on.
U bat Permanent power supply.
The power supply is connected directly to the bat-
teries and is permanently present.
+30 Power supply after the main switch has been turned
on.
This power supply is present after the main switch
relay has been turned on.
+15 Power supply after the contact switch has been
turned on.
This power supply is present after the contact
switch relay has been turned on.
+58 Parking lighting, switch search lighting and the light-
ing of instruments.
This power supply is present if, of all the vehicle
lighting, at least the parking lighting is switched on. ILAz0073
D+ Power supply if the engine is running.
This power supply is present after it has been
observed that the vehicle’s generators are charging
the onboard network.
31 Earth
Earth is an earth connection if the earth is perma-
nently present.
One of the codes given above is noted above every fuse in

the diagram to indicate the nature of the power supply (2).
If a (low-side) output of a node is used to switch a relay, then
it depends on the connection on the IOU unit and the pro-
gram in the central processor when such a power supply is
active.
The earth connection is always indicated with code ‘31’.
DD0855_02 3-1
Explanation and reading Citea LLE E6 EBS-1C
3.2 AREA INDICATION

3.2.1 SEARCH BAR
To make it easier to search a schematic diagram, there is a

search bar at the top and bottom of every page with the num-
bers 1 to 29.
These numbers are called the search bar numbers (A).
ILAz0072
A Search bar number
B Reference number
3.2.2 REFERENCES
If a wire ends with an arrow head in the diagram, then this

wire continues somewhere else.
The arrow head points to a number. This number is called the
reference number (B).
The reference number is displayed in two different ways:

1. The reference number 22 in illustration ILAz0072 refers
to search bar number 22, therefore, the area where wire
number 31089 can be found.
2. The reference number 28B/27 in illustration ILAz0124
9 indicates that the continuation of the wire can be found
on page 28B in the area of search bar number 27.
ILAz0124
B Reference number
3-2 DD0855_02
3.3 ELECTRIC PART CODE (EPC)

The EPCs (for example, K001) are given in the schematic
diagram.
This is a coding system according to DIN standard 40719.
This standard divides the electrical components into groups.
• Each group has a group letter, which is the first character
of the EPC.
• This group letter is followed by a serial number.
ILAz0073
A Search bar number
B Type of supply voltage
C EPC code
DD0855_02 3-3
3.3.1 LAYOUT OF ELECTRICAL PART CODE

NUMBERS
EPC component groups

Letter Types of component Example
A Control unit, electronic equipment A031 Engine management electronic unit
(DMCI)
A Control unit, electronic equipment A032 Engine management electronic unit
(ECM)
B Warning lights, sensors and switches (converter B003 Switch, engine oil pressure
from non-electrical to electrical variables or vice
versa)
B511 1st loud speaker - left
B581 Camera, blind spot
C Condensers
D Audiovisual equipment D020 CD changer
D039 Satellite receiver
E Interior and exterior lighting E005 Left-hand xenon dipped beam
F Safety devices, fuses F016 Lift main fuse
F108 AdBlue electronics fuse (+15)
G Power supply, generator, battery G001 Battery 1
G031 Generator 1
H Warning systems H003 Claxon 1
H121 Bus-stop brake inspection light
I
J Various components and systems J001 Left-hand reversing mirror
J204 Fridge 1
K Relay, safety device K001 Main switch relay
K083 Right-hand reading light relay
L Inductivity
M Engine M001 Starter motor
M021 Pre-heater circulation pump
N Regulator, plug N002 Front heater tap control button
O
P Measuring devices, indication devices, instrument P001 Electronic instrument panel
panel (measurement equipment)
P201 AS Tronic display
9 Q
R Resistance R001 Cigarette lighter
R105 CAN J1939 terminating resistance (120
Ohm)
S Switch, operation and control mechanically linked S002 Contact switch
to a function
S608 AdBlue hatch control switch
T Transformers, voltage distributors
U Modulator, converter U003 24 V/12 V converter
3-4 DD0855_02
EPC component groups

Letter Types of component Example
V Semiconductors V001 Night charging diode
W Aerials, connection lines W002 Radio/GSM/GPD aerial
X Clamp, plug connection, plug, distribution points X000 to (Reserved for functional connections)
X099
X000 VDL diagnosis connection
Y Electromagnetic valves, valves, fuel pump Y022 Valve, wastegate (DAF)
Y202 Lift brake valve
Z Filter, frequency distributors
3.3.2 LETTER ADDED AFTER THE EPC
A letter is added after the EPC number in the circuit diagram.

This letter indicates the location in the vehicle of the compo-
nent concerned.
This is based on an isometric vehicle layout which includes
the letters that are used to indicate a location.
If the location is (still) unknown, then an ‘x’ is given.
The code could then be as follows: A123v
The code is constructed as follows:
A Component group
123 Serial number
v Letter that indicates the location in the vehicle
3.3.3 EPC CODES INDEX
In the EPC index, the reference number is given after the

description of the EPC number, e.g. F203 52A/23. This way,
the location of a certain component can easily be found in the
diagram.
9
ILAz0125
DD0855_02 3-5
3-6 DD0855_02
5 FUNCTION DIAGRAMS
Citea LLE E6 EBS-1C
FUNCTION DIAGRAMS
10
DD0855_02
FUNCTION DIAGRAMS 5
Citea LLE E6 EBS-1C
10
DD0855_02
5 FUNCTION DIAGRAMS
Citea LLE E6 EBS-1C Function diagrams
1. FUNCTION DIAGRAMS
1.1 ANTIGAS
1.1.1 ANTIGAS ACCELERATOR PEDAL BLOCK PART
1
ILAh0980
Antigas 60_02_01
1 Start 9 ETC2 message OK?
2 Ignition active? 10 Display message: General CAN error
3 Override door brake switch active? 11 Accelerator pedal depressed?
4 Brake pedal switch active? 12 Transmission current gear neutral?
5 Control request bus-stop brake active? 13 ETC1 message OK?
6 ECAS tilt system active? 14 Display message: General CAN error
7 EEC2 message OK? 15 Transmission driveline engaged = 1? 10
8 Display message: General CAN error
DD0855_02 1-1
FUNCTION DIAGRAMS 5
Function diagrams Citea LLE E6 EBS-1C
1.1.2 ANTIGAS ACCELERATOR PEDAL BLOCK PART 2
ILAh0981
Antigas 60_02_01
1 P_OV_Tour active? 10 Vehicle speed <= 5 km/h?
2 ETC1 message OK? 11 CCVS message OK?
3 Display message: General CAN error 12 Display message: General CAN error
4 ETC2 message OK? 13 Parking brake switch active?
5 Display message: General CAN error 14 Air pressure circuit 1 low?
6 Transmission current gear neutral? 15 Air pressure circuit 2 low?
7 Transmission driveline engaged = 1? 16 Air pressure circuit 3 low?
8 TCO1 message OK? 17 Air pressure circuit 4 low?
10
1-2 DD0855_02
5 FUNCTION DIAGRAMS
1.1.3 ANTIGAS ACCELERATOR PEDAL BLOCK PART 3
ILAh0982
Antigas 60_02_01
1 End 6 Engine override control mode = 3
2 Air pressure circuit 1 low active > 30 s? 7 Override control mode priority = 2
3 Air pressure circuit 2 low active > 30 s? 8 Engine requested speed control conditions = 3
10
4 Coolant temp. high active > 30 s? 9 Engine requested torque/torque limit = 0
5 Gearbox temp. high active > 30 s? 10 Engine requested speed/speed limit = 8031
DD0855_02 1-3
FUNCTION DIAGRAMS 5
1.1.4 ANTIGAS DLM SPEED REDUCTION
ILAh0983
Antigas 60_02_01
1 Start 7 Engine override control mode = 3
2 Ignition active? 8 Override control mode priority = 1
3 CAN message PropB_DLMC OK? 9 Engine requested speed control conditions = 3
10 4 Display message: General CAN error 10 Engine requested torque/torque limit = DLM engine
requested torque/torque limit
5 End 11 Engine requested speed/speed limit = DLM engine
requested speed/speed limit
6 DLM derated mode > 0?
1-4 DD0855_02
5 FUNCTION DIAGRAMS
1.1.5 ANTIGAS TRANSMISSION NEUTRAL
ILAh0984
Antigas transmission neutral 60_02_01

1 Start 10 TCO1 message OK?
2 Ignition active? 11 Display message: General CAN error
3 ETC2 message OK? 12 Vehicle speed = 0 km/h?
4 Display message: General CAN error 13 Engine override control mode = 3
5 End 14 Override control mode priority = 2
6 Transmission current gear neutral? 15 Engine requested speed control conditions = 2
7 ETC1 message OK? 16 Engine requested speed control conditions = 2
8 Display message: General CAN error 17 Engine requested speed/speed limit = P_Limit
engine speed at neutral
9 Transmission driveline engaged = 1?
10
DD0855_02 1-5
FUNCTION DIAGRAMS 5
1.2 CLUTCH AIR CONDITIONING OFF
ILAh1623
Clutch air conditioning off 154_00_00

1 Start 6 Accelerator pedal position > 85%
2 Main switch active? 7 Clutch air conditioning off
10 3 Ignition active? 8 End
4 Engine speed < 1,700 9 Percentage engine load at current speed > 85%
5 Percentage engine load at current speed < 75% 10 Clutch air conditioning on
1-6 DD0855_02
5 FUNCTION DIAGRAMS
1.3 AIR CONDITIONING SPEED CONTROL
ILAh0951
Air conditioning speed control 03_00_00

1 Start 5 Antigas active
2 Engine running 6 Air conditioning compressor turned on 10
3 Gearbox in neutral 7 Engine speed control active with fixed speed setting
4 Parking brake OR bus-stop brake applied 8 End
DD0855_02 1-7
FUNCTION DIAGRAMS 5
1.4 ASR SWITCH ACTIVE
ILAh0946
ASR switch active 1_00_00

1 Start 4 Dashboard message ASR switch active
2 Ignition active? 5 End
3 ASR off-road switch active? 6
10
1-8 DD0855_02
5 FUNCTION DIAGRAMS
1.5 ASR WARNING SYMBOL
ILAh0945
ASR warning symbol 1_00_00

1 VDC information = 1 5 Ignition active?
2 Dashboard message: stability control active 6 ASR brake control active = 1?
3 Engine brake control active = 1? 7 End
4 Start 8
10
DD0855_02 1-9
FUNCTION DIAGRAMS 5
1.6 AUTOMATIC SUMP FILLING

1.6.1 SUMP FILL SIGNAL CAN
ILAh0973
Automatic sump filling 58_01_01

1 Start 5 End
2 Ignition active? 6 DTC SPN 98 FMI 1 active?
3 ECM communication OK? 7 DTC SPN 98 FMI 18 active?
10 4 Display message: General CAN error 8 Sump refill filling signal
1 - 10 DD0855_02
5 FUNCTION DIAGRAMS
1.6.2 SUMP FILLING SIGNAL HW
ILAh0974

1 Display message: General CAN error 6 Last engine shutdown > 15 minutes
2 Start 7 Engine oil level low active? 10
3 Main switch active? 8 Sump refill fill signal
4 CAN message EEC1 OK? 9 End
5 Engine speed <400 rpm for 2 seconds?
DD0855_02 1 - 11
FUNCTION DIAGRAMS 5
1.6.3 OIL LEVEL SUMP REFILL LOW
ILAh0975

1 Start 4 Dashboard request oil level sump refill low
2 Ignition active? 5 Box behind fuel cover oil level sump refill low
3 Oil tank level low? 6 End
10
1 - 12 DD0855_02
5 FUNCTION DIAGRAMS
1.6.4 OIL LEVEL MEASUREMENT DELAY
ILAh0976

1 Deactivate sump oil level measurement start delay 6 Delay signal active > 2 seconds?
control
2 Start 7 Deactivate sump oil level measurement. Start delay
signal
3 Ignition active? 8 Activate sump oil level measurement. Start delay
signal
4 Sump oil level. Measurement start control active? 9 End 10
5 Activate sump oil level measurement. Start delay
signal
DD0855_02 1 - 13
FUNCTION DIAGRAMS 5
1.7 CAN NETWORK
ILAh0947
CAN network 122_01_01

1 Start 5 CAN message "Not available" (for different ECUs)
2 Main switch on 6 CAN message "Timeout" (for different ECUs)
10 4 Yellow warning symbol CVM active 8 Dashboard yellow warning light CVM active
1 - 14 DD0855_02
5 FUNCTION DIAGRAMS
1.8 CENTRAL LUBRICATION
10
ILAh1627
DD0855_02 1 - 15
FUNCTION DIAGRAMS 5
Central lubrication 76_00_01

1 Start
2 Contact switch turned on pulse
3 Pump error
4 Vehicle speed V < 3 km/h
5 Pump timer elapsed AND pause timer inactive?
6 Pause timer elapsed AND pause timer inactive?
7 Reset pump timer value
8 Turn on pump
9 Activate pump timer AND deactivate pause timer
10 Reset pause timer value
11 Turn off pump
12 Activate pause timer AND deactivate pump timer
13 Stop grease pump
14 Stop and store pause timer
15 Stop and store pump timer
16 Stop grease pump
17 Stop and reset pause timer
18 Stop and reset pump timer
19 Activate warning symbol
20 Load pause timer value
21 Load pump timer value
22 End
10
1 - 16 DD0855_02
5 FUNCTION DIAGRAMS
1.9 CRUISE CONTROL
ILAh1556
Cruise control 007_01_01

1 Start 14 Cruise control active (ZR32) = activated
10
2 Ignition active 15 Cruise control active (ECM)
3 Parking brake applied 16 Cruise control SET + pressed
4 Brake pedal depressed 17 Cruise control speed increased
5 Clutch pedal depressed 18 Cruise control RESUME/SET - pressed
DD0855_02 1 - 17
FUNCTION DIAGRAMS 5
6 Gearbox in neutral 19 Cruise control speed decreased

7 Primary retarder active 20 Cruise control SET + pressed
8 Vehicle speed > 30 km/h 21 Cruise control speed is set at current vehicle speed
9 Vehicle speed is greater than Vmin 22 Cruise control RESUME/SET - pressed
10 Variable speed limiter active 23 Cruise control speed is previous cruise control
speed
11 Roll Over Protection active 24 Cruise control enabled = deactivated
12 ESC active 25 Cruise control active (ZR32) = deactivated
13 Cruise control enabled = activated 26 End
10
1 - 18 DD0855_02
5 FUNCTION DIAGRAMS
1.10 EAS EURO 6

1.10.1 EAS EURO 6 ADBLUE LEVEL LOW
ILAh1042
EAS Euro 6 AdBlue level low - 99_02_00

1 Start 6 AdBlue tank level low indicator = 1?
2 Ignition active? 7 AdBlue tank level low indicator = 4?
3 CAN message AT1T1l OK? 8 AdBlue level low symbol visible
4 Display message: General CAN error 9 AdBlue level low symbol flashing 1 Hz
5 End
10
DD0855_02 1 - 19
FUNCTION DIAGRAMS 5
1.10.2 EAS EURO 6 ADBLUE LEVEL
ILAh1043
EAS Euro 6 AdBlue Level 99_02_00

1 Start 5 AdBlue level signal 0%
10 3 CAN message AT1T1l OK? 7 After-treatment 1 SCR catalytic converter tank level
0-100%?
4 Display message: General CAN error 8 AdBlue level signal 0-100%
1 - 20 DD0855_02
5 FUNCTION DIAGRAMS
1.10.3 EAS EURO 6 ADBLUE QUALITY
ILAh1044
EAS Euro 6 AdBlue quality - 99_02_00

1 Start 5 End
2 Ignition active? 6 OBD fault indicator symbol command = 1?
3 CAN message DLCC1 OK? 7 Fault indicator symbol visible
10
DD0855_02 1 - 21
FUNCTION DIAGRAMS 5
1.10.4 EAS EURO 6 ADBLUE DPF SYMBOL
ILAh1045
EAS Euro 6 AdBlue DPF symbol - 99_02_00

1 Start 6 Diesel particle filter symbol command = 1?
2 Ignition active? 7 Diesel particle filter symbol command = 4?
3 CAN message DPFC1 OK? 8 Diesel particle filter symbol flashing 1 Hz
4 Display message: General CAN error 9 Diesel particle filter symbol visible
5 End
10
1 - 22 DD0855_02
5 FUNCTION DIAGRAMS
1.10.5 EAS EURO 6 ADBLUE DPF. SWITCH FOR

FORCED REGENERATION
ILAh1046
EAS Euro 6 AdBlue DPF. Switch for forced regeneration

- 99_02_00
1 Start 4 End
2 Ignition active? 5 Particle filter forced regeneration switch
3 Forced regeneration switch active?
10
DD0855_02 1 - 23
FUNCTION DIAGRAMS 5
1.10.6 EAS EURO 6 ADBLUE DPF. REGENERATION

INHIBITOR SWITCH
ILAh1047
EAS Euro 6 AdBlue DPF. Regeneration inhibitor switch -

99_02_00
1 Start 4 End
2 Ignition active? 5 Particle filter inhibit regeneration switch
3 Inhibit regeneration switch active?
10
1 - 24 DD0855_02
5 FUNCTION DIAGRAMS
1.10.7 EAS EURO 6 SYMBOL
ILAh1048
EAS Euro 6 symbol - 99_02_00

1 Start 6 Diesel particle filter symbol command = 1?
2 Ignition active? 7 Diesel particle filter symbol command = 4?
3 CAN message DPFC1 OK? 8 Diesel particle filter symbol flashing 1 Hz
4 Display message: General CAN error 9 Diesel particle filter symbol visible
5 End
10
DD0855_02 1 - 25
FUNCTION DIAGRAMS 5
1.11 EBS RED WARNING SYMBOL
ILAh0943
EBS warning symbol1_00_00

1 EBS status red warning symbol? 4 Ignition active?
2 Dashboard notification: brake system fault 5 EBS red warning symbol
3 Start 6 End
10
1 - 26 DD0855_02
5 FUNCTION DIAGRAMS
1.12 EBS YELLOW WARNING SYMBOL
ILAh0944
EBS warning symbol1_00_00

1 EBS status yellow warning symbol 4 Ignition active?
2 Dashboard notification: brake system warning 5 EBS yellow warning symbol?
3 Start 6 End
10
DD0855_02 1 - 27
FUNCTION DIAGRAMS 5
1.13 ECAS
1.13.1 PART 1, AXLE SELECTION
ILAh1590
ECAS Part 1 09_01_01

1 Start 6 Select rear axle, front axle warning light
10 2 Ignition active? 7 Raise request

3 Front axle kneel request 8 Select front axle, front axle warning light
4 Select front axle, front axle warning light 9 Select rear axle, front axle warning light
5 Rear axle kneel request 10 End
1 - 28 DD0855_02
5 FUNCTION DIAGRAMS
1.13.2 PART 2, SETTING THE DRIVING HEIGHT
ILAh1591

1 Start 6 Kneel signal
2 Ignition active? 7 Raise signal
3 Front axle kneel request 8 Raise signal 10
4 Rear axle kneel request 9 Kneel signal
5 Raise request 10 End
DD0855_02 1 - 29
FUNCTION DIAGRAMS 5
1.13.3 PART 3, VEHICLE SPEED LIMITER
ILAh1592

1 Start 5 Vehicle speed < 35 km/h
2 Ignition active? 6 Vehicle speed limiter active
10
3 Front axle kneel request 7 End
4 Rear axle kneel request
1 - 30 DD0855_02
5 FUNCTION DIAGRAMS
1.13.4 PART 4, AUTOMATIC RETURN TO THE DRIVING

HEIGHT FROM AN UNKNOWN DRIVING HEIGHT
ILAh1593

1 Start 5 All doors closed 10
2 Ignition active? 6 Automatic return to the driving height
3 ASC1 front axle nominal level = 0 7 End
4 ASC1 rear axle nominal level = 0 8
DD0855_02 1 - 31
FUNCTION DIAGRAMS 5
1.14 FAN OPERATION (WE)

1.14.1 FAN OPERATION WE PART 1
ILAh1595
Fan operation WE Part 1, 10_04_01

1 Start 6 Fan speed request based on the gearbox oil tem-
perature.
2 Ignition active? 7 Fan speed request based on the retarder oil tem-
perature.
3 Fan stop valve present: desired fan speed < 15% = 0 8 Fan speed request based on input signals.
Fan stop valve NOT present: desired fan speed =
desired fan speed
10 4 Fan speed request based on the coolant tempera- 9 End
ture.
5 Fan speed request based on the inlet manifold tem-
perature.
1 - 32 DD0855_02
5 FUNCTION DIAGRAMS
ILAh1596

1 Start 4 Display yellow warning symbol on instrument panel
3 Yellow warning light active
10
DD0855_02 1 - 33
FUNCTION DIAGRAMS 5
ILAh1597

1 Start 6 Fan speed = request
10 2 Ignition active? 7 Output current exceeded
3 CAN bus working 8 Yellow warning symbol active
4 CAN message "CAB" available 9 End
5 Request  100% 10 Fan speed = 100% Yellow warning symbol active
1 - 34 DD0855_02
5 FUNCTION DIAGRAMS
1.15 COOLANT LEVEL

1.15.1 COOLANT LEVEL
Coolant level 12_03_00

1 Start
2 Coolant level > 166 for longer than 1 sec.
3 Coolant level 110 <..< 136 for longer than 1 sec.
4 Coolant level 10 <..< 90 for longer than 1 sec.
5 Send FMI: 3
6 Send FMI: 11
7 Send FMI: 31
8 Coolant level > 123 
9 Coolant level 50 <..< 123 
10 Coolant level < 50 
11 Send EFL_P1: 100%
12 Send EFL_P1: 70%
13 Send EFL_P1: 0%
14 Send B_360_Error
15 Coolant level < 50 for longer than 8 sec.
16 Coolant level < 123 for longer than 30 sec.
17 Turn fuel cowl LED off
18 Coolant temperature > 70 °C
19 Coolant level low
20 Coolant level too low
21 End
10
DD0855_02 1 - 35
FUNCTION DIAGRAMS 5
10
ILAh1600
1 - 36 DD0855_02
5 FUNCTION DIAGRAMS
1.15.2 FUEL COWL STATUS
ILAh1601
Coolant level 12_03_00

1 Start 5 Coolant level > 135 
2 Turn fuel cowl LED off 6 Reset fuel cowl LED off
Turn on LED
3 Contact switch turned off 7 End
4 Time since engine was turned off > 2 hours 10
DD0855_02 1 - 37
FUNCTION DIAGRAMS 5
1.16 COOLANT TEMPERATURE
ILAh0960
Coolant temperature 31_01_01

1 Start 6 DTC SPN 110 FM 1 0 active?
2 Ignition active? 7 Dashboard message engine coolant temperature
too high
3 ECM communication OK? 8 Engine coolant temperature too high signal for FMS
10 4 Display message: General CAN error 9 Engine speed > 400 rpm?
5 End 10 Warning buzzer engine coolant temperature too
high
1 - 38 DD0855_02
5 FUNCTION DIAGRAMS
1.17 AIR PRESSURE GAUGES

1.17.1 PART 1
ILAh0968
Air pressure gauges 33_00_01

1 Start 7 Display air pressure bar graph circuits 1 and 2
2 Main switch active? 8 Continued from page 2
3 Air pressure signal circuit 1 error active? 9 Air pressure signal circuit 1 < 600 kPa 10
4 Dashboard notification: air pressure low circuit 1 10 Air pressure signal circuit 2 < 600 kPa
5 Air pressure signal circuit 2 error active? 11 Page 2 end
6 Dashboard notification: air pressure low circuit 2
DD0855_02 1 - 39
FUNCTION DIAGRAMS 5
1.17.2 PART 2
ILAh0969

1 Continued from page 1 7 Display air pressure bar graph circuits 3 and 4
2 Signal air pressure circuits 3 and 4 available? 8 Continued from page 3
10 3 Air pressure signal circuit 3 error active? 9 Air pressure signal circuit 3 < 600 kPa
4 Dashboard notification: air pressure low circuit 3 10 Air pressure signal circuit 4 < 600 kPa
5 Air pressure signal circuit 4 error active? 11 Page 1 end
6 Dashboard notification: air pressure low circuit 4 12 Page 3 end
1 - 40 DD0855_02
5 FUNCTION DIAGRAMS
1.17.3 PART 3
ILAh0970

1 Continued from page 2 5 Air pressure warning buzzer
3 Engine running? 7 Output air pressure low circuit 2 active?
4 Output air pressure low circuit 1 active? 8 Page 2 end
10
DD0855_02 1 - 41
FUNCTION DIAGRAMS 5
1.18 ENGINE START/STOP

1.18.1 STARTING THE ENGINE
ILAh1605
Engine start, part 1, 15_00_07

1 Start 5 Transmission: current gear in neutral?
2 Ignition active? 6 Transmission: selected gear in neutral?
3 Engine speed < 400 rpm for longer than 5 sec? 7 Sump oil level: measurement delay active?
4 Transmission driveline: engaged = 1? 8 Engine stop: control request active?
10
1 - 42 DD0855_02
5 FUNCTION DIAGRAMS
ILAh1606
Engine start, part 2, 15_00_07

1 Engine start: front enable active? 5 Engine start: rear request active?
2 Engine hatch: start front enable active? 6 Engine start: control request
3 Engine running? 7 End
4 Engine start: front request active?
10
DD0855_02 1 - 43
FUNCTION DIAGRAMS 5
1.18.2 ENGINE SHUTDOWN WHEN IDLING
ILAh1607
Engine shutdown when idling, 15_00_07

1 Start 6 Vehicle speed = 0
2 Engine speed < 400 rpm for longer than 5 sec? 7 P_time_idle_shutdown = 0
10 3 Parking brake status: active? 8 P_time_idle_shutdown = elapsed
4 Accelerator pedal: idle switch active? 9 Activate engine shutdown when idling
Stop request for 5 seconds
5 Brake pedal depressed active? 10 End
1 - 44 DD0855_02
5 FUNCTION DIAGRAMS
1.18.3 ENGINE STOP
ILAh1608
Engine stop, 15_00_07

1 Start 6 Idle shutdown engine stop request active?
2 Vehicle speed = 0 7 R36 emergency request active? 10
3 Engine stop: rear request active? 8 Vehicle speed = 0
4 Engine stop: front request active? 9 Activate: engine stop control request
5 Engine: protection engine stop request active? 10 End
DD0855_02 1 - 45
FUNCTION DIAGRAMS 5
1.19 ENGINE CONTROL SUMP REFILL

1.19.1 YELLOW WARNING SYMBOL
ILAh0961
Engine control sump refill 32_05_06

1 Start 5 End
2 Ignition active? 6 DM1: engine yellow warning symbol active
3 ECM communication OK? 7 Dashboard message: engine yellow warning sym-
bol
10
1 - 46 DD0855_02
5 FUNCTION DIAGRAMS
1.19.2 FAULT INDICATOR SYMBOL
ILAh0962

1 Start 5 End
2 Ignition active? 6 DLCC1: engine MIL active
3 ECM communication OK? 7 Dashboard message: engine MIL
4 Display message: General CAN error 8 Send DLCD1 feedback message
10
DD0855_02 1 - 47
FUNCTION DIAGRAMS 5
1.19.3 RED STOP SYMBOL
ILAh0963

1 Start 5 End
2 Ignition active? 6 DM1: engine red stop symbol active?
3 ECM communication OK? 7 Dashboard message: engine red stop symbol
10
1 - 48 DD0855_02
5 FUNCTION DIAGRAMS
1.19.4 SECONDARY SPEED LIMITER
ILAh0964

1 Start 4 End
2 Ignition active? 5 Dashboard message: secondary speed limiter
3 Suspension: secondary speed limiter active
10
DD0855_02 1 - 49
FUNCTION DIAGRAMS 5
1.19.5 STARTER MOTOR TEMPERATURE TOO HIGH
ILAh0965

1 Start 5 End
2 Ignition active? 6 Starter motor mode = 8?
3 EEC1 message OK? 7 Dashboard message: starter motor temperature too
high
10
1 - 50 DD0855_02
5 FUNCTION DIAGRAMS
1.19.6 ENGINE PARASITIC LOSSES
ILAh0966

1 Start 5 Engine estimated parasitic losses = 0
3 PropB_FD message OK? 7 PropB_FC message OK?
4 Display message: General CAN error 8 Engine estimated parasitic losses = ((reference fan
2 AC drive torque/actual AC drive fan 2 percent
torque) + (reference Fan 1 torque/actual fan 1 per-
cent torque)) / 1449
10
DD0855_02 1 - 51
FUNCTION DIAGRAMS 5
1.19.7 ENGINE PROTECTION ENGINE STOP REQUEST

PART 1
ILAh0967

1 Start 6 TCO1 message OK?
2 Ignition active? 7 ECM communication OK?
3 Parking brake activated 8 EEC1 message OK?
4 EEC2 message OK? 9 Engine speed >400 rpm for 20 seconds?
10
1 - 52 DD0855_02
5 FUNCTION DIAGRAMS
1.19.8 ENGINE PROTECTION ENGINE STOP REQUEST

PART 2
ILAh1009

1 Accelerator pedal 1: Low idle switch active 4 Coolant temperature too high active
2 Vehicle speed = 0 5 Activate engine protection: engine stop request for
5 sec.
3 Engine oil pressure too low active 6 End
10
DD0855_02 1 - 53
FUNCTION DIAGRAMS 5
1.19.9 OIL LEVEL WARNING
ILAh0993
10 Engine control sump refill 32_05_06

1 Start 13 Dashboard message engine oil level too high
2 Ignition active? 14 Dashboard message engine oil level not plausible
3 EEC1 message OK? 15 Dashboard message active > 60 s
1 - 54 DD0855_02
5 FUNCTION DIAGRAMS
4 Display 16 Engine oil level too low active

5 EFL/P1 message OK? 17 Dashboard message engine oil level too low
6 Display message: General CAN error 18 Deactivate dashboard message engine oil level not
plausible
7 End 19 Engine oil level low active
8 ECM communication OK? 20 Engine oil level sensor current below normal active
9 Display message: General CAN error 21 Engine oil level sensor voltage below normal active
10 Engine oil level 0% 22 Engine oil level sensor voltage above normal active
11 Engine oil level = invalid range 23 Dashboard message engine oil level low
12 Engine oil level too high active
10
DD0855_02 1 - 55
FUNCTION DIAGRAMS 5
1.20 ENGINE COMPARTMENT

TEMPERATURE
ILAh1618
Engine compartment temperature 72_01_00

1 Start 6 Yellow warning symbol off
2 Temperature > 110 °C 7 Yellow warning symbol on
3 Temperature > 150 °C 8 Red warning symbol off
4 Temperature increases with a gradient of 30 °C/ 9 Red warning symbol on
10 min.
5 Temperature increases with a gradient of 0 °C/min. 10 End
1 - 56 DD0855_02
5 FUNCTION DIAGRAMS
1.21 ADBLUE TANK LEVEL
ILAh1619
AdBlue tank level 67_00_01

1 Start 5 AdBlue level notification on dashboard
2 Reserve level = reserve level parameter value 6 Tank level above reserve level
3 Contact on position 7 AdBlue reserve level notification on dashboard
4 Determine AdBlue level 8 End
10
DD0855_02 1 - 57
FUNCTION DIAGRAMS 5
1.22 OIL SEPARATOR
ILAh1620
10
1 Start 7 Oil separator active < 15 minutes
2 Contact switch = on AND engine running OR Stop/ 8 Turn on oil separator
Start active 30 seconds ON
30 seconds OFF
1 - 58 DD0855_02
5 FUNCTION DIAGRAMS
3 Electric air compressor request 9 Ambient temperature < 3 °C

4 Time since last electric air compressor request < 10 Turn on oil separator
130 seconds 5 seconds ON
115 seconds OFF
5 Last engine shutdown < 2 minutes 11 Turn on oil separator
45 seconds ON
45 seconds OFF
6 Ambient temperature < 15 °C 12 End
A Only electric vehicles
10
DD0855_02 1 - 59
FUNCTION DIAGRAMS 5
1.23 OIL PRESSURE
ILAh1071
Oil pressure Cummins 18_01_00

1 Start 5 Engine running at least 2 sec.
2 Ignition active? 6 Activate oil pressure buzzer
3 Status of the oil pressure is low? 7 End
4 Activate red oil pressure symbol
10
1 - 60 DD0855_02
5 FUNCTION DIAGRAMS
1.24 PRIMARY RETARDER
ILAh0959
Primary retarder 22_00_01

1 Hand-operated retarder torque > foot-operated re- 8 TRANS message percentage torque = hand-oper-
tarder torque ated retarder torque
2 TRANS message percentage torque = foot-operat- 9 TRANS message percentage torque = 0
ed retarder torque
3 Start 10 Current driveline retarder percentage torque > 0
4 Ignition active? 11 The retarder is turned on
5 Foot-operated retarder OFF switch = ON 12 End
6 Activate yellow warning symbol and send status to 13 Retarder constant vehicle speed request = TRUE
EBS
7 Hand-operated retarder torque > 0 14 Hand-operated retarder torque > 0 10
DD0855_02 1 - 61
FUNCTION DIAGRAMS 5
1.25 BRAKE LINING WEAR
ILAh1144
Brake lining wear 21_00_01

1 Start 5 3rd axle present?
10 2 Ignition active? 6 3rd axle brake pads worn?
3 Front axle brake pads worn? 7 Activate "brake pads worn" signal.
4 Rear axle brake pads worn? 8 End
1 - 62 DD0855_02
5 FUNCTION DIAGRAMS
1.26 VOLTAGE SUPPLY
ILAh1059
Voltage supply 26_00_02

1 Start 6 End
2 Earth switch open? 7 Engine running = 0 10
3 S006 emergency operated? 8 Ignition control phase expired?
4 Switch S001 operated? 9 Turn off main switch K001
5 Turn on main switch K001
DD0855_02 1 - 63
FUNCTION DIAGRAMS 5
1.27 STEERING ADJUSTMENT LOCK
ILAh0987
Steering adjustment lock 70_00_01

1 Start 4 Steering adjustment switch active?
2 Parking brake activated? 5 Activate output steering adjustment valve
3 Vehicle speed ≤ 3 km/h 6 End
10
1 - 64 DD0855_02
5 FUNCTION DIAGRAMS
1.28 AUTOMATIC GEARBOX

1.28.1 PART 1, DASHBOARD NOTIFICATION
10
ILAh1621
DD0855_02 1 - 65
FUNCTION DIAGRAMS 5
Dashboard notification 34_04_01

1 Start
2 Ignition active?
3 No gearbox CAN message
4 No retarder CAN message
5 DMI yellow gearbox warning symbol active
6 Activate yellow gearbox warning symbol on dashboard
7 DMI red gearbox warning symbol active
8 Activate red gearbox warning symbol on dashboard
9 DMI gearbox present?
10 DTC: 5436/0 active
11 Gearbox temperature too high symbol active
12 Activate gearbox temperature too high symbol on dash-
board
13 DMI gearbox present?
14 DTC: 5438/0 active
15 Retarder temperature too high symbol active
16 Activate retarder temperature too high symbol on dash-
board
17 End
10
1 - 66 DD0855_02
5 FUNCTION DIAGRAMS
1.28.2 PART 2, NEUTRAL REQUEST
ILAh1622
Neutral request 34_04_01

1 Start 6 Alcohol lock neutral request 10
2 Ignition active? 7 Neutral request cover opened
3 Overrule neutral external request 8 Activation request neutral in TC1 message
4 Neutral request 9 End
5 External air supply neutral request
DD0855_02 1 - 67
FUNCTION DIAGRAMS 5
1.29 ENGINE PROTECTION VALVE
ILAh1624
Engine protection valve 162_00_00

1 Start 7 Delay of 500 ms
2 Ignition active? 8 Close valve
3 Coolant temperature > 81 °C 9 Delay of 500 ms
10 4 Coolant temperature < 71 °C 10 Open valve
5 Valve position = open 11 End
6 Valve position = closed
1 - 68 DD0855_02
5 FUNCTION DIAGRAMS
1.30 VEHICLE WEIGHT MONITORING

1.30.1 WEIGHT MONITORING
10
ILAh1625
Weight monitoring 288_00_00
DD0855_02 1 - 69
FUNCTION DIAGRAMS 5
1 Start 6 Vehicle weight > 14,800 kg

2 Ignition active? 7 Store duration violation in EEPROM
Violation counter +1
3 Max. vehicle weight parameter = 0 8 Vehicle weight > highest weight violation
4 Vehicle weight > max. vehicle weight parameter 9 Current vehicle weight = highest weight violation
5 Send vehicle weight too high warning 10 End
10
1 - 70 DD0855_02
5 FUNCTION DIAGRAMS
1.30.2 STORED VEHICLE IN USE TIME
ILAh1626
Stored vehicle in use time 288_00_00

1 Start 4 Parking brake NOT applied 10
2 Ignition active? 5 Store the vehicle in use time in EEPROM
3 Engine running or StopStart is active 6 End
DD0855_02 1 - 71
FUNCTION DIAGRAMS 5
10
1 - 72 DD0855_02

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WORKSHOP MANUAL

Citea LLE E6 EBS-1C

Whilst compiling this workshop manual, it has been

In this manual, this series of vehicles is referred to as:

ISB6.7 indicates that the contents of this manual relate to

E6 indicates that this manual contains guidelines for the

"EBS-1C" indicates that this vehicle series has a 1st gen-

Steering column switch..................................1-10

Technical information Diagnosis .......................................................2-1 0

Starting with the aid of auxiliary batteries ....... 6-3

© 1640 VDL Bus & Coach bv, Valkenswaard,

In the interest of continuous product development VDL

No part of this publication may be reproduced and/or

This manual shall be governed by and applied in

Next remark is relevant if the text has been translated for

Table 1 below gives all the plating combinations for contacts.

Always use gold-plated or silver-plated contacts if the current

Ring terminal symbol

Ring terminal with feed tube symbol

1.1 EARTH CONNECTIONS

Attention must be given to the following if an earth connec-

The most important earth wires go from the batteries to the

The earthing point on the flywheel may only be used for

All the inductive and capacitive consumers must be earthed

An ECU may not have an earth connection for inductive or

It is also not permitted to make a direct connection with the

1.2 WIRING HARNESSES

Protect the wiring harness by placing it in

Make sure the joins are watertight.

Never remove the connectors’ seals. Fit

Make sure the wiring is not too close to

Prevent wiring harnesses from rubbing

To prevent poor connections, the pins of

1.2.1 WIRING HARNESS SPECIAL TOOL

There is a special tool for closing the wiring harness sleeve.

Pliers for closing the wiring harness sleeve

Zipper tool for closing the wiring harness sleeve 0

1.2.2 REPAIRING THE WIRING HARNESS

• Clean the damaged part of the wiring harness.

• Remove the insulation sleeve and check whether the wires

• Tape all the wiring in the wiring harness’s sleeve.

• Tape the wiring harness’s sleeve to the wiring and tape

• Fit the new zip sleeve so that 50 mm protrudes on the left

• Tape the zip sleeve on the main wiring harness.

Main switch relay

Engine compartment temperature sensor

Battery terminal clamp

A Battery terminal clampa + 12 ± 2 Nm

1.1 BATTERY FAULT FINDING TABLE

FAULT: NEW BATTERY GETS VERY HOT DURING CHARGING

FAULT: BATTERY ACID SPILLS FROM THE PLUG HOLES

FAULT: ELECTROLYTE LEVEL TOO LOW

FAULT: SPECIFIC WEIGHT IS TOO LOW (< 1.240); POOR STARTING

FAULT: SPECIFIC WEIGHT IS TOO HIGH (> 1.290)

FAULT: BURNT-IN BATTERY TERMINALS

FAULT: BATTERY DISCHARGES QUICKLY (CANNOT CONTAIN ITS CHARGE)

FAULT: SHORT BATTERY LIFE

FAULT: BATTERY HAS EXPLODED

FAULT: BATTERY DOES NOT DO ANYTHING (NO VOLTAGE)