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D E A R D R I V E R,

This Manual should acquaint you with the correct operation and routinemaintenance of your new vehicle AVIA.

It also provides the important safety information.

We recommend you to read it thoroughly and to follow instructions andwarnings mentioned.

We would be pleased if you manage to make a full use of its advantages andpossibilities.

We believe that the vehicle AVIA will serve you many years to your completesatisfaction.

Avia Ashok Leyland Motors s.r.o.Beranových 14Praha - LetňanyCzech Republic

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DescriptionInterior ................................................. 4Keys ..................................................... 6Doors .................................................. 6Electrically actuated windows* ......... 7Instrument board - gauges ............... 8Indicator lights .................................... 8Display of AdBlue Level ................... 11Combined lever switch ................... 12Engine brake .................................... 13Controllers ........................................ 14Cruise control ................................... 16Vehicle height adjustment by remotecontrol* .............................................. 17Diagnostic sockets .......................... 17Ignition switch and steering lock ... 18Gearshift lever .................................. 19Steering wheel adjustment............. 19Heating and ventilation ................... 20Air-conditioning* .............................. 22Seats ................................................. 24Head restraints ................................ 25Sleep couch...................................... 25Seat belts .......................................... 26Rear-view mirrors ............................ 28Rear-view mirrors remote control* 28Headlights levelling device ............. 29Cabin interior lighting ...................... 29Digital clock* ..................................... 30

Vehicle documentation List of contents

The vehicle equipment parts markedwith * have been factory installed oncertain models or are delivered asoption only.

If you sell your vehicle, remember tooverhand the complete vehicle docu-mentation to a new owner.

Warning!n The texts in frames named"Warning!" must be unconditional-ly observed.

Operation ManualTo get acquainted with the vehicle prop-erly, it is necessary to read through the"Operation Manual" and all manuals,which were delivered together with yourvehicle (e.g. operating instructions forthe use of auto radio, tachograph, bat-tery warranty card, etc.).

Service BookletThe vehicle documentation also con-tains the "Service Booklet", in whichyou can find:n vehicle identification datan guarantee conditionsn warranty card and data on the ownern records on regular service inspecti-onsn service jobs and maintenance in-tervalsn body condition recordsn special servicing and maintenancen directory of authorized service stati-ons

Information

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Socket / cigarette lighter .................. 30Sun visors ......................................... 30Cup holder ........................................ 31Ashtray .............................................. 31Clothes hooks, glovecompartment .................................... 31Bonnet ............................................... 32Tools and equipment ...................... 33Hydraulic cabin tilting ...................... 34Instructions for cabin tilting ............ 34Cabin tilting at special versions ..... 35Chassis c/w cabin ........................... 36

Operating instructionsCheck before the drive .................... 38Vehicle running-in ........................... 38Maintenance ..................................... 38Starting the engine .......................... 39During driving ................................... 40Stopping the engine ........................ 41Idle run .............................................. 41Engine ............................................... 42Belt tensioning ................................. 43Lubrication system .......................... 44Turbocharger .................................... 45Fuel tank ........................................... 46Fuel .................................................... 46Draining the fuelfilter .................................................... 46AdBlue fluid tank .............................. 47AdBlue fluid ...................................... 47Cooling system ................................ 48

Air filter .............................................. 49Steering ............................................ 49Gearbox ............................................ 50Clutch ................................................ 51Front axle .......................................... 52Rear axle........................................... 52Brake system ................................... 53Service brake .................................... 54Checking the brake lining ............... 56Brake system inspections .............. 56Anti - blocking - system ................... 57ASR .................................................... 57Emergency brake ............................. 58Parking brake ................................... 58Windshield washer and wipers ..... 60Tyres and wheels ............................ 61Transport of loads ........................... 62Electronic vehicle height adjustment(ECAS)* ............................................. 63Draining the condensate from airtanks .................................................. 64Basic rules for the trailer coupling . 65Electrical equipment ....................... 67Location of battery ........................... 68Battery ............................................... 69Battery circuit breaker ...................... 69Alternator........................................... 69Headlamps and lights - location ... 70Vehicle care ...................................... 71

TroubleshootingEngine ............................................... 73

Electrical equipment ....................... 77Monoblock hydraulic powersteering ............................................. 78Brakes ............................................... 78Towing, vehicle recovery ................. 80Spare wheel holder (L, E, S, G) ...... 81Wheel chock (L, E, S, G).................. 81Spare wheel holder (K, N) .............. 82Wheel chock (K, N) .......................... 82Changing the wheel ........................ 84Replacing bulbs ............................... 85Fuse box ........................................... 91Use of jumper cables to start theengine ............................................... 93

Technical dataEngine ............................................... 95Undercarriage .................................. 96Dimensions of chassis c/w cabin . 98Weights and axle loads .................. 99Weights and axle loads - permittedtrailer weights .................................101Wheel turning diameter ................101Tires inflation pressures ..............102Maximum speeds and climbingabilities ...........................................103Operation fillings ...........................104Vehicle Identification Number ......105Vehicle labels .................................106

I N D E X ............................................107

D E S C R I P T I O N

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Interior

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579 8 2 4 17 6 3 1 11

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1 Combined lever switch- turn signals- side marker lights- low beam- high beam

2 Combined lever switch- wipers- washers- engine brake

3 Controllers- front fog lamps- tail fog lamps- display of AdBlue Level

4 Controllers- emergency flasher- rear-view mirrors heating

5 Controllers- power-take-off drive (PTO)*- differential lock- superstructure lighting*- air-conditioning*- cruise control- cruise control - off / on- cruise control - set / resume

6 Measuring instruments and indicator lamps7 Digital clock*8 Heater control9 Adjustable heater vents

10 Window lift mechanism*11 Door opening and locking12 Ignition switch13 Parking brake14 Headlamps beam adjustment15 Main rear-view mirrors

remote control*16 Gearshift lever17 Horn18 Loudspeaker19 Ashtray20 Storage compartments

21 Steering wheel positioning lever22 Clutch pedal23 Service brake pedal24 Accelerator pedal25 Seat belts height adjustment*26 Storage box (c/w cover*), fuse box27 Cigarette lighter28 12 V socket29 Sun visor30 Digital tachograph*31 Auto radio*32 Dome light

29 30 3231FN0011


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DoorsKeys

From outsideBoth doors can be unlocked and lockedfrom outside by the key which you insertand turn in the lock (item 1). Grasp thehandle grip (item 2) and pull it towardyou to open the door.

Unlocking - insert the key, give it 90°turn towards the face of the vehicle andback into the initial position when youcan remove it.Locking - insert the key, gently turn ittowards the rear of the vehicle and backinto the initial position.

From insiden (item 4)A - door unlockedB - door locked (when the door is lockedin that manner, it cannot be openedneither from the outside, nor from theinside).n Pull the lever (item 3) to open thedoor.n Turn the handle (item 5) to open or toshut the window.

n Your vehicle is delivered with twokeys - you should keep one in a safeplace outside the vehicle as a spareone.n Keys are provided with a label, onwhich the key number is stamped. Youshould keep the label in a safe placeoutside the vehicle and put down thenumber somewhere.n If the vehicle is fitted with the analo-gue tachograph, the key to open it isdelivered with the vehicle.

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A

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Electrically actuated windows*

Central door locking*Use the central door locking to lock or tounlock both doors simultaneously fromthe driver´s side.

n The windows can be lowered whenthe ignition is in position "ON" only.n The windows lowering is active onlywhen the button is hold depressed.n The control buttons are situated onthe top of the door.n Both side windows can be control-led from the driver´s place.n Only the window on the RH side canbe controlled from the co-driver´s side.n The control button (item 1) - for thewindow on the driver´s side.n The control button (item 2) - for thewindow on the co-driver´s side.

n Push the front part of the rockerswitch to open the windows, push theother half of the rocker switch to shutthe windows.

21Warning!n Remember always to removethe key from the ignition switchbefore leaving the vehicle.n Take care that the tailgate andside door of the box body are loc-ked properly. It is not allowed totransport the loads which do notallow a safe closing of the door.Should the box body be damageddue to the tailgate or side doorclosed wrong, the manu-facturerdoes not provide any guarantee forit.

Warning!n Do not leave your fingers on thewindow glass when closing it - themechanism can develop the force,which may cause injury.n The lowering button musn´t beheld pushed down if the door win-dow is fully in its extreme stoppositions. If disregarded, the win-dow lowering system can be dam-aged.

FN0050


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Instrument board - gauges Indicator lights

1 Tachometer2 Engine speed - indicator3 Air pressure gauge of 1st brake circuit4 Air pressure gauge of 2nd brake circuit5 Fuel gauge, indicator light

6 Coolant thermometer,indicator light

7 Group of indicator lights I8 Group of indicator lights II9 Group of indicator lights III

Turn signals

n The left or the right indicator lightflashes when you operate the turnsignal lever.n A short interval of flashing indicatesa defective bulb in the turn signal light(replace it immediately).

High beam

It lights with the high beam on.

Batteries charging

n It lights when the ignition is turned"ON" and it must go out after startingthe engine.

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2

4

3

FN0065N59

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Parking brake

n It lights when the parking brake isapplied and at low air pressure in theparking brake circuit.n If it lights, do not move off or if it lightsup on the move, stop and proceed perChapter Troubleshooting.

n If it does not go out after starting orit lights up during driving, move thevehicle a safe distance off the road,shut the engine off and proceed perChapter Troubleshooting.

Brake systemmalfunction

n It lights when the ignition is turned"ON" (to check the function), after theair brake system circuit is fullypressured it must go outn If it does not go out after a short whileor lights up on the move, it is necessaryto stop and proceed per Chapter Trou-bleshooting.

Wear of brake pads

n It lights when the brake pads wearexceeds the max. allowable limit. Adaptthe driving speed and proceed perChapter Troubleshooting.

Signalisation of AdBlueliquid level (reserve) inthe tank

n It lights when the AdBlue level in thetank is low (approx. 6l).n Top up the AdBlue liquid at next die-sel re-fuellingn Simultaneously warning bulb lightsup „Engine - warning or enginemaintenance“.

ABS (vehicle)

ABS (trailer)

n It lights when the ignition is turned"ON" (to check the function), it must goout after a short while.n If it does not go out after a short whileor lights up on the move, it is necessaryto stop and proceed per Chapter Trou-bleshooting.

ASR*

n It glows whilst ASR is in operationn Starts glowing when signalling theASR system fault. System ASR out offunctionality has no impact on dailyoperating the vehicle.


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Seat belt*

It reminds you of not buckling by theseat belt.

Differential lock

It lights when the differential lock is ON.

PTO*

Power - take off drive (PTO). It lightswhen the PTO is on.

Reverse light

It lights when the reverse speed isengaged.

Trailer turn signals*

n They light when the turn signals areswitched on and a trailer is coupled.n A short flashing interval indicates afaulty bulb in the turn signal light (repla-ce the faulty bulb immediately).

Engine - stop

n It lights when the ignition is turned"ON" (to check the function), it must goout after a short while.n It lights at a serious defect of theengine.n If it does not go out after a short whileor if it lights up on the move, move a safedistance off the road, stop the engine andproceed per Chapter Troubleshooting.

Stop light

n It comes on whilst brakes are being ap-plied and a bulb of brake lights is defective.n Replace the faulty bulb immediately.

Low beam

It lights with the low beam turned on.

Cabin tilting

It lights when the cabin does not restproperly in its rear location (correct itimmediately).

Air filter (polluted)

n It lights when the filter cartridge hasbeen clogged.n It is necessary to replace the filtercartridge.

FN0065N5

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Pneumatic suspension*/yellow control light/

Glowing if the tail part of the vehicle isoutside the driving position (level).

Failure in the pneumaticsuspension system* /redwarning light/

n Glowing if there is a system failure.n If it desn´t go off after short time-out, orit starts glowing while driving, the vehiclemust be halted and it must be proceededfollowing the chapter Failures - repairs.


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Warning!By emptying the AdBlue tank as aresult a crystallisation of the Ad-Blue in the functional parts of theSCR system and hence its damag-ing can occur.

Glowing

It lights when the ignition is turned "ON".You shall start the engine only after itgoes out.

SCR system malfunction

n It lights when the ignition box is inposition "ON" and goes out when theengine has been started.n It lights when a fault or malfunction inthe SCR (Selective Catalytic Reduc-tion) system occurs.n IIf the warning light flashes, it indi-cates the AdBlue quantity being toolow. It is necessary to refill the AdBlueat the nearest occasion.n If it doesn´t go out after the enginestart, or it goes on flashing even aftertopping the AdBlue liquid, it is neces-sary to proceed per Chapter – Trouble-shooting.

Display of AdBlue Level

If the AdBlue tank is emptied, thenafter the first engine stop the out-put of the engine is reduced fornext drives. This stage lasts untilthe AdBlue tank is re-filled.

n Signals continuosly AdBlue level inthe tank.n If the AdBlue level drops, a warningdiode lights on indicating level „0“ on theAdBlue level depiction and simultaneous-ly also the Engine warning control light.n If the AdBlue level further drops, awarning light „SCR system malfuncti-on“ starts flashing and the Engine war-ning control light goes off.n If the AdBlue tank is emptied, war-ning light "SCR system malfuncti-on"starts being on.

Warning!

Engine - warning light

n It lights when the ignition is turned"ON" (to check the function), it must goout after a short while.n It comes on when a malfunction ordefect on the engine component occursor level of fluid AdBlue is lower thanapprox. 1 litre. Simultaneously warningbulb lights up „Signalisation of Ad-Blue liquid level (reserve) in the tank.n If it flashes with the ignition in posi-tion "ON" for about 30 seconds, it isnecessary to proceed per Chapter Trou-bleshooting.n If it does not go out after a short whileor it flashes, proceed per Chapter Trou-bleshooting.

Warning!Euro 5 engines feature an afterglowafter the engine has been started.Under extreme cold this processmay last even several minutes.

172_7287p3

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n The audible signalling is active whenthe lights are on and the door is open.

3 Low / high beam changingn To turn on the high beam, push thelever away from the steering wheel (theindicator light will come on to indicatethe high beam function).n Pull the lever to the initial position tochange over to the low beam.

4 Headlight flashern Move the lever slightly toward thesteering wheel (the high beam indica-tor light will come on).n Headlights are on until you releasethe lever.

1 Turn signalsTurn signals are active when the igni-tion is in the position "ON". Move thelever perpedicularly towards the stee-ring wheel axis to switch the turn sig-nals on.

right turn signal - lever upleft turn signal - lever down

2 Side marker lights and lowbeamTurn the rotary end of the lever to switchthem on.The lights, whose symbol is againstthe mark, are on:OFF lights off

side marker lights on

low beam (and/or high beam) on

Combined lever switch

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2

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FN0110

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5 Windshield washern Windshield wipers and washer areactive when the ignition is turned "ON".n Push the switch at the end of thecontrol lever to turn on the washer. Thewasher pump will operate until yourelease the switch.

6 Windshield wipersTurn the rotary end of the lever to switchthe wipers on:OFF wipers offINT intermittent wiping (you can select

any wiping interval by the rotaryring in steps - item 7)

LO low speed and continuous wipingHI high speed and continuous wiping

7 Intermittent wiping intervalcontrolThe wiping interval is the shortest in theposition F, increase it by turning thering.

8 Engine brakePosition 0 - move the controller awayfrom you and down - the engine brakeis off.Position 1 - move the controller toward

Warning!n For the sake of proper opera-tion the engine brake has to beswitched on (switched off) at leastonce a week. Its lifetime will beprolonged by this measure.n Depress the accelerator pedalto put the engine brake automa-tically out of function.

you and down - the engine brake is acti-vated when the service brake is ap-plied.Position 2 - move the controller awayfrom you and up - the engine brakeworks when the accelerator pedal isreleased (in the speed zone above theidle run).Position 3 - move the controller towardsyou and up - combined function.


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Controllers

1 Power take-off drive *n It can be engaged on vehicle at stand-still and after the engine speed drops- after about 6 s.n When the engine is running, de-press the clutch pedal to engage thePTO.n The indicator light comes on to indi-cate the PTO engagement.

2 Differential lock on /off n It can be engaged on vehicle at stand-

still and after the engine speed drops- after about 6 s.n Use it only for the necessarily nee-ded time to overcome the hard drivingcondit ions.n The indicator light comes on to indi-cate the differential lock engagement.n Maximum speed with differential lockengaged is 40 km/h.n After switching off the differential lockit can arrive, that it still remains en-gaged for a certain time. During thistime it is necessary to respect the speed

Warning!n Positions 1 and 2 can be en-gaged when the air pressure ex-ceeds 0.55 MPa - otherwise theengagement cannot be guaranteed.n We recommend you to switchthe differential lock on / off once aweek at least - hereby the servicelife will increase.

3 Emergency flasher n The bulb in the switch indicates thefunction.n It can be turned on even with theignition off.

4 Main rear-view mirrors

heating *

it is indicated by the bulb in the switch.

Warning!Operate the heating for the neces-sarily required time only.

.

limit 40 km/h and to adjust driving be-haviour to these circumstances.

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9 Resume / reduce n It resumes the speed already set onthe cruise control.This can also reduce the engine speedduring driving or in the PTO regime.

10 Permanent (main)n It activates the cruise control or PTOregime speed setting.

11 Adjust / increase n It stores the instantaneous speedof the cruise control.This control switch can also increasethe engine speed during driving or inthe PTO regime.n When the diagnostic test is perfor-med, another malfunction code willenter when pushed.

Horn The horn switch is situated in the mid-dle of the steering wheel.

5Tail fog lamps

n The tail fog lamps can be turned ononly when the low beam or front foglamps are on.n With regard to a dazzling effect, it can beturned on only in fog, heavy rain or snow.n The bulb in the switch comes on toindicate the function.

6

Fog headlights n Fog headlights can be turned onwhen the side marker lights and lowbeam and/or high beam are on.n The bulb in the switch comes on toindicate the function.

7 Loading space lighting*The bulb in the switch comes on toindicate the function.

8 Air-conditioning *n The cooling equipment works withthe engine running only.n The air-conditioning does not workwhen the rotary switch of the fan is off.n The bulb in the switch indicates itsfunction.

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Cruise control

Warning!n When the cruise control is notused, the "permanent (main)" con-trol button 10 must be switched off.n The vehicle speed can be influen-ced by driving uphill or by the loadweight. For that reason use the cru-ise control only when driving on le-vel ground or in slight hilly terrain.n With PTO engaged it is necessaryto use higher engine revs than at idle.

Setting the PTO speed onvehicle at standstilln Activate the PTO.n Push and hold the button 11 "adjust/ incre-ase" depressed (the adjustable speed range850 ÷ 2,500 rpm) to increase the speed - holdthe button depressed to increase the PTOspeed gradually - when the button is depres-sed repeatedly, the PTO speed increases byabout 25 rpm steps.n Push the button 9 "resume / reduce" toactivate the speed 1,200 rpm automatically.n By pressing the button 11 “adjust/in-crease” 850 rpm will be automatically set.n Other rpm values may be set uponspecial request by the manufacturer.

Adjustment of cruise controln Push the button 10 to activate thecruise control.n When the desired speed has beenachieved, push briefly the button 11 "ad-just / increase" - now the speed is storedand maintained by the engine withoutapplying the accelerator pedal.n The speed can be increased by de-pressing the accelerator pedal - afterreleasing it, the cruise control functionis resumed (however, first the cruisecontrol must be activated).n All functions will be cancelled by de-pressing the clutch or brake pedal and/or by switching off the button 10. Theresuming of the cruise control functioncan be performed when you push brieflythe button 9 "resume / reduce", it meansthat the cruise control need not be setagain.n If the exhaust brake’s stalk is in theposition 1,2 or 3 and if vehicle speedexceeds the set-up speed about ap-prox. 3 km/h (riding downhill) the ex-haust brake is automatically applied.When the desired speed is reached theexhaust brake will come out.

n The cruise control allows you tomaintain a desired speed (engine spe-ed - both on the move and in the PTOregime) - without actuating the acceler-ator pedal.n Use three control buttons located onthe central panel of the instrument bo-ard to control it.n The cruise control starts to operatewhen the speed reaches about 48 km/hand in the PTO regime up to 48 km/h (itcan be selected).

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Diagnostic sockets

n Diagnostic sockets are situatedunder the storage box in the instrumentboard.n They are accessible after removal ofthe storage box bottom, which is rele-ased by turning the two rotary holders(sense of rotation is shown on the co-ver).

1 Socket for the ABS,ECAS diagnostics

2 Socket for the enginediagnostics

Vehicle height adjustment by remote control*

n Operated by remote control device,placed in the holder on the rear wall ofthe cab, in extended cab versions at thedriver´s seat.

n Operating and more detailed in-structions for handling the pneu-matic suspension can be found inthe chapter "Operating guidelines"

FN0134_b

System "switch-on" - indicatedby control lamp on the remotecontrol deviceMemory 1 - memory input, moveto saved position

Memory 2 - memory input, moveto saved position

Automatic adjustment to normal(operational) driving height.

Move "Upwards"

Move "Downwards"

STOP - the operation - raising orlowering the pneumatic suspen-sion - is immediately halted..

DCS00054

Warning!

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Ignition switch and steering lock

Switch positionsn "LOCK" positionOnly in this position the key can beinserted and removed. Only tachogra-ph, electric clock or radio are powered.The steering shaft will be automaticallylocked in this position.

n "ACC" positionSteering is unlocked, electric circuitsconnected through the ignition switchare not powered. When turning the igni-tion from "ON" into this position, theengine will be stopped.

FN0140

Warning!If after a moment any indicatorlight, at which its own test wasactivated, remains on, proceed perChapter "Troubleshooting".

n Position "ON"The indicator lights (see Fig.) of batterycharging, brake system malfunction,parking brake, ASR* function, glowing,ABS, coolant temperature and reservefuel amount, engine - stop, engine -warning, engine - maintenance, SCRand ECAS* system malfunction willcome on. After several second the lightsof battery charging, parking brake, SCRsystem malfunction, eventually of

glowing and depending on the level ofoperational liquids also warning lightsof fuel minimum level and AdBlue levelremain ON. If the air pressure in thebrake system is insufficient, the indica-tor light of the brake system malfunctionremains ON. When the parking brake isapplied its warning lamp will stay on.When the glowing light goes out, theengine is ready to be started. After star-ting the engine the warning light of the„SCR system malfunction“ goes off.Electric circuits connected via ignitionswitch are powered.

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Gearshift lever

Engage gear speeds mechanically bythe gearshift lever with the clutch pedaldepressed.

n Pull the positioning lever towardsyou to release the steering wheel andadjust the steering wheel into the desi-red position.n After the desired steering wheelposition has been achieved, push thepositioning lever as far as it goes.

Warning!It is not permitted to adjust thesteering wheel during driving.

FN0170

Steering wheeladjustment

Warning!n The ignition switch function issecured with the battery circuitbreaker on.n Do not switch off the batterycircuit breaker or do not discon-nect battery clamps to avoid dam-age to alternator or some electricconsumers.

n "START" positionThe engine can be started only when nogear speed is shifted.Do not depress the accelerator pedalwhile starting.The position is not arrested. Whenstarting repeatedly, move the key backto position "ACC" - this prevents to startthe already running engine and avoidsdamage to starter.

FN0160 FN0161

Number oggear speeds

6

Type ofgearbox

ZF 6 S 850


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Heating and ventilation

1 Heater fan control2 Airflow direction control

3 Heater valve control knob - regulationof temperature of the airflow4 Regime of air circulation

n The cabin is heated by the hot-waterheating. It can be used also for heatingof coolant in the cooling and heatingcircuits after starting the engine.n The heater is controlled by heatercontrol elements on the instrumentboard.n By turning the heating control knob(item 3) you will regulate volume of coldand hot air flowing into the cab(turn thecontrol knob to the red zone to supplythe hot air).n Use the control knob (item 1) to ad-just the fan speed and thus the airvolume circulating through the system.The airflow speed can be set in foursteps.n The control knob of the airflow dire-ction (item 2) allows you to change thedirection of airflow (way of cabin hea-ting).n Push the button (item 4) to turn on /off the regime of circulating air in thecabin.

to crew headsto crew feet and heads

to crew feetto feet , windshield and side windows

to windshield and side windows

n Deflect the fins (item 5) at air vents tochange the angle of airflow.The air volume emitted from individualvents is controlled by thumbwheels(item 6).

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Window defoggingn (item 1) fully to position IVn (item 3) to extreme leftn (item 2) to position n Close air vents by thumbwheels.

Windshield defrostingn (item 1) fully to position IVn (item 3) to extreme leftn (item 2) to positionn Switch on the regime of air circulationn Close air vents by thumbwheels.

Keeping windows being notfogged under increased humidityWhen windows are still being fogged (forexample in rainy weather), it is necessary:n (item 1) to position II or III.n (item 2) to positionn (item 3) if necessary, turn on heating.

Ventilationn (item 1) to desired position.n (item 3) to extreme right.n (item 2) to position(or to desired position).

Optimum heatingn (item 1) to position II or III.

n (item 3) to desired heating output.n (item 2) to position

Maximum heatingn (item 1) to position IV.n (item 3) to extreme leftn (item 2) to positionn Switch on the regime of air circulation.

Warning!The heating output depends on thecoolant temperature. The maxi-mum heating output can be obtai-ned after the engine has reachedthe opera-ting temperature.

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Air-conditioning*

n The air-conditioning is a combinedcooling and heating device.n The a/c cooling unit cools down theair and dehumidifies it.n The cooling unit works with the engi-ne running only.

Adjust the air volume by selecting oneof four fan speeds.n The airflow direction control knob(item 2) allows to change the airflowdirection (way of cabin heating).n Push the button (item 5) to switch on/off the regime of circulating air in cabin(signalled by the bulb in the button).n Deflect the fins (item 6) at air vents toadjust the airflow in desired angle. Theair volume is controlled by thumbwhe-els (item 7).

Control elementsn Switch on/off the air-conditioning bymeans of the switch (item 1) (signal-led by the bulb in the switch).n The air-conditioning does not work ifthe fan rotary switch is off.n Depending on the heater valve con-trol knob position (item 4), the tempe-rature of the drawn airflow is controlled(when in the red zone, the hot air iscirculated and contrariwise). It can beused even with the air-conditioning on.n Use the control knob (item 2) to con-trol the fan speed and thus also the airvolume circulating through the system.

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6

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Warning!Smoking is not advisable whenbeing in regime of air circulation.

Warning!n When the vehicle was parked inthe direct sun, remember to openthe windows before switching onthe air-conditioning.n It is recommended to switch onthe air-conditioning once a weekat least (even in the winter mon-ths) to prolong the a/c service life.Optimum cooling

n (item 1) to desired position (positionII or III are optimum)n (item 3) to extreme right, turn it slight-ly to left to adjust the temperature ifneededn (item 2) move it to positionn Push the button with symbol (thebulb comes on in the switch)n The outside air is being sucked upand cooled in that regime

Maximum coolingn Close all windowsn (item 1) to position IVn (item 3) to extreme rightn (item 2) turn it to positionn Push the button with symbol (thebulb comes on in the switch)n Switch on the regime of air circula-tion

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Seats

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Warning!For reasons of safety the driver´sseat may be adjusted on vehicle atstandstill only.

seat.n The seat should be adjusted so thatthe driver could control the pedalssafely.

Seat cushion inclination (c)and height (d) adjustment onthe pneumatically controlleddriver´s seat*n Raise the lever (item 3) to adjust thefront part of the seat cushion.n Raise the lever (item 4) to adjust therear part of the seat cushion.n Take your body weight off to adjustthe seat cushion height.

Correct adjustment of seatsn The seatback should be adjustedso that the driver can hold the steeringwheel at its top point with hands slightlybent.n A quick and safe handling thecontrols required for the drive must besecured.n Keeping your body at ease for themaximum protection offered by seatbelts must be obtained.

FN0210

Seatback adjustment (a)Lift the control lever (item 1) with yourbody weight taken on the seatback to tiltthe seatback to the rear. To adjust theseatback to the front, lift the control leverwith your body weight taken on theseatback slightly and after that releasethe seatback, which will tilt automa-tically forward. Release the lever to lockthe seatback in position.

Forward and backwardadjustment (b)n Pull the control lever (item 2) up torelease the longitudinal shift and theseat can be adjusted into desiredposition. Release the lever to lock the

a b

c d

Fixed seat Sprung seat


25

Warning!n The head restraint being setproperly will support the back ofthe skull when the vehicle is cra-shed from the rear.n For reasons of safety the headrestraint may be adjusted on ve-hicle at standstill only.

FN0220

n Head restraints are height adjustable.n To adjust the head restraint vertically,push the stop toward the rear cab wall.n Adjust the head restraint so that itsposition is adapted to fit the seatingheight of occupant.

Head restraints Sleep couch

On vehicle versions with a long cab, thereis an emergency couch with a storagecompartment in the rear part of the cab.

The storage compartment is acces-sible after unlocking the rubber ele-ment and tilting the couch.

FN0221 FN0222


26

Seat belts

n The cabin is equipped with three-point seat belts and retractors on twoside seats.

n The middle seat has got the two-point seat belt and mechanical ad-justing equipment.n Seat belts offer a protection for pas-sengers in case of an accident.

n Seat belts have to be buckled whene-ver you drive the vehicle - even in urbandriving.

FN0230a


27

n The belt strap must not be wornover rigid or breakable objects,which are stored in your clothing inpockets.n Seat belts, which have beensubject to an accident or have beendamaged, must be uncon-ditional-ly replaced with new ones.n Take care that the belt is nottwisted and is worn across pelvisand not across soft parts of thebody if possible.n The maximum effect can bereached only with a correct sea-ting position in cabin.n Do not strap in more than oneperson with each belt.n Keep the seat belts clean (dirtimpairs the function of the retrac-tor). Use the soap water to cleanthe seat belts.n If the seat belt has been dama-ged, it is necessary to have it re-placed.

Warning!Use of seat beltsn The respective warning light re-minds you of necessity of the use ofseat belts*.n Grasp the belt holding it at tongueand slowly fit it across the chest andpelvis.n The belt must fit snugly to the centreof arm and to your pelvis.n If the belt locks when being pulledout, release it, let it rewind and after thatpull it out again.n Insert the belt tongue into a respecti-ve seat buckle. The belt is anchoredproperly when it clicks into a buckle.n To release the seat belt, press the

red marked cap on the buckle.Seat belts height adjustment*n Due to the height adjustable beltanchorage, the belt can be adapted tofit the body dimensions.n To adjust the belt height, push thebutton downwards, tilt the upper an-chorage toward you (up) and adjust it tothe desired position.


28

Rear-view mirrors

n Vehicles are equipped with heatedmain rear-view mirrors.n The heating is controlled by the con-troller on the instrument board and isindicated by the indicator light situateddirectly in the controller.n Use the heating for the necessarytime only.

Rear-view mirrorsremote control*

Warning!n For reasons of safety the mir-rors must be adjusted prior to moveoff.n Pay extreme attention whenconsidering the size and distan-ces of cars and other objects whenseen in a convex mirror. Alwaysremember that they will look smal-ler and appear farther away than inreality.

n Turn the controller to select adjust-ment of the left or right mirror.to left - left mirror - position Ato right - right mirror - position Bn Deflect the four-position controllerto obtain the desired position of themirror.

A B

FN0240a

FN0240

BA

Version A

Version B


29

Cabin interior lighting

Vehicle loadout of the max. payload

30% 50% 70% 100%

K 1 2 3N 1 2 3L 1 2E 1 2S 1 2G 1 2

Headlights levelling device(not applicable for vehicles with air suspension)

n Use the thumbwheel to change theheadlights beam inclination.n The basic adjustment of headlampshas been performed on the unloadedvehicle (the control thumbwheel markis against zero).n Payloads for the respective vehicleversion are mentioned in table Weightsand axle loads.

2 31

FN0260

n Bulbs of the dome light are turnedon/off by switches situated in the lightdirectly.n Use the switch (item 1) and (item 2)to turn on/off the light on the driver´sside.n Use the switch (item 3) to turn on/offthe light on the co-driver´s side.

Warning!The driver is obliged to adjust theheadlamps depending on theinstantaneous vehicle load.

FN0250a


30

Socket / cigarette lighterDigital clock* Sun visors

FN0270

n Use button "HOUR" to set hours.n Use button "MIN" to set minutes.n Use button "SET" to zero minutes towhole hours.n The button "DISPLAY" will show theclock when the ignition is in "LOCK"position only. The clock displays onlywhen the button is hold depressed.

n The socket (item A) can be used forcigarette lighter only.The socket (item B) can be used for 12 Vappliances.n Push the knob in to switch on the ciga-rette lighter. When the spiral is ready for use,it will spring back. Pull out the lighter and useit immediately (the heating spiral will loosethe thermal energy soon).

Warning!n It is forbiddent to use the ciga-rette lighter socket for other ap-plieances, the electroinstallationmight be damaged.n Pay attention not to burn yourselfwhen handling the cigarette lighter.n If the lighter does not spring backafter about 30 seconds, it must beremoved not to burn through.

FN0290

n Sun visors are situated above thewindshield in the cabin ceiling.n They can be tilted as desired.n Adjust the sun visors to protect youagainst sun glare.

A

B

FN0015aFN0280b


31

Ashtray Clothes hooks, glovecompartment

Cup holder

n To slide the holder out, push it andrelease.n After use, slide it back.

Warning!n Do not use the cup holder if thevehicle is in motion.n Do not use the cup holder tohold other objects.

n Pull it to open it.n To clean it, remove the sheet insert.

Never put paper and otherflammable objects in the ashtray- danger of fire!

Warning!

FN0320

FN0300a FN0310a


32

Warning!You should check a proper bonnetlocking whenever you move off.

Opening the bonnetn Push the bonnet in its lower part,press the release lever (item 1) to left.n Raise the bonnet.n Take strut out of holder (item A) andinsert the strut end in hole (item B) tosecure the lifted bonnet.

Closing the bonnetn Raise the bonnet slightly.n Unhook strut from hole and put it inholder (item A).n Tilt the bonnet in the vertical positionand push its lower edge until it clicksinto lock (item 2).n When the bonnet snaps in, you canhear it.

Bonnet

2

B1

A

FN0345FN0330


33

Tools and equipment

A - co-driver´s seatB - driver´s seat

n Tools and equipment are placedunder the co-driver´s seat and areaccessible after tilting the seat cushion.n The hydraulic jack is attached to thecab floor behind the driver´s seat.n Tools must be attached firmly.

Warning!n Tools, which is not stored pro-perly, may cause a personal injuryor disturb you by vibrations duringdriving.n The jack delivered with the ve-hicle is determined to be used withthis vehicle model only. It must notbe used to lift other vehicles orother loads.n Tools and equipment must beattached properly on the move orduring the cabin tilting.

Wrench 30 x 30Lever adaptor item1Box with bulbsFirst aid kitWarning triangle item 2Lug wrench item 3Rod for jack and cabin tilting item 4Hydraulic jack item 5

Wrench 24 x 24

FN0360 FN0350n431

2

b

5

A


34

Instructions for cabintiltingWarning!n Prior to tilt the cabin, shut theengine off and shift into neutral.n Set the vehicle parking brake.n Secure the objects which areplaced inside the cabin and shutthe doors properly .n Prior to start tilting, we recom-mend to open the bonnet.n Take an extreme care when til-ting.n Be very careful when workingbeneath the tilted cabin.n It is not allowed to stay ahead ofthe cabin tilted.n It is not allowed to stay beneaththe cabin if tilted partially.n The necessary workshop he-ight to tilt the cab is 3,000 mm and3,800 mm with the additional su-perstructure.n If your vehicle is supplied withsafety strut of tilted cab you mustalways use it! This is applicableespecially for sleeper and crewcab.

Hydraulic cabin tilting

Cabin loweringn Move the distributor lever (item 3)into vertical position downwards.n Pump until locks of the rear locationare closed (cabin rests down in placeand is locked).n Move the distributor lever (item 3)into horizontal position.

Cabin tiltingn Move the distributor lever (item 3)into vertical position upwards (seeschema on the pump).n Insert rod (item1) into lever of thehydraulic pump (item 2) and pump.Hydraulic locks of the rear location willopen and cabin starts to tilt itself.n The cabin must be tilted fully to itstilted position - a partial tilting is notallowable for entering beneath thecabin.n Let the distributor lever be in verticalposition with the cabin lifted.

31 3

2

FN0390FN0395


35

Cabin tiltingn Move the distributor into position.n Pump until the cabin is tiltedcompletely (cabin will not fall over itszero point).Note: The cabin starts to raise itselfonly after several lever strokes.

Cabin loweringn Move the distributor into positionn Continue to pump until the locks clickin place and until you feel an increasedresistance on the lever.n Move the distributor into position.n Go on pumping by about 15 strokesto adjust the position of the cabin pininto a centre of the oval hole in thecylinder eye.n Move the distributor into position O.

FN0391

Cabin tilting at special versions


36

Chassis c/w cabin

1 Strut2 Bonnet3 Bonnet lock4 Front coupling (for towing)5 Washer tank6 Clutch tank7 Expansion tank8 Fuel tank filler neck9 Fuel tank drain plug

10 Air filter11 Power-steering tank12 Spare wheel (four positions -

vehicle version dependent)

9 10111221FN0404

22

8

23

24

6

5 4 3 7

1

2

FN0345

13


37

14

16

20

15

2019

13 Oil dipstick14 Gearbox15 Propeller shaft16 Air pressure regulator

c/w air drier17 Drain valve (2 x)18 Regenerating air reservoir 4.5 l19 Brake pressure regulator20 Battery case c/w circuit breaker21 Wheel chock22 Fuel filter23 AdBlue fluid tank filler neck24 Air intake filter into the SCR unit

17

17

11

FN0422cu

19

1816

FN0431a

O P E R A T I N G I N S T R U C T I O N S

38

Maintenance

n To achieve a maximum usevalue, economic and safe ope-ration and maximum possibleservice life, it is necessary tocarry out all maintenance worksat regular intervals as stipula-ted in the Service Booklet.n The vehicle maintenancemust be carried out by autho-rized workshops, whichhave been acquainted withthe vehicle design, do theirwork on a professional level,have the necessary equip-ment and are in direct contactwith the manufacturer.

n The running-in of a new ve-hicle or vehicle after the generaloverhaul is terminated aftercovering 3,000 km (practically,the vehicle engine will reachthe maximum possible outputafter covering several furtherthousands of kilometres).n During the running-in pe-riod, do not run the engineabove 3/4 of its top speed orat maximum fuel delivery un-der low engine speed.n Avoid full throttle starts,running the engine at highspeed and abrupt stops.n Do not run the cold engineat high speed.n Do not let engine labor.Downshift when engine nolonger runs smoothly.n Vehicle must not be loa-ded extremely.

Vehicle running-in

Warning!The way of running in thevehicle has a great influ-ence upon its service life.

n For the sake of properoperation the engine brakehas to be switched on(switched off) at least oncea week. Its lifetime will beprolonged by this measure.n The differ. lock shouldbe engaged / diseng. oncea week at least. Its servicelife will be increased.

Warning!

n engine lubricating oil level – check/top-upn urea (AdBlue) level – check/top-upn drive belts + belts tensioner - check/correctn fuel – check/top-upn fuel-water separator – drainn crankcase breather tube – inspectn cooling fan – inspectn engine coolant level – check/correctn intercooler - check conditionn air cleaner – inspectn air intake piping – inspectn brake fluid in clutch booster circuit – check/top-upn brake fluid in steering power circuit – check/top-upn brakes and parking brake – checkn air tanks – drain (after trip)n If the draining air contains excessive amount of water it isnecessary to change air drier filtern tyres – check pressure and conditionn cab – secure in locks at rearn hood – secure in lockn fluid level in tank of washers – check/top-upn outside lamps, indicators and brake lamps – checkn head lamps – adjust tilt with regard to load weightn check for possible leakage of fluids (oils, brake fluid, ... etc.)– by sight – on the spot where your vehicle was stopped afterlast tripn In case of towing a trailer it is necessary to check the trailerconnection to towing coupling, connection and functionabilityof electrical wiring and air brake hoses.

Check before the drive


39

Warning!

Starting the engine

n Insert the ignition key and turn in"ON" position.n Starting the engine is possible onlywith no gear shifted in gearbox. Do notdepress the accelerator pedal.n When the glow plug warning lamphas gone out (applies to cold and evenhot engine), start the engine by turningthe ignition key to "START" positionand hold it for a while (the engine willcrank when holding the key in this po-sition), until the engine starts running,however, for 10 seconds as a maxi-mum. When starting repeatedly, keepthe interval of min. 30 s between indivi-dual starting attempts.

Warning!n When the indicator and warninglights of battery charging, parkingbrake, engine - stop, engine - war-ning and ECAS do not go out afterstarting the engine, do not moveoff . Depending on the AdBlue quan-tity the control light engine-war-ning and SCR system malfunctionmay be ON.n The vehicle must not be put inmotion in any way unless the batte-ry circuit breaker is on and theignition key is inserted into ignitionswitch and turned in position "ON".The steering is unlocked in thisposition. Before you move off,check whether the steering wheelis free to turn.n Do not run the cold engine athigh speed - it could be damaged.

n Should the indicator and war-ning lights of brake system mal-function, parking brake, engine -stop, engine - warning and ECAS*be still on after turning the ignitionto "ON" position even after a shortwhile, you must not move off - findout the cause of the defect perChapter "Troubleshooting". War-ning light „SCR system malfuncti-on“ remains on and goes off short-ly after the engine start.n Use the winterized Diesel fueland engine oil of the viscosity gra-de in accordance with climaticconditions in the winter months.

n After starting the engine, release thekey, it will automatically return to "ON"position. Shortly ofter the engine startthe warnign light „SCR system mal-function“ goes off. When the regularengine run is achieved, the chargingcontrol light has to go off. If not, find outthe cause of the defect according tochapter Troubleshooting.


40

During driving

n It is not allowed to drive without theengine running and the gear shifted.n Watch the indicator and warninglights on the move from time to time.n If any of the warning lamp shown inthe picture above comes on while dri-ving, it is necessary to stop the vehicle(at the soonest with regards to the traf-fic circumstances for the sake of safe-ty). In addition, if the engine - stop lightcomes on, it is also necessary to shut

n After the vehicle is set in motion,check the efficiency of the servicebrake. Checking the braking efficiencyis important especially in winter, afterwashing the vehicle or after fording(passing through a deeper pool ofwater). Brake up the vehicle repeatedlyto allow a quick drying out of the brakesystem.n Do not brake sharply - on one handthe tires and brake system would beworn quickly and too much, on the otherhand this way of braking would endan-ger the other motorists.n Depress the accelerator pedal gra-dually.n Depress the clutch pedal as far as itgoes.n Shift to gears smoothly not to stressthe engine extremely. Before engagingthe reverse run, put the vehicle to a fullstop not to cause damage to gearbox.n Before shifting to reverse gear at thegearbox model ZF 6 S 850 it is neces-sary to wait 3 to 5 seconds after depres-sing the clutch pedal (to allow stoppingof shafts in gearbox) and only after thatengage the reverse gear.

the engine off.Then proceed according to Chapter:Troubleshooting.If the coolant temperature indicator lightcomes on, it is necessary to reduce thevehicle speed, to downshift, and stopthe vehicle as soon as possible andallow cooling down the engine by theenhanced speed (1,200÷1,500 rpm).

Warning!

If the fuel reserve indicator light comeson (item 1), it is still about 16 l fuel in thefuel tank.If the yellow control light ECAS* startsglowing, then the rear part of the vehicleis outside the driving height position(level) Applicable for version with pne-umatick suspension only.

In any case it is not allowed to shutthe engine off when the coolanttemperature indicator light comeson.FN044cu


41

Stopping the engine

Warning!n Turn off the battery masterswitch only 30 seconds after tur-ning off the ignition to allow dataprocessing by ECM (Engine Con-trol Module) and to allow air to blowthrough the AdBlue injection sys-tem into the exhaust system (noi-se from the area of AdBlue tankmay be heard). If the instruction asabove is not followed a fault may bereported by warning lamps or theSCR system and/or damage of theSCR system may be caused due toinsufficient removal of AdBlue re-sidues (possible crystallization orfreezing) and thus causing blocka-ge of it.

n Turn the ignition key from position"ON" to position "ACC" to stop theengine.

FN0441

Warning!Do not let the engine run at idle orat speed to 1,000 rpm without loadfor more than 10 minutes. Whenthe engine is running for a longtime in these regimes, the tempe-rature of the combustion spacewill drop so that the fuel cannot beburned completely. This may re-sult in creation of carbon in thesurrounding of holes of injectionnozzles and piston rings what maylead to damage the engine. In ad-dition, low temperatures will cau-se that all oil penetrating from valvegaskets will not burn in exhaustchannels. The oil not burned cancause damage to turbocharger.

Idle run

Warning!n Never shut the engine off by tur-ning off the battery circuit breaker -it may result in damage to wiringcables and alternator.n The ignition key may be remo-ved from the ignition switch onlyafter full stopping of the vehicle.n Before stopping the engine af-ter a full load operation, allow itto idle 1 minute at least - see thelabel on the instrument board.


42

Engine

FN0482a

7 2

9

46 3

10

1 Alternator2 Oil filter3 Engine starter4 Fuel filter5 Engine control unit

6 Fan c/w visco-coupling7 Tension roler

8 Water pump 9 Oil filler neck10 Compressor

1

5

8


43

Cummins ISB4.5E5 160- Diesel engine- four-cylinder- 16 valves- max. power output

118 kW (160 HP) / 2 500 rpm


136 kW (185 HP) / 2 500 rpm


152 kW (207 HP) / 2 300 rpm

n The belt is tensioned automaticallyby the pulley (item A), which cares of theconstant tension.n When the belt has been damaged, itmust be replaced immediately.

Belt tensioning

A

FN04821a


44

FN0450

n Have the oil changed and oilfilter replaced at the authorizedservice station.n The insufficient oil level will cau-se damage to engine.n Keep the environment cleanwhen handling the oil.n When it looks that oil quality gotworse (presence of water), con-tact the authorized service stationpromptly.n Dispose of used oil in accordan-ce with environmental regulations.

Warning!

Checking the oil level and kindof oiln It is necessary to check the oil levelbefore each drive (the oil is consumed a littleby the vehicle operation).n The vehicle must stand on level ground tocheck the oil level.n Check the oil level before starting theengine when the oil level is stabilized.n Pull dipstick out, wipe it clean with a ragand push it in a hole all the way. nPull dipstick out again. The oil level is correctwhen it is between marks on the dipstick. Itmust not be above the MAX mark, becausethe engine could be damaged.n Add the oil in time not to allow the oil levelto drop below the MIN mark.n Always add the oil of the same quality.n For the oil change intervals see theService Booklet.

Lubrication system

Warning!n The manufacturer is not respon-sible for damages caused by neg-lecting the oil economy .n The manufacturer does not pro-vide any guarantee for enginesdamaged by use of oil additives.

n Always use the approved engineoils only.n Use of special oil additives is forbid-den, because some additives combi-ned with brand name engine oils mayresult in impairing the function resul-ting in damage to engine.

Engine oilspecificationA C E A

E5, E7

Recommended oil viscosity grade

S A E

15W - 40 recommended viscosity for normaloperation at ambient temperatures above 15°C

10W - 40

5W - 40viscosity for using at colder climate

n The oil class, which was filled in theengine in the manufacturing plant, ismentioned on a sticker on the cap of oilfiller hole.


45

Filling the engine with oiln Unscrew the filler neck cap.n Keep the environment perfectly cle-an when adding the oil.n Do not fill the oil above MAX mark.n When the oil level is correct, mountthe cap again.

FN0460cu

Turbocharger

n Keep the environment clean andavoid mechanical damage to impellerof centrifugal blower by sucking in themechanical dirt (for example duringoperation without installed coarse airfilter).n Before stopping the engine from afull load operation, allow it to run at idlefor one minute at least (see the label onthe instrument board) to secure thecooling down of turbocharger by oil andthus to avoid burning-in of carbon onthe turbocharger shaft.U

FN0441

n If the turbocharger is defective,have it repaired at the authorizedservice station.n To increase the service life ofturbocharger, keep the air filterand the whole intake manifold per-fectly clean.

Warning!


46

Fuel tank Fuel

FN0520

n To prevent air from entering the fuelsystem, never allow the fuel tank becompletely empty.n The fuel tank capacity is 120 l (160 l*,200 l*).The float device is installed in the fueltank. The fuel reserve in tank is checkedby the fuel gauge on the instrumentboard.n The minimum fuel reserve makes16 l (20 l*) as indicated by the signalbulb at the fuel gauge.n The fuel gauge is operative with igni-tion turned in "ON" position.n The fuel tank neck is fitted with alockable cap.

Warning!n Do not allow all the fuel be pum-ped out of the fuel tank.n The use of bio-Diesel is not per-mitted.n It is not allowed to add petrolinto Diesel fuel.

n When operating the engines usefuel as per ČSN EN 590 (656506) orASTM No 2D. At external temperaturesbelow 0 °C a fuel mixture No 2D and No1D can be used. Prefer using theDiesel fuel with a low sulphur content(0.05% hm), which is available on themarket.n In the winter months (from Novem-ber 1 to March 31) you should use theDiesel fuel whose filtering ability (CFPPspecification) meets the climatic con-ditions.n To assure the operation under lowtemperatures, you may put additivesinto Diesel fuel, which improve the fil-tering ability under low temperatures.Perform the mixing according to manu-facturer´s instructions.

Draining the fuel filter

Unscrew drain bolts on the fuel filterbottom to allow draining of water fromthe fuel filter. When all dirt particles dripout, screw the bolts again.

fram

e

FN0474


47

AdBlue fluid

n Use exclusively the AdBlue fluid de-termined for the vehicle operation (stan-dard DIN V 70070).n It is not permitted to replace the Ad-Blue fluid with other product or to mix itwith other product. The catalytic conver-ter system reducing the exhaust emis-sions could suffer a damage.n Always remember to handle theAdBlue fluid with care. The AdBlue is acorrosive agent, which must nevercome in contact with other chemicals.n If you stain your skin or hit your eyeswith the AdBlue fluid, rinse the stainedspots with a lot of water.Call a doctor ifneeded.

AdBlue fluid tank

FN0403cu1

n Tank volume (item 1) is 30 l.In the tank the fluid level measuringdevice is installed. The shortage of fluidis indicated by the indicator light on theisntrument board.n When the AdBlue fluid level dropsbelow 6 l of the capacity, the warninglamp „engine - warning“ comes onand if AdBlue tank goes on emptying,warning light "SCR system mal-function" starts flashing.n Make it a habit to check the AdBluefluid level in tank at every Diesel refuel-ling.

n AdBlue consumption fluctuates from0,5 up to 3% of fuel consumption de-pending on ways how your vehicle isbeing operated and on engine load.

Warning!n If the AdBlue tank is emptied,then after the first engine stop theoutput of the engine is reduced fornext drives. This stage lasts untilthe AdBlue tank is re-filled.n If the warning lamp “SCR sys-tem malfunction” is on you mustnot drive the vehicle – exhaustemissions do not meet requiredvalues. Driving with the illuminat-ing warning lamp is stored in theengine ECM.


48

tioned coolants can be mixed with cool-ants based on ethylene-glucol (C type).n Check the coolant level at regularterms.n The coolant level must be betweenMIN and MAX marks when the engineis cold (when the engine is warm, thecoolant level may exceed slightly theMAX mark). If the coolant level is toolow, it is necessary to add it.n All year-round use of antifreeze pro-tects the cooling and heating systemagainst corrosion and sediments. Forthat reason do not reduce the concen-tration of the antifreeze by adding watereven during the warm season of theyear (always add it in the ratio withantifreeze).n Take care not to spill the antifreeze onthe body paint.n Before the winter season comes,check the antifreeze in the cooling sys-tem for condition and concentration.n Before the summer season comesand anytime when the face body areahas been polluted, clean the radiatorwith compressed air or stream of hotwater from the engine side.Check the expansion tank cap.

n Have the coolant changed at theauthorized service station.n Do not open the cap of coolantreservoir when the engine is hot -danger of scalding!n Never run the engine with thethermostat removed.n The expansion reservoir pre-vents the bleeding of the coolingand heating circuit. Remember tocheck the coolant level.n When the engine overheats orthe coolant leaks, have it correctedby the authorized service station.

Warning!

Cooling system

FN0530

Checking and adding thecoolantn For year round, add antifreeze (spe-cification ASTM 4985) and distilled waterin the ratio specified (see the manu-facturer´s instructions on the antifre-eze packing).n The label saying which kind of coolanthas been filled, is situated on the expan-sion tank or by the expansion tank.Thecooling system has been filled with thefluid based on ethylene-glycol. The men-


49

FN0540n

n The air filter cartridge replacementinterval is stated in the Service Booklet.n The clogged filter cartridge isindicated by the indicator light. When itcomes on, you should visit theauthorized repair shop immediately.n Without regard to the pollutionsignalling, keep the replacementinterval as mentioned in the ServiceBooklet.n The condition of the air filter andintake manifold have a great influenceupon the service life of turbocharger.

Warning!n Have the air filter cartridge re-placed at the authorized servicestation.n When the vehicle is operated invery dusty conditions, reduce thereplacement intervals according-ly.

Air filter Steering

FN0550

Checking and adding thesteering oiln Check the oil level regularly.n The oil level in the tank must reachthe "LIVELLO OLIO" mark. If it dropsbelow this mark, it is necessary to addthe oil of the ATF D II specification intocircuit.n If the steering play was found out, it isnecessary to have it adjusted and/or re-paired at the authorized service station.


50

Warning!n Have the oil changed and oilfilter replaced at the authorizedservice station.n If the oil needs to be refilled toooften, visit the authorized servicestation.n Do not run the engine when the-re is no oil in the power steeringhydraulic circuit.n Keep the environment cleanwhen handling the oil.

n If the steering effort increases consi-derably during the vehicle operation,stop immediately and check the oil le-vel in the tank of monoblock hydraulicpower steering and check the hydrauliccircuit for condition.

Gearbox

n Have the oil changed at the au-thorized service station.n When the vehicle is towed withengine at standstill and no gearshifted, disconnect the propellershaft (at the rear axle) to avoiddamage to gearbox due to insuffi-cient lubrication.n Do not start the engine whenthere is no oil in gearbox.

Warning!

FN0560

n Check oil level and quality in gear-box during service inspections.n Check the gearbox for leaks. If youfind out leakage, visit the authorizedservice station.


51

Clutch

n The clutch is actuated hydraulicallyand completed with the air booster.n In case that the fluid circuit has beenaerated (clutch will disengage poorly),it is necessary to look for the authorizedservice station.n When the clutch plate has been worn,the clutch system will be set automa-tically what is evident by dischargingthe fluid into tank (the fluid volume in-creases in the tank).

Checking and adding the fluidn Check the fluid level in circuit regu-larly.n The fluid level must be between MINand MAX marks. If it drops below MINmark, add the fluid of the specificationDOT3, DOT4, DOT4+ or SAE J 1703.

FN0600

Warning!n Have the fluid changed at theauthorized service station.n Keep the environment cleanwhen handling the fluid.n When air leaks from the air sys-tem (for example during a long-term vehicle storage), the air boost-er will be put out of function whatresults in increasing the force need-ed to press down the clutch pedal.n If the fluid needs to be added toooften, contact the authorized servi-ce station.n The fluid is harmful to health.


52

Rear axle

Transmission Recommendedoil specification viscosity grade

A P I S A E

GL - 5 85 W - 140 H

n Check the oil level and change theoil in axle final drive housings duringservice inspections.n Visually check the axle final drivehousings for leaks only. If you find outleakage, have it repaired at the autho-rized service station.

FN0610n Warning!Have the oil changed at the autho-rized service station.

Warning!Entrust some authorized servicestation to carry out all repairs,refills or adjustments.

n If you notice that tyre treads wearunevenly on the front axle, check and/or have the front axle geometry adjus-ted at the authorized service station.n The life of shock absorbers and theirfunction depend on the way of drivingand kind of operation.

Front axle

FN0620


53

Brake system

1 Compressor2 Air pressure regulator c/w air drier3 Air reservoir 4.5 l4 Four-way relief valve5 Air reservoir 30 l6 Air reservoir 30 l7 Master brake valve8 ABS valve (1st circuit)9 ABS valve (2nd circuit)

10 Automatic brake pressure regulator

11 Combined brake cylinder12 Manual brake valve of parking brake13 Switch of minimum air pressure of spring loaded cylinder14 Front axle brake system15 Rear axle brake system16 Air reservoir of parking brake circuit17 Valve relay18 Trailer brake valve*19 ASR valve*20 Minimum air pressure sensor in circuits of service brake21 Membrane brake cylinder

1514 2 3

5 67

1017

16

18

8

8

19

11

11

12 FN0650FN0431a4

20 19 13

14 15

21

21


54

Service brake

Air pressure in circuit of servicebrakeNominal pressure

0.85 ± 0.02 MPa (8.5 bar)

Minimum pressure

0.55 MPa (5.5 bar)

Warning!If it is not possible to reach theminimum level of the air pressurein the brake system, there is afault in the service brake circuitwhich must be promptly repairedat the authorized service station.It is not permitted to continue todrive the vehicle until the fault isrepaired.

n Disc brakes are mounted on bothaxles.n The service brake system is dual-circuit, controlled pneumatically.n Vehicles are standard equipped withABS, the ASR is installed as option.n The first circuit of the master brakevalve controls the rear brake system.n The second circuit of the masterbrake valve controls the front brakesystem.n The automatic brake pressure regu-lator controls the braking force of rearaxle wheels in dependence on the ve-hicle load.

Correct function of the servicebrake is indicated by:1. Air pressure gauges picking up thepressures in 1st and 2nd circuits.2. ABS indicator light.

Air pressure regulator c/w airdriern This serves to clean and dry the airsupplied from the compressor and tocontrol the operating pressure in brakecircuits.

FN06502

1

FN0650n


55

The used filter must be disposed ofin accordance with environmentalregulations (it may contain oil).

Warning!

Air drier filter replacement(item1)n Replace the air drier filter alwaysbefore the winter season. If you find outwater in drain valves, replace it immedi-ately (water can be found in drain valvesduring regular service inspections).n No air pressure is allowed in the airdrier.n Prior to start the replacement, cleanthe surface of the air drier and loosen theunion nut to release the pressure (item2) on the inlet.n Clean the upper part of the air drierbody, gently oil the gasket of a new filterand hand tighten to 15 Nm.

Automatic brake pressureregulatorn The automatic load sensing valve ser-ves to control the air pressure enteringthe combined cylinder of the rear axledependent on the load on the rear axle.n All adjustments must be carried outat the authorized service station. Du-ring operation, check visually the con-nection of regulator lever with axle, afree travel of the regulator lever andinstrument tightness.n The vehicle operator only gives theadjusting values of the brake pressureregulator according to vehicle versionin case that real values do not respondto ones given on the label in the cabin.

FN0660n

Draining the condensatefrom air tanks

n In all air tanks of the pneumatic sus-pension and pneumatic brakes a watercondensate accumulates, which hasto be drained after every journey.n When draining, a full operational airpressure must be in the system. Watercondensate must be drained by swing-ing the handling levers of drainingvalves placed at the bottom part of airtanks.

FN0655

n In winter season and humidweather the draining has to bedone several times a day..n If the draining is not done regu-larly, as a consequence the vehi-cle safety can be compromisedand instruments can be damaged;for such cases warranty is notapplicable.

Warning!


56

Checking the brake lining

Wheels brake systemn Disc brakes are mounted on bothaxles.n Brake pads have been worn if theindicator light on the instrument boardand diode on the check module underthe glove box of the instrument boardcome on.

Warning!Only the authorized servicestation may perform the repla-cement of brake pads.

FN0670

n Brake pads need to be replacedwhen there is no gap in their centres(see the figure).n The minimum thickness of the brakepad friction material is 2 mm.n The minimum total thickness of thebrake pad is 9 mm.n Replace the pads with ones of theapproved type only.

2mm

Brake systeminspectionsn To assure a correct function of thebrake system, it is necessary to checkit for a good condition at regular terms.n Daily:

-drain the air reservoirsn Once a month:

-clean the air reservoirs from outsideand check whether they have notcorroded and if attached pro-perly.Replace the damaged airreservoir immediately.

-check the compressor intakemanifold and check whether the airfilter has not been polluted.

-check the screwed connections andmanifolds of the whole brake systemfor leaks.

-check the pipes and hoses fora good condition. If damaged, carry outa replacement.


57

Anti - Blocking - System

The ABS system enhances conside-rably the active driving safety of thevehicle. Compared with common bra-ke systems, it keeps a good drivingmaneuverability even at sudden bra-king on wet roads because the wheelswill not block.However, you cannot expect that thebraking distance will be reduced withABS under all circumstances!The ABS has been designed not toshorten the braking distance, but tokeep the control ability over the vehicle.If the circumferential wheel speed istoo low related to the vehicle speed andthe wheel tends to slip, the brakingpressure of this wheel will be reduced.The braking pressure controls eachaxle separately. Hereby the brakingeffect will be balanced and the drivingmaneuverability is kept as much aspossible.To allow a good function of ABS, thebrake pedal must be hold depressed -never brake up interruptedly!

n When the ignition is on, the ABSindicator light must always comeon. If the ABS indicator light doesnot go out in several seconds afterthe ignition is on, or when it doesnot come on at all and/or comes onduring driving, the system is defe-ctive and the vehicle is braked wi-thout ABS. Only the normal brakesystem is operative on vehicle.Proceed to your nearest authori-zed service station in that case.n The enhanced safety which isoffered by the ABS must not temptyou to undergo any risking!n All repairs and interventions inABS may be performed by the au-thorized service station only.

Warning!

ASR*

n The ASR system facilitates the ac-celeration and driving when the roadadhesion is decreased. At the momentwhen the wheel on the driving axlestarts to slip, it will be braked up andhereby the torque on the wheel withbetter adhesion conditions will be in-creased. At the same time enginespeed (revolutions) and torque is be-ing decreased.n While the ASR is being in operationthe ASR warning lamp is illuminating.

n If the ASR indicator light doesnot go out in several seconds afterthe ignition is on, or when it doesnot come on at all and/or comespermanently on while driving, thesystem is defective and ASR isprobably out of function.Proceed to your nearest authori-zed service station in that case.n When ASR is not functional, thenormal vehicle operation is not in-fluenced.n All repairs and interventions inASR may be performed by the au-thorized service station only.

Warning!


58

Emergency brake

Warning!Any unprofessional interventioninto the brake system is not al-lowed and all repairs and interven-tions must be entrusted to authori-zed service stations.

Warning!The use of emergency brake alwaysmeans the endangering of the ve-hicle operation because the emer-gency braking effect is always muchlower than that of the service brake.

The brake system has been designedso that when one circuit is defective, theemergency braking effect is secured.

A loss of operating braking effectmay be caused by:n Malfunction in the pneumatic part ofthe service brake due to air loss. Thedefect is indicated by the decreased pres-sure in one of two service brake circuits.n Defect in the pneumatic part aheadof the four-way relief valve.n Defect in one of four pneumatic cir-cuits behind the four-way relief valve.n Defect in the electrical part of thebrake system - in the ABS system.n Failure of the trailer brake system.

Conclusionn Always before the set out for thedrive and when driving, do not forgetto check a good function of the brake

system so that you are watching airgauges and warning lamps of the brakesystem.n Check a good function of bulbs of thebrake system indicator lights by turning theignition key from "ACC" to "ON" positionwhen the indicator lights must come on.n After full operating air pressure in thesystem is reached the warning lampsmust go out.n After the indicator lights have goneout, you may move off.Brake system instrumentsThe vehicle user is obliged to carry outthe continuous inspections of the bra-ke system to check its condition andfunction. When some defect or suspi-cion of the defect has been found out,have the diagnostics and possiblerepair performed by the authorizedservice station.

Parking brake

n The parking brake is of spring-loa-ded type and acts on wheels of the rearaxle.n The energy needful to brake up thevehicle is accumulated in the spring ofcombined brake cylinder being air com-pressed. Air pressure will press thespiral spring and this way the parkingbrake is released.n The parking brake is controlled bymeans of the manual brake valve lever,which is located behind the gearshiftlever.

Position of the parking brake le-vern Parking position:

FN0690a

drivingposition

parkingposition check

position


59

FN0700n1

Warning!n The use of parking brake duringdriving is dangerous - danger of lossof control and skidding. Apply theparking brake only in case of urgentneed. n It is not allowed to drive the vehiclewhen the indicator light of minimumair pressure in the spring-loadedbrake lights - the vehicle is beingbraked up.n Pressures in a circuit of thespring-loaded brake:

Nominal pressure

0.85 ± 0.02 MPa (8.5 bar)

Minimum pressure

0.55 MPa (5.5 bar)

Releasing the combined brakecylinder - for the need oftowing onlyn Place the wheel chock to secure thevehicle against motion.n Turn the nut 1 to unscrew the stemout of spring-loaded cylinder.

(before the parking position isachieved, you have to overcome a pointof pressure resistance and then thelever is automatically secured in theparking position).n Check position(it applies to some vehicle versionsonly)This position is designed to check if theparking brake system of the towingvehicle is capable to brake up the ve-hicle combination in a certain gradientin a safe manner. A function of theparking brake of the trailer brake isdisengaged after pushing the manualbrake lever and its displacing from theparking position rearwards into thecheck position; hereby the vehicle com-bination will be braked up by the par-king brake of the towing vehicle only(hold the lever in this position duringinspection). After releasing, the controllever will automatically return into theparking position.n Driving positionAfter releasing, gently raise the lockring of the manual brake lever andmove the lever forwards into a drivingposition.


60

Windshield washer & wipers

Replacement of wiper bladen Tilt the wiper arm.n Tilt the wiper blade horizontally.n Depress the plastic locking springand remove blade by pulling it fromlocation.n Installation is a reverse of removal.

Fluid containern The windshield washer container issituated in the front bumper.n The container capacity is 7.5 l.n The fluid can be added after openingthe front bonnet.n The respective indicator light* indi-cates the minimum fluid level.n Use water with glass washer sol-vent agent to add the fluid. In winterkeep the stipulated ratio not to allow thefluid will freeze up (follow instructionsmentioned on the antifreeze package).

Warning!n Do not use wipers to wipe dryglass - they may scratch it.n Do not use wipers when thereis a layer of snow on the windshi-eld - clean the glass first.n In the winter months, makesure first whether the wipers havenot frozen up to the glass.

FN0720FN0710

Wipersn For reasons of safety, keep the wiperblades in a perfect condition to assuregood visibility.n To assure good wiping, wash therubber blades with glass washing agentregularly.n On the wiper arm there are washerjets.n The jets can be adjusted with a ne-edle.n The whole wiper arm body c/w jetscan be moved freely along the arm.


61

Tyres and wheels

Wheels and wheels dataWheels of the front axle - 2 balancedonesWheels of the rear axle - 4 non-balancedonesSpare wheel - 1 balanced one

Disc wheel:D60-100: 17,5 x 6,00(6 wheel bolts M18)

D100-120: 17,5 x 6,75(8 wheel bolts M20) 19,5 x 6,75

Tyres (radial):D60-100: 215/75R 17,5(6 wheel bolts M18) 9,5R 17,5

225/75R 17,5

D100-120: 245/70R 17,5(8 wheel bolts M20)265/70R 17,5

245/70R 19,5265/70R 19,5

235/75R 17,5 (D110)ALLSTEELTUBELESS

n Check the tyre pressures always be-fore you drive the vehicle. Rememberalso to check the tyres if they are in agood condition (look for the tyre repairshop if they have been damaged).n Tyre inflation pressures are men-tioned on the plate inside the cabin andin table in Chapter Technical Data.n No cuts, bruises or other damagesshowing the tyre casing cord are al-lowed on tyre treads or sides.n In case of the uneven wear of tyretreads on front axles, check and/or ad-just the front axle wheels geometry.n The depth of tread grooves of tyresmust be 1.6 mm at least. If tyres treadsare marked REGROOVABLE, the tre-ads can be cut through to make themdeeper (only a specialist may performit).n Only balanced tyres may be mountedon front wheels and all wheels must bein a good technical condition.n Only tyres stated for the given type ofthe vehicle and recommended by thetyre manufacturer may be used on thevehicle.n Protect tyres against oils and fuel.

n If the vehicle is put out of operation fora long time, it should be slightly raisedto relieve the tyres.n The dismounted wheels (tyres)should be stored in a dry and dark place.n Check the tightening-up of wheel nutsat intervals stipulated in the ServiceBooklet.n In addition, check the tightening-upof nuts on wheel bolts after covering thefirst 50 ÷ 100 km and after every wheelremoval to the torque of:M18 (6 wheel bolts) - 370 ± 30 NmM20 (8 wheel bolts) - 485 ± 35 Nm

The service life of tyresdepends on:n way of driving and driving habitsn correct tyres inflationn vehicle operating conditionsn geometry of front axlen proper distribution of load on the loadspace


62

Transport of loads

During the load transport, it is neces-sary to abide by the below mentionedinstructions:n Do not exceed the maximum allowa-ble front axle load (see Chapter: Weightsand axle loads in the section Tech. Data).n Take care that the load is distributedcorrectly on the load space of the vehicle:- place the load to the centre of theload space- place the load evenly on the wholeload space- keep a correct distribution of the weight(1/3 to the front ax. and 2/3 to the rear ax.)

Loading the train combination -towing vehicle with trailern For combinations with central axlestrailer (trailer with fixed towbar) it isnecessary to consider for calculateingthe total load of the towing vehicle avertical statica load coming from thetrailer, developing load strain onto thecoupling point (up to 10% of the totaltrailer weight, max.1000kg). This addi-tional load surcharges the rear axleand simultaneously discharges thefront axle of the towing vehicle.

Warning!n The towing combination loadmust be equally distributed in sucha way, that the minimal front axleload is at least 30% of the totalaxle load of the towing vehicle andat the same time the maximalaxle loads on all axles are notexceeded.n For unloaded towing vehicle isallowed to tow only an unloadedcentral axle trailer with fixed tow-bar. This guideline is however notapplicable for standard trailer withsteering bogie.

OK OKOKOK

FN0721a


63

Electronic vehicle height adjustment (ECAS)*

n The pneumatic suspension allowsyou to adjust the height of the vehicle tailpart, suitable for coupling/discouplingthe trailer or for loading/unloading thevehicle at a ramp.n The height can be adjusted alsowhile driving, however maximally up to10 km/h speed.n If the vehicle height is outside thedriving position (level), the height willbe automatically corrected after exceed-ing the speed 15 km/h.

Operating guidelinesn System "switch on"By pushing the button the systembecomes active. Activated system isindicated by the control light over thebutton.n Adjustment of desired heightBy buttons or choosing theheight desired.n Memory utilisationNote: there are 2 memories for savingtwo different heights.To reach the height desired push thebutton "STOP" and simultaneously

push button or . Desired heightis saved in the selected Memory.

Then in case you operate the button

or , the height saved in the selectedmemory is automatically adjustedi. Dif-ferent height can be adjusted in thesame way.

FN0134_b

n Button utilisation

By pushing the button the opera-tion raising / lowering the pneumaticsuspension is immediately stopped.

By pushing the button while switch-ing off the ignition the "Stand by" func-tion is activated, which enables normalhandling of the pneumatic suspensionfor 60 seconds (this is limited by airpressure).

n In case of any danger the oper-ation can be stopped by pushingthe button .n Fix the rear axle to the vehicleframe when raising the wholevehicle in order to avoid so called"sagging" of the rear axle.If this instruction is not respect-ed, the damage on pneumaticsuspension bellows may be theconsequence.

Warning!


64

Draining the condensatefrom air tanks

n In all air tanks of the pneumatic sus-pension and pneumatic brakes a watercondensate accumulates, which hasto be drained after every journey.n When draining, a full operational airpressure must be in the system. Watercondensate must be drained by swing-ing the handling levers of drainingvalves placed at the bottom part of airtanks.

FN0655

n In winter season and humidweather the draining has to bedone several times a day..n If the draining is not done regu-larly, as a consequence the vehi-cle safety can be compromisedand instruments can be damaged;for such cases warranty is notapplicable.

Warning!


65

n Secure the trailer rear wheels withchocks.n The front trailer axle must remain ste-ering.n Adjust the trailer draw bar into aheight of the trailer hitch.n When engaging the reverse speed,make sure that nobody is standingbetween the trailer and vehicle.n Make sure that the trailer is coupledcorrectly.n Attach the brake hoses coupling he-ads and plug connectors of electric con-ductors.n Check the brake system and lightsfor a correct function.n Proceed very carefully when towinga trailer and do not exceed the allo-wable load limits.n When stopping during uphill or down-hill driving, check the manual brake fora good efficiency. It must hold the wholevehicle combination in a gradient onthe spot.

Basic rules for the trailer coupling

Warning!The pieces of information men-tioned in this chapter are the basicones only. You should abide mainlyby the instructions given in the Op-eration Manual for the connectedvehicle.


66


67

n Clamps of all electrical consumersof the vehicle must be connected cor-rectly and their polarity must not bemutually exchanged.n Always charge the batteries outsidethe vehicle.n With the engine running, do not switchoff the battery circuit breaker and do notdisconnect battery terminals.n During handling the vehicle whenshort-circuit could occur, remember toswitch off the battery circuit breaker.n When you wash the vehicle, protectstarter, alternator, glowing regulatorand battery case against water to avoidshort-circuit.n For reasons of safety, during vehiclestandstill (when parking in garage, etc.),when leaving the vehicle or when youfind out any fault in the electrical equip-ment, switch the battery off.n When the fire could occur, use thebattery circuit breaker to disconnect theelectrical equipment.

n When the engine is not running,the battery is discharged by use ofelectrical consumers.n Interdiction of electric arc weld-ing outside the dealer service net-work. In case of breach of thisinterdiction damages on vehicleelectrical components wil be theconsequence.

Warning!

Electrical equipment


68

Location of battery

drivi

ng

direc

tion

1 Plastic cover2 Holder clip3 Rubber holder4 Profiled battery holder5 Battery holder screw6 Central ground point

1

2

6

35

4

FN0731cu


69

n Instructions for the operation andmaintenance are a part of the batterywarranty card delivered with the vehic-le.n Check the battery condition, electro-lyte level and tightening-up of the groundscrew (item 7 on the previous page)every six months.n When disconnecting the battery ter-minals, be sure to disconnect first thenegative ("–") terminal. Proceed withcare during removal of battery termi-nals not to cause short-circuit between"+" battery terminal and vehicle ground.After cleaning and careful connectionof terminals connect the positive termi-nal ("+") to the battery circuit breakeragain.n Replace the discharged battery witha battery of the same capacity, voltage,ampere load and size.

n Charge up the battery alwaysoutside the vehicle.n The used battery must bedisposed of with regard to environ-mental regulations.

Warning!

Battery circuit breaker

Alternator

With the engine running the alter-nator terminals must not be dis-connected and the battery circuitbreaker must not be switched off -the alternator must not run withoutload.

Warning!

Battery

Acircuit breaker on / Bcircuit breaker off

Warning!n Turn off the battery master switchonly 30 seconds after turning off theignition to allow data processing byECM (Eng. Cont. Mod.) and to allowair to blow through the AdBlue injec-tion sys. into the exhaust system(noise from the area of AdBlue tankmay be heard). If the instruction asabove is not followed a fault may bereported by warning lamps or theSCR sys. and/or damage of the SCRsys. may be caused due to insuffi-cient removal of AdBlue residues(possible crystallization or freez-ing) and thus causing blockage of it.

A

BFN0741

Never shut the engine off by thebattery circuit breaker - this coulddamage the electrical equipmentand alternator.

Warning!


70

14 3

Headlamps and lights - location

1 Front headlamps2 Front auxiliary side marker lamps3 Front fog lamps4 Turn signals5 Stop lights6 Rear side marker lights7 Reverse lights8 Tail fog lamps9 License plate light10 Side positioning lamps11 Side turn signals(If the vehicle is fitted with a superstructure2,550mm wide, mount the side marker lampsof the superstructure manufacturer.)

10

2

10

54 6 97 8

11 FN0750


71

Cleaning agentsn As far as the cleaning agents orother chemical vehicle-care productsare concerned, you should follow themanufacturer´s directions when usingthem both for the vehicle interior orexterior.n The non-suitable cleaning agentsmay impair the value of vehicle compo-nents.n You should not use the volatileagents (acetone, diluents, gasoline),cleaning agents (wash powders) andbleaching or other aggressive agentsexcept for those recommended to re-move spots from clothes.n Take care that the ventilation is enou-gh when working in interior (vapours ofsome agents are harmful to health).

Vehicle care

Care of the vehicle interiorIt is important to use correct cleaningagents and procedures (see instruc-tions mentioned on cleaning agents).When not observing these instructi-ons, hard removable spots may stay oninterior materials after cleaning.

Plastic partsn Use wet rag to clean the plastic parts.n After a rough cleaning by wet rag, youcan apply the agents recommended.

Seat beltsClean them with a soap water solution.

Warning!In case that the vehicle is fittedwith a superstructure and the tail-gate covers the rear cluster lampsin a tilted condition, the driver isobliged to place a warning trianglebehind the vehicle under dec-rea-sed visibility with the tailgate tiltedand standing on a road. The spe-cial label inside the cabin beingvisible from the driver´s place re-minds you of this obligation.

Warning!n The seat belts should be keptclean - dirt would affect the functi-on of retractor.n Before winding, the seat beltsmust be perfectly dry.n The seat belts must not be cle-aned chemically.


72

Warning!Do not apply polishing and waxingagents to plastic parts.

Warning!Keep environmental regulationswhen washing the vehicle.

Doors and windows sealsApply rubber preserving agents to sealsof doors and windows from time to timeto increase their life.

Windowsn Use window cleaning agents.n Use a plastic scraper to removesnow in winter.

Care of the vehicle exteriorn Frequent washing and preservingare a good protection of the vehicleagainst negative influences of the en-vironment.n Regular care will contribute to main-tain the value of your vehicle.n It is important to use correct clea-ning agents and procedures (see in-structions mentioned on packages ofcleaning agents). When not observingthese instructions, hard removablespots may stay on exterior surfacematerials after cleaning.

Washing the vehiclen The best way how to maintain thepaint in a good condition is to wash itvery often.n Use the lukewarm or cold water towash the vehicle.n Do not use hot water or do not washthe vehicle in direct sunlight.n First use plenty of water to wash offthe dirt thoroughly.n After washing off the dirt, use a softsponge to clean the body from the roofdown using water and car-wash sham-poo in ratio as mentioned on the pac-king. It is necessary to rinse the spongeoften during washing.n Use plenty of water to rinse the ve-hicle off after washing (do not allow theagents to dry on the body paint) and dryit out with a chamois.

Waxing and polishingn When waxing and polishing the ve-hicle regularly, you will obtain a goodshine and easier maintenance duringthe next washing.n Apply wax to a clean and dry body.

Damage to the body paintCorrect each damage to paint promptlynot to allow a rapid corrosion of the baremetal. Entrust the work to a specializedworkshop.

73

T R O U B L E S H O O T I N G

Engine

1. Starter does not crank the engine orcranks slowly

A) Fault: Battery circuit breaker is offRemedy: Switch the battery circuit breaker on

B) Fault: Engaged gearRemedy: Move the gearshift lever to the neutral position.

C) Fault: Blown fuseRemedy: Replace the fuse. If the new fuse blows immediatelyagain, have the vehicle checked at the authorized service station

D) Fault: Charged batteryRemedy: Charge the battery according to instructionsmentioned in the battery warranty card delivered with thevehicle

E) Fault: Faulty electric wiringRemedy:- Check and clean battery outlets and terminals- Check and/or clean connections from battery to engine- Check the cables connection of starter and/or tighten

F) Fault: Faulty neutral switchRemedy: Contact and have it repaired at the auth. serv. station

G) Fault: Faulty starterRemedy: Contact and have it repaired at an authorized servicestation

2. Starter cranks the engine but theengine cannot be started

A) Fault: No fuel in tankRemedy: Fill the fuel and bleed the fuel system

B) Fault: Crystallised paraffin has clogged the fuel filterRemedy: If possible, put vehicle into warmer environmentand contact next authorised workshop.

3. Engine starts but will not keep running

A) Fault: Too low idle run speedRemedy: Contact and have it repaired at an authorizedservice station

B) Fault: Faulty fuel inletRemedy: Contact and have it repaired at an authorizedservice station

C) Fault: Clogged fuel filter cartridgeRemedy: Contact and have it repaired at an authorizedservice station

D) Fault: Air penetrates into the fuel systemRemedy: Contact and have it repaired at an authorizedservice station

74


Engine

4. Engine will not reach the rated output

A) Fault: Fuel filter has been clogged with dirtRemedy: Contact and have it repaired at an authorizedservice station

B) Fault: Wrong function of injection systemRemedy: Contact and have it repaired at an authorizedservice station

C) Fault: AdBlue tank emptyRemedy: AdBlue tank re-filling

D) Fault: SCR system malfunctionRemedy: In Authorised workshop

5. Engine is knocking

Remedy: Contact and have it repaired at an authorizedservice station

6. Engine smokes excessively

A) Fault: Faulty or wrong adjusted injection unit orfuel injectorsRemedy: Contact and have it repaired at an authorizedservice station

B) Fault: Faulty turbochargerRemedy: Contact and have it repaired at an authorizedservice station

7. Engine overheats

A) Fault: Insufficient coolant levelRemedy: Check the cooling circuit for leaks, repair thefault and add the fluid

B) Fault: Insufficient function of coolerRemedy: Clean the cooler surface

C) Fault: Faulty thermostatRemedy: Contact and have it repaired at an authorizedservice station

D) Fault: Faulty function of the fan visco-couplingRemedy: Contact and have it repaired at an authorizedservice stationCAUTION:If the cooling indicator light comes on, it is necessary tostop the vehicle as soon as possible and to cool down theengine by enhanced engine speed (1,200 ÷ 1,500 rpm).In any case do not shut the engine off after the coolingindicator light comes on.

75


8. "Engine - stop" indicator light ON

Fault: Serious engine defect (probably coolanttemperature, charge air temperature or oil pressure,eventually others)Remedy: Stop the vehicle and shut the engine off.Check engine oil and cooland level. If the level is toolowk, top up the level, re-start the engine and let itrunning at idle revs for 30 seconds. If the warning lightdoesn´t go off, it is necessary to effect diagnostic test(for diagnostics procedure consult next page of theManual). It is recommendable to note the lighted faultcodes and then it is necessary to contact nextAuthorised workshop. Further drive is strictly forbidden.

9. Indicator light "engine-warning" is ON

Fault: Fault in the engine system or in the enginecomponent and/or drop of the AdBlue fluid volume in thetank. If the AdBlue level drops the control light "engine-warning“ gets ON and at the same time also the diodeindicating level „0“ on the AdBlue level depiction.Remedy: Add the AdBlue fluid to tank. If the indicatorlight still remains ON, you can continue to operate thevehicle, but when you reach ther nearest servicestation, have the fault repaired.

Engine

10. Indicator light "engine - warning" flashes

Fault: If the indicator light flashes for about 30seconds when the ignition is in the position "ON". Itreminds you of carrying our the necessary servicejob (e.g. the engine oil change) or it indicates thepresence of water in fuel.Remedy: Drain the fuel filter according to Chapter"Draining the fuel filter".If the indicator light is still ON, it is necessary to contactthe authorized service station.Note: After the oil has been changed do not forget tostore this action into the engine ECM - have it carriedout by the authorized repair shop.

11. Indicator light " SCR system malfunction" is ON

Fault: The tank of AdBlue is emptyRemedy: The vehicle may be still operated, but whenyou reach ther nearest service station, have the faultrepaired.

76


Which of two indicator lamps ison determines the kind of defect(three- to four-digit fault code).

How to start the diagnostic test:1) The ignition key must be inposition "ON" (item 1).2) Depress three times the ac-celerator pedal and release it(item 2) -3) The orange indicator light"engine - warning" will beginlighting and when it goes out,the red indicator light "engine -stop" will start blinking to show

12. Indicator light "SCR system malfunction" flashes

Fault: EmptyAdBlue tankRemedy: Top up the AdBlue liquid in the tank.

13. Diagnostic test

Fault: The indicator lights"engine - stop" "engine - warning" are ON

the fault code.The fault code blinking repeatsitself continuously. It is neces-sary to put down the fault codenumber.On termination of the diagnostictest, move the ignition key (item4) to position "ACC" and wait 30seconds.

FN0751

1

FN0757

4

FN0754r

3

2

FN0752r

77


Engine

it comes on

it goes out

it goes out

Example of fault codesP=pause Fault code 115:

1 it lights

1x blinks 1 x blinks 5 x blinks

P P P P

Fault code 244:

1 it lights

2x blinks 4x blinks 4x blinks

P P P P

FN075 8

The indicator light "engine-stop" displays the fault codenumber. The example of fault code determination is illustrated.

- after the orange indicator light "engine-warning" goes out-1x the red light blinks-pause 1-2 s-1x the red light blinks-pause 1-2 s-5x the red light blinks-pause 1-2 s- the orange light come on again (end of fault code lighting)fault code = 115

it comes on

Electrical equipment

1. The battery charging indicator light ison

A) Fault: Fault in the charging circuitRemedy: First check whether all cables of alternator,accumulator batteries and battery circuit breaker aretightened thoroughly and/or connected to respectiveterminals. Check also whether connections includingthe battery ground cable have not been corroded. If allthe above have been checked and found correct it isnecessary to go to an authorised repair shop.

2. The battery charging indicator lightdoes not come ON when the ignition is ON


78


Monoblock hydraulic power steering

1. Oil leaks from the hydraulic circuit

Fault: Leaky connectionsRemedy: Tighten the loose connections, check the oillevel and/or add the oil and visit the authorized servicestation

2. Faults of individual instruments


Brakes

1. Indicator light - Brake system malfunction - is ON

Fault: Low pressure in the 1st or 2nd circuit ofservice brake.Remedy: If even after several minutes of engine runningthe operating air pressure in the system is not reached,release the spring brake cylinders (see Chapter Parkingbrake) and have the vehicle towed to the nearest repairshop

2. Indicator light - Brake pads wear - is ON

Fault: The brake pads wear exceeded the allowablelimit.Remedy: the vehicle must be brought to an authorisedrepair shop to have the brake pads replaced

79


3. The parking brake has been blocked,the air pressure gauge of brake systemindicates the pressure below the mini-mum value, the vehicle cannot be put inmotion

Remedy: If even after several minutes of engine running theoperating air pressure in the system is not reached, releasethe spring brake cylinders (see Chapter Parking brake) andhave the vehicle towed to the nearest repair shop.

4. The ABS indicator light is on

Remedy: The equipment is not OK, the vehicle is brakedwithout ABS function. Only the normal brake system isfunctioning on the vehicle. In that case it is promptlynecessary to visit the authorized service station. Adapt thedriving to the situation.

5. The ASR indicator light is on

Remedy: The equipment is not OK, the ASR system is notworking. It is necessary to visit the authorized servicestation.Note: When the ASR system is out of function, the commonvehicle operation is not influenced.

6. Warning lamp is flashing "Airsuspension system failure*/red warning lamp/

Repair: The pneumatic suspension system is out oforder.If the situation allows that, it is possible to drive to thenearest authorised workshop. The driver however has todrive with maximum precaution with regard to existingcircumstances so that the road circulation safety or hisown personal sefaty are not endangered.If the vehicle height is below the driving height (level),continuation of the journey is inadmissible and Assistanceservice has to be called in.

80


Towing

FN0770FN0760

There is a special hook welded to the leftbracket on the rear bumper to hold arope in case of recovery.

n With the engine off, the powersteering and brake booster are outof function.n Use only the tow bar to tow thevehicle; other connection is notpermitted.

Warning!

Disconnecting the propellershaftn Secure the vehicle against motion.n Dismount bolts fixing the propellershaft to the axle final drive housingflange.n Attach the propeller shaft to the vehi-cle frame in a suitable manner.n After the vehicle towing and repairhave been accomplished, remount thepropeller shaft to the axle final drivehousing flange again; tighten the self-locking nuts to Mk = 60±10 Nm.

n Use the pin to attach the towing barin the middle part of the front bumper.n When towing the vehicle with theengine at standstill and no gear speedshifted in gearbox, disconnect the pro-peller shaft not to damage the gearboxdue to insufficient lubrication and rele-ase the spring-loaded cylinder in ac-cordance with Chapter "Parking bra-ke".n The ratio of the towed and towingvehicles weights must be 1.4:1 at least.

Vehicle recovery

81


Spare wheel holder (L, E, S, G)

n Raise the wheel while holding thetire (Fig. B) in point 1 and with the wheellifted, push in point 2 towards the centreof the vehicle (the wheel will swing - seeFig.C - danger of injury).n Remove the wheel from holder.

Installation of spare wheeln Use the assembling bar for the cabinlifting to raise the wheel so that itremains hanging in grooves of frontholder brackets (Fig.D).n Swing the wheel into the horizontalposition towards you so that it rests onthe contact surface of the rear bracketand simultaneously on contact surfa-ces of front brackets ahead of stoplugs.n Tighten the thrust plate from belowby two nuts and secure with the wire clipat one of two bolts.

Removal of spare wheeln Dismount the spring split pin andtwo nuts to loosen the thrust plate(Fig. A).

Wheel chock (L, E, S, G)

Warning!Proceed with extreme care withregard to the wheel weight.

FN0790

A

DC

B

211

FN0780

It is fitted above the holder of the sparewheel.

82


Spare wheel holder (K, N)

Removal of spare wheeln Dismount bolt 1 c/w nut 2 and nut 3on the LH and RH side of the sparewheel hanger.n Put the handle out of the vehicleequipment onto a winch 4 and turn thehandle to lower the spare wheel c/whanger on ground.n Dismount four bolts c/w nuts 5 andremove the wheel from hanger.

Wheel chock (K, N)

5

Warning!Proceed with extreme care withregard to the wheel weight.

FN0820FN0801

4

Installation of spare wheeln During installation first attach thespare wheel by four bolts c/w nuts to thehanger, use the winch to attract thehanger c/w spare wheel to the frameand secure the hanger with bolt 1 c/wnut 2 and nut 3 on each side.

FN0800a

1 3

2

It is fitted on the rear bumper.

83


84


Changing the wheel

FN0830n

n When changing a wheel, the vehiclemust stand on level ground if possible.n Secure the vehicle with the wheelchock and set the parking brake.n Remove the spare wheel from hol-der.n Loosen the wheel nuts by a lug wrench(from the vehicle equipment) by 1/2 turn.n Location of jack:- on the front axle, place the jack with itshead into a hole in the metal sheetguide situated under the leaf springahead of the axle (see the figure).- on the rear axle, place the jack with itshead into a recess of the clampingplate of the leaf spring shackle.

n Raise the wheel by several centimet-res above the ground by moving the lever(with the valve closed).n Unscrew the wheel nuts, remove thewheel and fit the spare wheel in place.n The contact surfaces of disc andwheel hub must be clean.n Tighten the wheel nuts partially andevenly.

FN0840n

Front axle

Rear axle

Warning!The jack must stand firmly on thefirm subgrade.

Warning!With the vehicle lifted, never startthe engine.

n Open the jack valve slowly and care-fully lower the vehicle on ground.n Tighten the wheel nuts completelyto:M18 (6 wheel bolts) - 370 ± 30 NmM20 (8 wheel bolts) - 485 ± 35 Nmn Check tightness of wheel nuts aftercovering 50 ÷ 100 km.

Warning!Operating and transporting posi-tions are shown on stickers placeddirectly on the jack.

85


Replacing bulbs

n Prior to the bulb replacement, switchoff the respective light.n Replace the defective bulbs withbulbs of the same parametres (desig-nation and parametres are mentionedon the bulb).n Do not touch the halogen bulb glasswith bare fingers - it would loose itsefficiency after switching on.

Main headlampn Tilt the cabin to replace the bulb.n Slightly turn the cover plastic lid ofthe headlamp counterclockwise andremove.

Warning!n Only the authorized service sta-tion may adjust the main head-lamps.n A new bulb must correspond tothe specified bulb by its type andoutput.

FN0850

86


FN0870

Front side marker lightsn Remove the socket out of theheadlamp.n Take the bulb out of socket.n Insert a new bulb and proceed in areverse manner.

FN0880

Front part H4 24 V 70/75 W 2 headlamp - low and high beam

24 V 5 W 2 side marker light

Low and high beamn Unplug the connector (item 1)from the bulb.n Unhook and fold the flexible wireholder (item 2).

n Remove the faulty bulb and fit a newbulb - lugs (item 3) on the bulb basemust engage into recesses of theheadlamp.n Installation is reverse of removal.

3

FN08601

2

87


FN0890 FN0900

Front 24 V 21 W 2 turn signals

part 24 V 5 W 2 auxiliary side positioning lights

Front turn signalsn To make a faulty bulb better acces-sible, open the cabin door.n Turn the plastic socket of the bulbcounterclockwise and pull it out of thelight housing.n Push the faulty bulb into socket, twistcounterclockwise and remove.n Fit a new bulb, push it and turn clock-wise.n Install the bulb socket into a lighthousing and turn clockwise as far as itgoes.

Front auxiliary side positioninglightsn Use a screwdriver to remove coverfrom the light housing.n Push the faulty bulb into socket, twistcounterclockwise and remove.n Fit a new bulb, push it and turnclockwise.n Install cover and push it in place.

88


Front H3 24 V 70 W 2 fog lampspart

Front fog lampsn Unscrew plastic clips (item 1) fromthe fog lamp housing.n Remove the housing.n Bend the ground connectorperpendicularly (item 2).n Disconnect the cable (item 3) bypulling it out.n Unhook and fold the flexible wireholder (item 4).n Remove the defective bulb and inserta new one (slots on the bulb socketmust engage into lugs in the fog lamphousing).n To reinstall, reverse the aboveprocedure (do not forget to bend theground connector back into the initialposition).n The designation TOP must bedirected up.n Have the headlamps adjusted at theauthorized service station.

2

31

4

FN0910

89


Rear 24 V 10 W 2 red side marker lightpart 24 V 21 W 2 red stop light

24 V 21 W 2 orange turn signal24 V 21 W 2 red fog lamp

24 V 21 W 2 white reverse light24 V 10 W 2 license plate lights

FN0920

n Fit a new bulb, push it and turnclockwise.n Install and screw the cover. Tightenthe cover carefully as this may crack.

Rear cluster lampsn Unscrew the lamp cover.n Push the defective bulb into socket,twist counterclockwise and remove.

License plate lightn Unscrew the lamp cover.n Push the defective bulb into socket,twist counterclockwise and remove.n Fit a new bulb, push it and turnclockwise.n Install and screw the cover. Tightenthe cover carefully as this may crack.

FN0921

90


FN0950

Side turn signalsn Unscrew the lamp.n Push the faulty bulb into socket, twistcounterclockwise and remove.n Fit a new bulb, push it and turnclockwise.n Install the lamp spring clip in thefront part and screw. Tighten it carefullyas this may crack.

FN0940

Interior 24 V 12 W 3 dome light

Side 24 V 21 W 2 side turn signals

part 24 V 4 W 6 side positioning lights

Side positioning lightsn Unscrew the light cover.n Push the defective bulb into socket,twist counterclockwise and remove.n Fit a new bulb, push it and turnclockwise.n Install and screw the cover. Tightenthe cover carefully as this may crack.

FN0930

Dome lightn Use a small screwdriver to pull coverout of the light housing (you can see twoslots to insert the screwdriver in thecover).n Push the faulty bulb into socket, twistcounterclockwise and remove.n Fit a new bulb, push it and turnclockwise.n Carefully install cover and push it inplace.

91


Fuses

F1 10A speedometer, tachograph, clockF2 10A brake lamps, instrument clusterF3 10A indicator lightsF4 10A reverse lampsF5 10A cab and cont lamps*F6 10A hornF7 10A wipersF8 25A controlled and heated mirrorsF9 25A blower engineF10 25A air condition*F11 25A power windows*F12 10A differential lock, PTO, clock displayF13 20A plug EURO 24F14 not usedF15 not usedF16 not usedF17 not usedF18 not usedF19 10A central door locking*, cigarette lighterF20 10A engine control unit-tell taleF21 25A converter 24V/12VF22 10A instrument cluster, speedometer, tachographF23 10A radioF24 10A plug EURO 12VF25 10A LH position lamps, RH outl. lamps,

instrument cluster illumination

F26 10A RH pos. lamps, LH outl. lamps,switches illumination

F27 10A LH low beamF28 10A RH low beam RH, headlamp level motorF29 10A LH high beamF30 10A RH high beamF31 10A LH front fog lamp*F32 10A RH front fog lamp*F33 10A rear fog lampF34 10A engine starterF35 15A fuel heatingF36 10A air heatingF37 30A engine control unitF38 20A SCR doser pumpF39 5A engine control unit (ECM)F40 5A SCR doser pumpF41 10A ABS control unitF42 10A ABS control unitF43 10A ABS control unit - towed vehicleF44 10A ABS control unit - towed vehicleF45 25A power for towed vehicleF46 10A turn signal trailerF47 20A sensor NOxF48 5A airsuspension - control unit

Fuse box

92


Replacing a fusen Switch off the battery circuit breakerduring the fuse replacement.n The fuse box is situated under the glovebox in the instrument board.n Fuses are accessible after removal ofthe glove box bottom which wil be releasedby turning two rotary holders (sense ofturning is illustrated on the cover).n The individual electric circuits are secu-red by fuses.n The blown fuse can be recognized by the

burnt metal strip.n It is necessary to keep spare fuses onhand in vehicle.

FN0972_E5_rhd

Warning!n A new fuse must have the sameampere value.n Values and markings indicated onthe sticker, fixed on the floor side ofthe glove box bottom take priorityover the information on this and fol-lowing page.

Relays

R01 side lightR02 low beamR03 high beamR04 intermittent wiperR05 rear fog lampsR06 front fog relay*R07 break lightR08 stop lamp monitorR09 turn signalR10 hazard relayR11 turn signal trailerR12 not usedR13 power windows 1*R14 power windows 2*R15 power windows 3*R16 power windows 4*R17 relay IGN 1R18 heated mirrorR19 front axle moduleR20 rear axle moduleR21 brake lin light relayR22 relay IGN 2R23 clutchR24 cruise controlR25 relay "start"R26 relay "lockout"R27 ground relayR28 heated fuel relayR29 exhaust brake relayR30 PTO relayR31 wiper activate 1R32 wiper activate 2R33 aircondition* relay

93


Warning!n Replace the blown fuse with afuse of the same ampere value. Donot use a fuse of higher amperagebecause this could cause damagethe electrical part or even cause afire.n If the fuse blows repeatedly afterswitching on the respective elect-rical consumer, it is necessary tocontact and have the vehicle repai-red at the authorized service stati-on.n Never repair the blown fuses.n Do not use a screwdriver or othermetal object to remove the fuse.

n The vehicle with a discharged batterymay be started only by connecting it tothe battery of some other vehicle withthe same nominal voltage.

n Only approved jumper cables ofsufficient cross section may be used.n Do not use cables with insulatedclamps only.

Warning!The battery of the other vehicle musthave the nominal voltage of 24V.

n When starting, the engine of thevehicle, whose battery is used to start,must run.

Connecting procedure1. Connect one clamp of "+" cable (item 1) to positive terminal of the frontdischarged battery (item 3).2. Connect clamp on opposite end ofthe same cable to positive terminal of24V booster battery (item 5).3. Connect clamp of "-" cable (item 2) tonegative terminal of 24V booster battery(item 5).

Use of jumper cables to start the engine

FN0991

4

3

2

24V

5

1

94


4. Firmly connect clamp on oppositeend of the same cable to "-" terminal ofthe rear discharged battery (item 4).5. The engine of the vehicle, whosebattery is used to start the other vehicle,must run all the time.

Starting the enginen Start the engine in accordance withChapter Starting the engine.n After the engine starts to run, removejumper cables in reverse order.

n When using the jumper cablesto start the vehicle, the auto radiomust be turned off because thismay be damaged.n Non-insulated parts of cableclamps must not touch each other.The jumper cable connected to thepositive terminal of the battery mustnot come in contact with the vehic-le ground because this could leadto short circuit.

Warning!

95

T E C H N I C A L D A T A

Engine

n Diesel n turbocharged nwith charge-air n OHV, four-stroke n four-cylinder, n waterwith direct injection by one turbocharger cooling in-line cooled

Engine type designation CUMMINS

Type ISBe4.5E5 160 ISBe4.5E5 185 ISBe4.5E5 207 Number of cylinders / valves 4/16 4/16 4/16 Cylinders bore 107 mm 107 mm 107 mm Pistons stroke 124 mm 124 mm 124 mm Displacement 4500 cm3 4500 cm3 4500 cm3 Compression ratio 17,3:1 17,3:1 17,3:1 Maximum performance 118 kW/2500 min-1 136 kW/2500 min-1 152 kW/2300 min-1 Maximum torque 600 Nm/1600 min-1 700 Nm/1600 min-1 760 Nm/1600 min-1 Injection system Common Rail Bosch, electronic control unit

96


Propeller shaftn the version "K" has the one-shaftarrangement with two universal jointsn versions N, L, E with two-shaft arran-gement and three cross-shaped jointswith one intermediate bearing and sli-ding splined adaptorn versions S,G with three-shaft arran-gement and four cross-shaped jointswith two intermediate bearings andsliding splined adaptor

Rear axlen driving, banjo-type rigid axlen axle final drive with single hypoidgearing and bevel differentialn mechanical differential lockn parabolic spring suspension withstabilizer bar /non-existent in the versi-on with pneumatic suspension/, orpneumatic suspension.n fluid shock absorbers with lower stopn rubber upper stop for the versionwith pneumatic suspension in the bel-low.

Engine cooling systemn fluidn overpressure type with the forcedcoolant circulation by means of thecentrifugal pumpn cooling circuit is fitted with two-flapthermostat and expansion tank

Air filterdry filter cartridge

Clutchn dryn one-discn with asbestos-free liningn with mesh dampern hydraulically controlled, with air boos-ter

Gearboxn mechanicaln with layshaft gearn with gears in constant meshn synchronizedn gearshift lever control on floorn gearbox allows to mount the powertake-off drive with pump, outlet shaft orflange

Undercarriage

n hypoid gears:D75 - D100: 3.73; 4.1; 4.56D120: 3.73; 4.1; 4.56; 5.13

Front axlen rigid, with forged axle casingn parabolic spring suspension withstabilizer bar, liquid shock absorberswith lower stop

97


Steeringn monoblock hydraulic power steeringn gear ratio from 14 to 16.6 - change-able during turning the steering wheelbetween full locksn split steering shaft c/w longitudinallysplined cardan joints

Framen ladder-typen cold rivetedn screwedn brackets or clips to attach chassisgroups or components are riveted orscrewed to the framen holes for brackets ready to attachsuperstructures or directly rivetedbrackets on frame longitudinal beamsn towing hook for the vehicle recoverysituated on the rear bumper bracket

Parking brake systemn parking braking secured by spring-loaded braken controlled by the manual brake valvesituated near to driver behind the gear-shift levern the air pressure drop in the chamberof spring-loaded cylinders to the value,at which the spring-loaded brake isactivated, is indicated to a driver by therespective indicator light.

Service brake systemn dual circuitn pneumaticn with brake pressure control of therear axle wheels (adjusted values ofthe load sensing valve are stated on theplate placed on the front door frame)n TT system of brake circuits connec-tionn Anti-blocking Brake System (ABS)as standard

Brake systemn disc brakes with rigid yoke on bothaxlesn the brake system completed withthe parking brake equipment on therear axlen two pressure gauges on the instru-ment board indicate the air pressuresin the brake system

Emergency brakethe emergency braking is secured byone non-defective brake circuit

98


Dimensions of chassis c/w cabin

FN1002c

A B C D E F Version D60-120 D60-90 D100 D110-120 D60-90 D100 D110-120 D60-90 D100 D110-120 D60-90 D100 D110-120 D60-90 D100 D110-120 Axle base ( mm )

K 2950 1415 - - 5590 - 2280 1849 1736

N 3400 1415 1415 1365 6040 6040 5990 2730 2730 2730 1849 1849 1845 1736 1736 1740

L 3900 1670 1670 1620 6795 6795 6745 3230 3230 3230 1849 1849 1845 1736 1736 1740

E 4500 2070 2070 2020 7795 7795 7745 3830 3830 3830 1849 1849 1845 1736 1736 1740

S 5100 2470 2470 2420 8795 8795 8745 4430 4430 4430 1849 1849 1845 1736 1736 1740

G 5600 - - 2520 - 9345 4930 1845 1740

The tolerance + 1 %, holds for dimensions If not stated otherwise.

99


Weights and axle loads

Vehicle type D 60/65/70/75/80/85/90/100/110/120 Vehicle version K N L E S G kg

Curb weight chassis + cabin

D60-75 3325 3374 3423 3472 3521 - D80 3340 3389 3438 3487 3536 - D85-90 3393 3442 3491 3540 3589 - D100 - 3462 3511 3560 3609 - D110-120 - 3585 3635 3685 3735 3794

Portion of the chassis c/w cab service weight to front axle

D60-75 2168 2206 2247 2287 2327 - D80 2183 2221 2262 2302 2342 - D85-90 2183 2221 2262 2302 2342 - D100 - 2231 2272 2312 2352 - D110-120 - 2305 2344 2386 2426 2465

Portion of the chassis c/w cab service weight to rear axle

D60-75 1157 1168 1176 1185 1194 - D80 1157 1168 1176 1185 1194 - D85-90 1210 1221 1229 1238 1247 - D100 - 1231 1239 1248 1257 - D110-120 - 1280 1291 1299 1309 1329

Carrying capacity of chassis + cabin (c/w crew)

D60-75 2665-4165

2616- 4116

2567- 4067

2518-4018

2469-3969 -

D80 4650 4601 4552 4503 4454 -

D85-90 5097-5607

5048-5558

4999-5509

4950-5460

4901-5411 -

D100 - 6528 6479 6430 6381 -

D110-120 - 7405-8405

7355-8355

7305-8305

7255-8255

7196-8196

The table is continued on the next page

100


Weights and axle loads

Vehicle type D 60/65/70 /75 /80 /85/90/100/110/120 Vehicle version K N L E S G kg

Max.vehicle overall weight1

D60 5990 D65 6490 D70 6990 D75 7490 D80 7990 D85 8490 D90 9000 D100 9990 D110 10990 D120 11990

The maximum allowable front axle load

D60-90 3400 D100 3500 D110 4000 D120 4200

The maximum allowable rear axle load

D60 4100 D65 4450 D70 4800 D75-80 5200 D85 5800 D90 6200 D100 6600 D110 7400 D120 8200

The table is continued on the next page

101


Weights and axle loads - permitted trailer weightsWheel turning diameters

Non-brake trailer

Trailer with interia

brake

Brake trailer w

ith steering bogie C

entral axle trailer w

ith lowered

drawbar

Central axle trailer

with trailer

coupling fixed at fram

e rear end cross-m

ember

version / type K N; L; E; S G K N; L; E; S; G G K N; L; E; S; G G K; N; L E; S G K N; L E; S G

D60

750

750

3500

3500

6000 6000

6000

6000 6000 6000

D75 4500 4500 4500 4500 4500 4500

D80 6000 6000 6000 6000 6000 4500

D85 5500 5500 5500 5500 5500 4500

D90 9000 9000 7000 6000 6000 4500 D100

8000 7000

6500 6500 5500

D110 750 3500 10000 10000 10000 10000 6500 6500 D120

The individual maximum permitted loads must not be exceeded!; The tolerance ± 3 % holds for the weight data; Maximum distance from the king pin to the rear axle must be maximum 1550 mm!; Instantaneous front axle load must be 30% at minimum of the instantaneous vehicle weight.; Weights of vehicle combination are subject to instructions in the Bodybuilder Manual D60/D120. Contact your dealer for more instructions.

V eh ic le vers io n Turn ing d iam ete r e xterna l w he el (m m ) E xtern al w all-to-w all turn ing d ia m eter (m m ) K 104 10 +5 00 1 179 0 + 50 0 N 116 40 +5 00 1 308 0 + 50 0 L 141 50 +5 00 1 454 0 + 50 0 E 147 60 +5 00 1 613 0 + 50 0 S 165 70 +5 00 1 799 0 + 50 0 G 178 50 +5 00 1 926 0 + 50 0

102


Tyres inflation pressures

2 05/7 5 R 17 ,5 fron t / rea r / sp a re w hee l

typ e / vers ion K N L E S G D 60/ 75 750 / 55 0 / 5 50 750 / 5 50 / 550 75 0 / 550 / 550 7 50 / 550 / 55 0 750 / 55 0 / 5 50


typ e / vers ion K N L E S G D 60/ 75 550 / 50 0 / 7 00 600 / 5 00 / 700 60 0 / 500 / 700 6 00 / 500 / 700 600 / 50 0 / 7 00 D 80/ 90 700 / 70 0 / 7 00 700 / 6 70 / 700 70 0 /6 70 / 700 7 00 / 670 / 70 0 700 / 67 0 / 7 00


typ e / vers ion K N L E S G D 60/ 75 600 / 50 0 / 7 00 600 / 5 00 / 700 60 0 / 500 / 700 6 00 / 500 / 70 0 600 / 50 0 / 7 00 D 80/ 90 680 / 65 0 / 7 00 680 / 6 50 / 700 68 0 / 650 / 700 6 80 / 650 / 70 0 680 / 65 0 / 7 00 D 10 0 680 / 70 0 / 7 00 680 / 7 00 / 700 68 0 / 700 / 700 6 80 / 700 / 70 0 680 / 70 0 / 7 00


typ e / vers ion K N L E S G D 11 0 800 / 8 00 / 800 80 0 / 800 / 800 8 00 / 800 / 80 0 800 / 80 0 / 8 00 80 0 / 800 / 800









9 ,5 R 17, 5 front / rea r / spa re w hee l

typ e / vers ion K N L E S G D 60/ 75 600 / 50 0 / 7 50 600 / 5 00 / 750 60 0 / 500 / 750 6 00 / 500 / 75 0 600 / 50 0 / 7 50 D 80/ 90 670 / 50 0 / 7 50 670 / 5 00 / 750 67 0 / 500 / 750 6 70 / 500 / 75 0 670 / 50 0 / 7 50

D 10 0 750 / 7 50 / 750 75 0 / 750 / 750 7 50 / 750 / 75 0 750 / 75 0 / 7 50 T h e p la te w ith the ti re in flatio n pre ssures is s itu ated i n th e d oo r sp ace o n th e dr ive r´s s id e .

103


Maximum speeds and climbing abilities

Power train

Engine ISBe4.5E5 160 (118kW) ISBe4.5E5 185 (136kW) ISBe4.5E5 207 (152kW)

Gearbox ZF 6 S 850

Rear axle ratio

I = 3

,73

I = 4

,10

I = 4

,56

I = 5

,13

I = 3

,73

I = 4

,10

I = 4

,56

I = 5

,13

I = 3

,73

I = 4

,10

I = 4

,56

I = 5

,13

I = 3

,73

I = 4

,10

I = 4

,56

I = 5

,13

I = 3

,73

I = 4

,10

I = 4

,56

I = 5

,13

I = 3

,73

I = 4

,10

I = 4

,56

I = 5

,13

Disc dimension 17,5

19,5

17,5

19,5 17,5 19,5

Maximum theoretical speed (km/hod) 121 110 99 88 131 119 107 95 121 110 99 88 131 119 107 95 121 110 99 88 131 119 107 95

Maximum theoretical climbing ability (%)

D75 56,9 64,9 76,3 - - - - - 71,3 83,1 101,5 - - - - - 79,7 94,3 118,7 - - - - -

D80 52,2 59,2 69,1 - - - - - 64,7 74,8 89,5 - - - - - 71,8 83,9 102,6 - - - - -

D90 44,9 50,5 58,2 - - - - - 54,9 62,5 73,2 - - - - - 60,4 69,2 82,1 - - - - -

D100 39,5 44,3 50,7 - - - - - 48,0 54,2 62,7 - - - - - 52,5 59,5 69,4 - - - - -

D120 32,0 35,7 40,4 46,7 - 32,7 37,0 42,5 38,4 43,0 49,1 57,4 35,2 39,3 44,7 51,8 41,7 46,8 53,7 63,1 38,1 42,7 48,7 56,8

104


Engine oil 13 lCooling circuit c/w heater circuit 17,5 lGearbox ZF 6 S 850 7.5 l (with PTO 8 l)Fuel tank capacity 120 l, 165 l, 200 lMinimum fuel reserve 16 lAdBlue tank capacity 30 lRear axle Albion 5.14 - differential 4 l

- wheel body 2 x 0,25 lRear axle Albion 8.20 - differential 8 l

- wheel body 2 x 0,25 lRear axle Meritor - differential 6,5 l

- wheel body 2 x 0,5 lMonoblock power steering 1.7 lWindshield washer tank 7.5 lHydraulic circuit for clutch release 0.5 lHydraulic circuit for cabin tilting 0.75 l

Operation fillings

105


Vehicle Identification Number

T N A A 2 X 0 0 0 X A 0 1 2 3 4 5

W M I V D S V I S

type

of ve

hicle

whee

lbase

( N,

L, E

,S,G

)

chas

sis n

umbe

r

Euro

pe

Czec

h R

epub

lic

year

of pr

oduc

tion

man

ufac

turin

g pla

nt

VIN(Vehicle Identification Number)n The vehicle is marked with the VINnumber in accordance with the unifiedinternational vehicle marking.n The VIN number is stamped on theweb of the right frame longitudinal beamahead of the shock absorber holder ofthe front axle.The manufacturer´s plate VIN is situa-ted also on the right door jamb abovethe door lock.

FN1020FN1010

AALM

s.r.o

.

106


Vehicle labels

On the left door jamb abovethe door lockn absorption coefficient (F)n air-conditioning* (G)n tires inflation pressures (H)n warning - batteries circuit breaker (I)

On the cabin right side in the rearinformation about cabin tilting (J).

On the right door jamb abovethe door lockn homologation (A)n automatic brake pressure control (B)n VIN (C)n headlamps adjustment (D)n cabin (E)

FN1040nFN1030n FN1053n

107

A.............................................................AdBlue fluid ....................................... 47AdBlue fluid tank ............................... 47Air filter ............................................... 49Air-conditioning* ............................... 22Alternator ........................................... 69Anti - blocking - system .................... 57Ashtray............................................... 31ASR .................................................... 57Axle (front) ......................................... 52Axle (rear) .......................................... 52

B.............................................................Basic rules for the trailer coupling .. 65Battery ............................................... 69Battery circuit breaker ...................... 69Battery location ................................. 68Belt tensioning ................................. 43Bonnet ............................................... 32Brake (emmergency) ....................... 58Brake (parking) ................................. 58Brake (service) ................................. 54Brake lining - checking .................... 56Brake system D60 - 120 .................. 53Brake system inspections ............... 56

C.............................................................Cabin interior lighting ...................... 29Cabin tilting ....................................... 34Cabin tilting at special versions ...... 35

Cabin tilting (instructions) ............... 34Clothes,hooks,glove compartment 31Clutch ................................................ 51Combined lever switch .................... 12Controllers ........................................ 14Cooling system ................................ 48Cruise control ................................... 16Cup holder ........................................ 31

D.............................................................Diagnostic socket ............................ 17Digital clock* ..................................... 30Doors .................................................. 6Draining the fuel filter ....................... 46Draining the condensate from airtanks ............................................55, 64During driving ................................... 40

E .............................................................Electronic vehicle heightadjustment (ECAS)* ......................... 63Electrical equipment ........................ 67Electrically actuated windows* ......... 7Engine ............................................... 42Engine brake .................................... 13

F .............................................................Fuel .................................................... 46Fuel tank ........................................... 46Fuse box ........................................... 91

G.............................................................Gearbox ............................................. 50Gearshift lever .................................. 19

H.............................................................Head restraints ................................ 25Headlamps and lights - location .... 70Headlamps leveling device ............. 29Heating and ventilation .................... 20

CH ..........................................................Changing the wheel ......................... 84Chassis c/w cabin ........................... 36Check before the drive ..................... 38

I ..............................................................Idle run .............................................. 41Ignition switch and steering lock .... 18Indicator lights .................................... 8Instrument board - gauges ............... 8Interior ................................................. 4

K.............................................................Keys ..................................................... 6

L .............................................................Lubrication system ........................... 44

M ............................................................Maintenance ..................................... 38

I N D E X

108

R.............................................................Rear-view mirrors ............................ 28Rear-viev mirrors remote control* ... 28Replacing bulbs ............................... 85

S .............................................................Seat belts .......................................... 26Seats ................................................. 24Sleep couch ...................................... 25Socket / cigarette lighter .................. 30Spare wheel holder (L, E, S, G) ....... 81Spare wheel holder (K, N) ............... 82Starting the engine ........................... 39Steering ............................................. 49Steering wheel adjustment ............. 19Stopping the engine ......................... 41Sun visors ......................................... 30

T .............................................................Technical data ......................................- Dimensions of chassis c/w cabin ........................................ 98- Engine ............................................. 95- Maximum speeds and climbing abilitie ............................................103- Operation fillings ..........................104- Tires inflation pressures ............102- Undercarriage ................................ 96

- Weights and axle load ................... 99- Weights and axle loads - permitted trailer weights ..............101- Wheel turning diameters .............101Tools and equipment ....................... 33Towing, vehicle recovery .................. 80Transport of loads ............................ 62Troubleshooting ...................................- Brakes ............................................. 78- Electrical equipments .................... 77- Engine ............................................. 73- Monoblock hydraulic power steering ........................................... 78Turbocharger .................................... 45Tyres and wheels ............................. 61

U.............................................................Use of jumper cables to start theengine ............................................... 93

V .............................................................Vehicle care ...................................... 71Vehicle height adjustment byremote control* ................................. 17Vehicle identification number ........105Vehicle labels .................................106Vehicle running-in ............................ 38

W ...........................................................Wheel chock (L, E, S, G) .................. 81Wheel chock (K, N) ........................... 82Wheel turning diameter .................101Windshield washer and wipers ...... 60

Avia Ashok Leyland Motors s.r.o.Beranových 140

199 03 Praha - Letňany

Version 6a / English / 8/2009D60/65/70/75/80/85/90/100/110/120 E5

Alternations reserved

n 6a en rhd 1-3

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