návod d120 str 1-3v

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

2

DescriptionInterior ................................................. 4Keys ..................................................... 6Doors .................................................. 6Electrically actuated windows* ......... 7Instrument board - gauges ............... 8Indicator lights .................................... 8Combined lever switch ................... 12Controllers ........................................ 14Cruise control ................................... 16Diagnostic 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* ..................................... 30Socket / cigarette lighter .................. 30Sun visors ......................................... 30Cup holder ........................................ 31Ashtray .............................................. 31

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 vehicledocumentation to a new owner.

Warning!n The texts in frames named"Warning!" must be unconditionallyobserved.

Operation ManualTo get acquainted with the vehicleproperly, it is necessary to readthrough the "Operation Manual" andall manuals, which were deliveredtogether with your vehicle (e.g.operating instructions for the use ofauto radio, tachograph, batterywarranty card, etc.).

Service BookletThe vehicle documentation alsocontains the "Service Booklet", inwhich you can find:n vehicle identification datan guarantee conditionsn warranty card and data on the ownern records on regular service inspectionsn service jobs and maintenance intervalsn body condition recordsn special servicing and maintenancen directory of authorized service stations

Information

3

Clothes hooks, glove compartment31Bonnet ............................................... 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 .................................................... 46Cooling system ................................ 47Air filter .............................................. 48Steering ............................................ 48Gearbox ............................................ 49Clutch ................................................ 50Front axle .......................................... 51Rear axle .......................................... 51

Brake system D100,110,120 .......... 52Service brake .................................... 53Checking the brake lining ............... 55Brake system inspections .............. 55Anti - blocking - system ................... 56ASR .................................................... 56Emergency brake ............................. 57Parking brake ................................... 57Windshield washer and wipers ..... 59Tires and wheels ............................. 60Transport of loads ........................... 61Basic rules for the trailer coupling . 62Electrical equipment ....................... 62Location of battery............................ 63Battery ............................................... 64Battery circuit breaker ...................... 64Alternator........................................... 64Headlamps and lights - location ... 65Vehicle care ...................................... 66

TroubleshootingEngine ............................................... 68Electrical equipment ....................... 72Monoblock hydraulic powersteering ............................................. 73Brakes ............................................... 73Towing, vehicle recovery ................. 75Spare wheel holder (L, E, S, G) ...... 76Wheel chock (L, E, S, G).................. 76Spare wheel holder (N) ................... 77Wheel chock (N) ............................... 77

Changing the wheel ........................ 78Replacing bulbs ............................... 79Fuse box - cabin ............................... 85Fuse box - under the battery cover . 87Use of jumper cables to start theengine ............................................... 88

Technical dataEngine ............................................... 89Undercarriage .................................. 90Dimensions of chassis c/w cabin . 92Weights and axle loads .................. 93Tires inflation pressures ................. 96Maximum speeds and climbingabilities ............................................. 97Operation fillings ............................. 98Vehicle Identification Number ........ 99Vehicle labels .................................100

I N D E X ............................................101

D E S C R I P T I O N

4

Interior

11110 3 6 17 4 2 8 5 7 9

21 22 12 23 24 13 14 16 20 19 26 18

25

20 1527FN0010

28


5

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

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 vents10Window lift mechanism*

11 Door opening and locking12 Ignition switch13 Parking brake14 Headlamps beam adjustment15 Rear-view mirrors remote control*16 Gearshift lever17 Horn18 Loudspeaker19 Ashtray20 Storage compartments21 Steering wheel positioning lever22 Clutch pedal

23 Service brake pedal24 Accelerator pedal25 Seat belts height adjustment*26 Storage box (c/w cover*),

fuse box27 Socket / cigarette lighter28 12 V socket29 Sun visor30 Digital tachograph*31 Auto radio*32 Dome light

29 30 3231

FN0011


6

Doors

2

1

4

3

5

B

A

FN0030

Keys

FN0040FN0020

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 theanalogue tachograph, the key to openit is delivered with the vehicle.


7

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 controlledfrom 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.

21

Warning!n Remember always to remove thekey from the ignition switch beforeleaving the vehicle.n Take care that the tailgate andside door of the box body are lockedproperly. It is not allowed to transportthe loads which do not allow a safeclosing of the door. Should the boxbody be damaged due to the tailgateor side door closed wrong, the manu-facturer does not provide anyguarantee for it.

Warning!Do not leave your fingers on thewindow glass when closing it - themechanism can develop theforce, which may cause injury.

FN0050


8

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 light7 Group of indicator lights I8 Group of indicator lights II9 Group of indicator lights III

FN0071

5 86

17

2

4

3

FN0065N9

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 starting the engine.


9

Parking brake

n It comes on when the parking brakeis applied and at low air pressure.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.

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 ChapterTroubleshooting.

Warning!The indicator light may flash with areduced brightness on the moveat irregular intervals. This flashingdoes not indicate a failure but it iscaused by its continuous checkperformed by the ABS control unit.

Brake systemmalfunction or brakepads wear

n It lights when the ignition is turned"ON" (to check the function) and it mustgo out 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 ChapterTroubleshooting.

FN0081

Stop light

n It comes on with a defective bulb ofthe stop light.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).


10

Air filter (polluted)

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

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.

FN0091

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 (replacethe 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.

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 lights when a malfunction or defecton the engine component occurs.


11

Engine maintenance

n It lights when the ignition is turned"ON" (to check the function), it must goout after a short while.n It lights when some servicing isnecessary (oil change, cleaning ofwater separator in fuel, etc.) and withthe engine at standstill, it will go outafter starting.n If it does not go out after a short whileor it flashes, proceed per ChapterTroubleshooting.

Glowing

It lights when the ignition is turned "ON".You can start the engine after it goesout.

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.


12

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 indicatorlight will come on).n Headlights are on until you releasethe lever.

1 Turn signalsTurn signals are active when the ignitionis in the position "ON". Move the leverperpedicularly towards the steeringwheel axis to switch the turn signals on.

right turn signal - lever upleft turn signal - lever down

2 Side marker lights and low beamTurn 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

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

Combined lever switch

3

2

1

4

FN0100


13

FN0110

87

6

5

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 selectany wiping interval by the rotary ring insteps - item 7)LO low speed and continuous wipingHI high speed and continuous wiping7 Intermittent wiping intervalcontrolThe wiping interval is the shortest in theposition F, increase it by turning the ring.

8 Engine brakePosition 0 - move the controller awayfrom you and down - the engine brake isoff.Position 1 - move the controller towardyou and down - the engine brake is acti-vated when the service brake is applied.

Warning!n Depress the accelerator pedalto put the engine brake automa-tically out of function.n The engine brake function isindicated by the red indicator lighton the instrument board.n The indicator light signallingdepends on the engine brakefunction, not on the position of thecontrol lever.

We recommend you to switch theengine brake on / off once a week atleast. Hereby the service life will beincreased.

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.


14

Controllers

3 8 7 1

5

6

4FN0120

1 Power take-off drive *n It can be engaged on vehicle atstandstill and after the engine speeddrops - after about 6 s.n When the engine is running, depressthe clutch pedal to engage the PTO.n The indicator light comes on toindicate the PTO engagement.

2 Differential lock on /off n It can be engaged on vehicle atstandstill and after the engine speeddrops - after about 6 s.n Use it only for the necessarily neededtime to overcome the hard drivingconditions.n The indicator light comes on toindicate the differential lock enga-gement.

Warning!Positions 1 and 2 can be engagedwhen the air pressure exceeds 0.55MPa - otherwise the engagementcannot be guaranteed.

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

4 Rear-view mirrors heating

Warning!Operate the heating for thenecessarily required time only.

.

291011

We recommend you to switch thedifferential lock on / off once aweek at least - hereby the servicelife will increase

it is indicated by the bulb in the switch.


15

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.

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 W hen the diagnostic test isperformed, another malfunction codewill enter when pushed.

Horn The horn switch is situated in the middleof the steering wheel.

FN0130a

5 Tail 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 canbe turned on only in fog, heavy rain orsnow.n The bulb in the switch comes on toindicate the function.


16

Cruise control

Warning!n When the cruise control is notused, the "permanent (main)" controlbutton 10 must be switched off.n The vehicle speed can beinfluenced by driving uphill or by theload weight. For that reason use thecruise control only when driving onlevel ground or in slight hilly terrain.

Setting the PTO speed onvehicle at standstilln Push the button 10 to activate the PTO.n Push and hold the button 11 "adjust/increase" depressed (the adjustable speedrange 950 ÷ 3,000 rpm) to increase the speed- hold the button depressed to increase thePTO speed gradually - when the button isdepressed repeatedly, the PTO speedincreases by about 25 rpm steps.n Push the button 9 "resume / reduce" toactivate the speed 1,200 rpm automatically.

Adjustment of cruise controln Push the button 10 to activate thecruise control.n When the desired speed has beenachieved, push briefly the button 11"adjust / increase" - now the speed isstored and maintained by the enginewithout applying the accelerator pedal.n The speed can be increased bydepressing the accelerator pedal - afterreleasing it, the cruise control functionis resumed (however, first the cruisecontrol must be activated).n All functions will be cancelled bydepressing the clutch or brake pedaland/or by switching off the button 10.The resuming of the cruise controlfunction can be performed when youpush briefly the button 9 "resume /reduce", it means that the cruise controlneed not be set again.

n The cruise control allows you tomaintain a desired speed (engine speed- both on the move and in the PTOregime) - without actuating theaccelerator pedal.n Use three control buttons located onthe central panel of the instrument boardto 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).

FN0131

91011


17

Diagnostic sockets

n Diagnostic sockets are situatedunder the storage box in the instrumentboard.n They are accessible after removal ofthe storage box bottom, which isreleased by turning the two rotaryholders (sense of rotation is shown onthe cover).

1 Socket for the ABS diagnostics2 Socket for the engine diagnostics3 Engine diagnostics switch4 Fuse box for voltage transformer

(fuses: 2x 5 A, 1x 10 A)

1

2

3

4

FN0132


18

Ignition switch and steering lock

Switch positionsn "LOCK" positionOnly in this position the key can beinserted and removed. Only tachograph,electric clock or radio are powered. Thesteering shaft will be automaticallylocked in this position.

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

n "ON" positionThe indicator lights (see the figure) ofbattery charging, brake systemmalfunction, parking brake, ASRfunction, glowing, ABS, coolanttemperature and reserve fuel amount,engine - stop, engine- warning, engine- maintenance will come on. After severalseconds only charging and/or glowingindicator lights remain on. When the

FN0140

FN015cu

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

glowing light goes out, the engine isready to be started.Electric circuits connected through theignition switch are powered.


19

Gearshift lever

Position Type of gearbox Number ofgear speeds

1 ZF S5-42 5

2 ZF 6 S 850 6

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 thedesired 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 wheel adjustment

1 2

FN0160Warning!n The ignition switch function issecured with the battery circuitbreaker on.n Do not switch off the battery circuitbreaker or do not disconnect batteryclamps to avoid damage to alternatoror some electric consumers.

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.


20

31 24

Heating and ventilation

1 Heater fan control2 Airflow direction control

3 Heater valve control - control of thedrawn airflow temperature4 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 Use the heater valve control knob(item 3) to adjust the water volumepassing through the heating insert, andthus also the temperature of the drawnairflow (turn the control knob to the redzone to supply the hot air).n Use the control knob (item 1) toadjust 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 airflowdirection (item 2) allows you to changethe direction of airflow (way of cabinheating).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

FN0180

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).


21

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 position n Switch on the regime of air circulationn Close air vents by thumbwheels.Keeping windows being not foggedunder increased humidityWhen windows are still being fogged(for example in rainy weather), it isnecessary:

5 5 5

666

5

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 position n Switch on the regime of air circulation.

Warning!The heating output depends on thecoolant temperature. The maximumheating output can be obtained afterthe engine has reached the opera-ting temperature.

FN0190


22

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 theengine running only.

volume by selecting one of 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 thumbwheels(item 7).

Control elementsn Switch on/off the air-conditioning bymeans of the switch (item 1) (signalled by the bulb in the switch).n The air-conditioning does not work ifthe fan rotary switch is off.n Depending on the heater valvecontrol knob position (item 4), thetemperature of the drawn airflow iscontrolled (when in the red zone, the hotair is circulated and contrariwise). Itcan be used even with the air-conditioning on.n Use the control knob (item 2) to controlthe fan speed and thus also the air volumecirculating through the system. Adjust the air

2 3 45

6

7

6 7 6 6

7 FN01901


23

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 months)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 slightlyto left to adjust the temperature if neededn (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

31 2 FN0180

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 circulation


24

2

34

1

Seats

1

2FN0200

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

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 backward adjustment (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 theseat.

a b

c d


25

Warning!n The head restraint being setproperly will support the back ofthe skull when the vehicle iscrashed from the rear.n For reasons of safety the headrestraint may be adjusted onvehicle 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 elementand tilting the couch.

FN0221 FN0222


26

Seat belts

FN0230

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 mechanicaladjusting equipment.n Seat belts offer a protection forpassengers in case of an accident.

n Seat belts have to be buckled wheneveryou drive the vehicle - even in urban driving.


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 havebeen damaged, must be uncon-ditionally 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 correctseating position in cabin.n Do not strap in more than oneperson with each belt.n Keep the seat belts clean (dirtimpairs the function of theretractor). Use the soap water toclean the seat belts.n If the seat belt has been dama-ged, it is necessary to have itreplaced.

Warning!Use of seat beltsn The respective warning light remindsyou of necessity of the use of seat 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 arespective seat buckle. The belt isanchored properly when it clicks into abuckle.n To release the seat belt, press thered 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 upperanchorage toward you (up) and adjustit to the desired position.


28

Rear-view mirrors

n Vehicles are equipped with heatedrear-view mirrors.n The heating is controlled by thecontroller on the instrument board andis indicated 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 mirrorsmust be adjusted prior to move off.n Pay extreme attention whenconsidering the size and distancesof cars and other objects whenseen in a convex mirror. Alwaysremember that they will looksmaller and appear farther awaythan in reality.

A B

FN0240a

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.

FN0240

BA

Version A

Version B


29

Cabin interior lighting

Vehicle loadout of the max. payload

30% 50% 70% 100%

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

Headlights levelling device

FN0250

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.


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 toconnect the cigarette lighter or auxiliary24 V electric consumers.The socket (item B) can be used for 12 Vappliances. n Push the knob in to switch on thecigarette lighter. When the spiral isready for use, it will spring back. Pull outthe lighter and use it immediately (theheating spiral will loose the thermalenergy soon).

Warning!n Pay attention not to burnyourself when handling thecigarette lighter.n If the lighter does not springback after about 30 seconds, itmust be removed not to burnthrough.

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.

AB

FN0280


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.

FN0300 FN0310

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


32

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

FN0340FN0330

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


33

4 3 1

2A

FN0350n

5

FN0360

Tools and equipment

B

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 properly,may cause a personal injury or disturbyou by vibrations during driving.n The jack delivered with the vehicleis determined to be used with thisvehicle model only. It must not beused to lift other vehicles or otherloads.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


34

Instructions for cabin tilting

Warning!n Prior to tilt the cabin, shut theengine off and shift into neutral.n Secure the objects which areplaced inside the cabin and shut thedoors properly .n Open the bonnet before tilting.n Take an extreme care when tilting.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 workshopheight to tilt the cab is 3,000 mmand 3,800 mm with the additionalsuperstructure.

FN0390

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.

2

13


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

6

5 4 3 7

1

2

Chassis c/w cabin

FN0412

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 10 111221FN0402cu

228 13


37

14

16

20

15

2019

13 Oil dipstick14 Gearbox15 Propeller shaft16 Air pressure regulator

c/w air drier17 Drain valve18 Regenerating air reservoir 4.5 l19 Brake pressure regulator20 Battery case c/w circuit breaker21 Wheel chock22 Fuel filter

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

n Adjustment of headlamps related toloadn Cabin locking in the rear locationn Cabin securingn Engine oil leveln Fuel amount in tankn Coolant level in expansion tankn Fluid level in clutch circuitn Oil level in tank of the monoblockhydraulic power steering circuitn Efficiency of service and parking brakesn Washer tank fluid leveln Tires pressures and conditionn Function of outer illumination, turnsignals and stop lightsn Pollution of the intake system andair filtern Dewatering of water separatorn Cooling fan and intercoolern Engine and its ventilation

MaintenanceCheck before the drive

n To achieve a maximum use value,economic and safe operation andmaximum possible service life, it isnecessary to carry out all maintenanceworks at regular intervals as stipulatedin the Service Booklet.n The vehicle maintenance must becarried out by authorized servicestations, which have been acquaintedwith the vehicle design, do their work ona professional level, have the necessaryequipment and are in direct contactwith the manufacturer.

n The running-in of a new vehicle orvehicle after the general overhaul isterminated after covering 3,000 km(practically, the vehicle engine will reachthe maximum possible output aftercovering several further thousands ofkilometres).n During the running-in period, do not runthe engine above 3/4 of its top speed or atmaximum fuel delivery under low enginespeed.n Avoid full throttle starts, running theengine at high speed and abrupt stops.n Do not run the cold engine at high speed.n Do not let engine labor. Downshiftwhen engine no longer runs smoothly.n Vehicle must not be loaded extremely.

Vehicle running-in

Warning!The way of running in the vehiclehas a great influence upon itsservice life.

n The engine brake should beengaged / disengaged once a week atleast. Its service life will be increased.n The differential lock should beengaged / disengaged once a week atleast. Its service life will be increased.

Warning!


39

Warning!

Starting the engine

n Insert the ignition key and turn in"ON" position. Indicator and warninglights as shown in the illustration on thenext page will come on.n Starting the engine is possible onlywith no gear shifted in gearbox. Do notdepress the accelerator pedal.n When the glow plug light has goneout, start the engine by turning theignition key to "START" position andhold it for a while (the engine will crankwhen holding the key in this position),until the engine starts running,however, for 10 seconds as amaximum. When starting repeatedly,keep the interval of min. 30 s betweenindividual starting attempts.

Warning!n When the indicator and warninglights of battery charging, parkingbrake, engine - stop, engine -warning and engine- maintenancedo not go out after starting theengine, do not move off .n The vehicle must not be put inmotion in any way unless thebattery circuit breaker is on andthe ignition key is inserted intoignition switch and turned inposition "ON". The steering isunlocked in this position. Beforeyou move off, check whether thesteering wheel is free to turn.n Do not run the cold engine athigh speed - it could be damaged.

n Should the indicator andwarning lights of brake systemmalfunction, parking brake,engine - stop, engine - warningand engine - maintenance be stillon after turning the ignition to "ON"position even after a short while,you must not move off - find outthe cause of the defect perChapter "Troubleshooting".n When starting the warm engine,wait until the glowing indicatorlight goes out.n Use the winterized Diesel fueland engine oil of the viscositygrade in accordance with climaticconditions in the winter months.

n After starting the engine, release thekey, it will automatically return to "ON"position. After a regular engine run hasbeen achieved, the glowing andcharging indicator lights must go out. Ifnot, find out the cause of the defectaccording to chapter 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 one of lights shown in the abovementioned figure comes on duringdriving, it is necessary to stop thevehicle. In addition, if the engine - stoplight comes on, it is also necessary toshut the engine off.

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 wouldendanger the other motorists.n Depress the accelerator pedalgradually.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 necessaryto wait 3 to 5 seconds after depressingthe clutch pedal (to allow stopping ofshafts in gearbox) and only after thatengage the reverse gear.

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.

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 circuitbreaker only 30 seconds afterturning off the ignition (to allowthe PC data processing).n Never shut the engine off byturning off the battery circuitbreaker - it may result in damage towiring cables and alternator.n The ignition key may be remo-ved from the ignition switch onlyafter full stopping of the vehicle.n Before stopping the engineafter a full load operation, allowit to idle 1 minute at least - see thelabel on the instrument board.

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 mayresult in creation of carbon in thesurrounding of holes of injectionnozzles and piston rings what maylead to damage the engine. Inaddition, low temperatures willcause that all oil penetrating fromvalve gaskets will not burn inexhaust channels. The oil notburned can cause damage toturbocharger.

Idle run


42

Engine

FN0482

3

6

5

14 2

7

1 Fuel filter2 Engine starter3 Tension roller4 Fan c/w visco-coupling5 Oil filler neck6 Oil filter7 Compressor


43

Cummins ISBe 150 30- Diesel engine- four-cylinder- 16 valves- max. power output

110 kW / 2,500 rpm

Cummins ISBe 170 30- Diesel engine- four-cylinder- 16 valves- max. power output

125 kW / 2,500 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

FN04821


44

FN0450

n Have the oil changed and oil filterreplaced at the authorized servicestation.n The insufficient oil level willcause damage to engine.n Keep the environment cleanwhen handling the oil.n When it looks that oil quality gotworse (presence of water), contactthe authorized service stationpromptly.n Dispose of used oil inaccordance with environmentalregulations.

Warning!

Checking the oil level and kind of oiln It is necessary to check the oil levelbefore each drive (the oil is consumeda little by the vehicle operation).n The vehicle must stand on levelground to check 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 arag and push it in a hole all the way.n Pull dipstick out again. The oil levelis correct when it is between marks onthe dipstick. It must not be above theMAX mark, because the engine willsmoke too much in that case.n Add the oil in time not to allow the oillevel to drop below the MIN mark.n Always add the oil of the same quality.

Lubrication system

Engine oil Recommendedspecification oil viscosity

gradeA C E A S A E

E5 10 W - 40or E7 5 W - 40

Warning!n The manufacturer is notresponsible for damages causedby neglecting the oil economy .n The manufacturer does notprovide any guarantee for enginesdamaged by use of oil additives.

n The oil class, which was filled in theengine in the manufacturing plant, ismentioned on a sticker on the cap of oilfiller hole.n Always use the approved engineoils only.n Use of special oil additives is notrecommended, because someadditives combined with brand nameengine oils may result in impairing thefunction resulting in damage to engine.

n For the oil change intervals see theService Booklet.


45

Filling the engine with oiln Unscrew the filler neck cap.n Keep the environment perfectly cleanwhen 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 manifoldperfectly 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 withignition turned in "ON" position.n The fuel tank neck is fitted with alockable cap.

Warning!n Do not allow all the fuel bepumped out of the fuel tank.n The use of bio-Diesel is notpermitted.n It is not allowed to add petrolinto Diesel fuel.

n Your Diesel engine has been specificallydesigned to operate on Diesel fuel perČSN EN 590 (656506). Prefer using theDiesel fuel with a low sulphur content (0.05%hm), which is available on the market.n In the winter months (from November 1to March 31) you should use the Diesel fuelwhose filtering ability (CFPP specification)meets the climatic conditions.n To assure the operation under lowtemperatures, you may put additives intoDiesel fuel, which improve the filtering abilityunder low temperatures. Perform themixing according to manufacturer´sinstructions.

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.

frame

FN0473


47

is 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 For year round, add antifreeze(specification ASTM 4985) and distilledwater in the ratio specified (see themanufacturer´s instructions on theantifreeze packing).n All year-round use of antifreezeprotects the cooling and heating systemagainst corrosion and sediments. Forthat reason do not reduce theconcentration of the antifreeze byadding water even during the warmseason of the year (always add it in theratio with antifreeze).n Take care not to spill the antifreeze onthe body paint.n Before the winter season comes,check the antifreeze in the coolingsystem 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 the coolantn The label saying which kind ofcoolant has been filled, is situated onthe expansion tank. The cooling systemhas been filled with the fluid based onethylene-glycol. The mentionedcoolants can be mixed with coolantsbased on ethylene-glucol (C type).n Check the coolant level at regularterms.n The coolant level must be betweenMIN and MAX marks when the engine


48

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 cartridgereplaced at the authorized servicestation.n When the vehicle is operated invery dusty conditions, reduce thereplacement intervals accordingly.

Air filter Steering

FN0550

Checking and adding the steering oiln Check the oil level regularly.n The oil level in the tank must reach the"LIVELLO OLIO" mark. If it drops belowthis mark, it is necessary to add the oil ofthe ATF D II specification into circuit.n If the steering play was found out, it isnecessary to have it adjusted and/orrepaired at the authorized service station.


49

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 thereis no oil in the power steeringhydraulic circuit.n Keep the environment cleanwhen handling the oil.

n If the steering effort increasesconsiderably during the vehicleoperation, stop immediately and checkthe oil level in the tank of monoblockhydraulic power steering and check thehydraulic circuit for condition.

Gearbox

n Have the oil changed at theauthorized 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 toinsufficient lubrication.n Do not start the engine whenthere is no oil in gearbox.

Warning!

FN0560

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


50

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 volumeincreases in the tank).

Checking and adding the fluidn Check the fluid level in circuitregularly.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.

Warning!n Have the fluid changed at theauthorized service station.n Keep the environment cleanwhen handling the fluid.n When the air leaks from the airsystem (for example during a long-term vehicle storage), the airbooster will be put out of functionwhat results in increasing the forceeven to 500 N needed to depressthe clutch pedal.n If the fluid needs to be addedtoo often, contact the authorizedservice station.n The fluid is harmful to health.

FN0600


51

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 theauthorized service station.

FN0610nWarning!Have the oil changed at theauthorized service station.

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

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

Front axle

FN0620


52

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 regulator11 Combined brake cylinder12 Manual brake valve of parking brake

13 Switch of minimum air pressure of spring loaded cylinder

14 Front axle brake system15 Rear axle brake system16 Air reservoir of parking brake circuit17 Valve relay18 Trailer brake valve19 ASR valve20 Minimum air pressure sensor in circuits of

service brake

Brake system D100/110/120

1514 2 3

5 67

1017

16

18

8

8

19

11

11

12 FN0650FN0431a4

20 19 13

14 15


53

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 pressureregulator controls the braking force ofrear axle wheels in dependence on thevehicle 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 air driern This serves to clean and dry the airsupplied from the compressor and tocontrol the operating pressure in brakecircuits.

FN06502

1

FN0650n


54

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 itimmediately (water can be found indrain valves during regular serviceinspections).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.

Condensate draining from airreservoirsn The condensate (condensed water)settles in air reservoirs of the brakesystem during vehicle operation. Thecondensate must be drained at regularterms:

- several times a day in winter andhumid weathern The full operating pressure must bein the pressure system during draining.To drain the condensate, deflect controllevers of drain valves on bottom of airreservoirs.

FN0660

Automatic brake pressureregulatorn The brake pressure regulator serves tocontrol the air pressure entering thecombined cylinder of the rear axle.n All adjustments must be carried out atthe authorized service station. Duringoperation, check visually the connection ofregulator lever with axle, a free travel of theregulator lever and instrument 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

FN0655


55

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 is:2 ÷ 9 mmn 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.


56

Anti - Blocking - System

The ABS system enhances conside-rably the active driving safety of thevehicle. Compared with common brakesystems, it keeps a good drivingmaneuverability even at sudden brakingon wet roads because the wheels willnot 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 isdefective and the vehicle is brakedwithout ABS. Only the normal brakesystem is operative on vehicle.Proceed to your nearest authorizedservice 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 theauthorized service station only.

Warning!

ASR

The ASR system facilitates the move-off of the vehicle 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 beincreased.

n When the ignition is on, the ASRindicator light must always comeon. 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 comes onduring driving, the system isdefective and ASR is probably outof function.Proceed to your nearest authorizedservice station in that case.n When ASR is not functional, thenormal vehicle operation is notinfluenced.n All repairs and interventions inASR may be performed by theauthorized service station only.

Warning!


57

Emergency brake

Warning!Any unprofessional interventioninto the brake system is not allowedand all repairs and interventionsmust be entrusted to authorizedservice stations.

Warning!The use of emergency brakealways means the endangering ofthe vehicle operation because theemergency braking effect isalways much lower than that of theservice 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 decreasedpressure in one of two service brakecircuits.n Defect in the pneumatic part aheadof the four-way relief valve.n Defect in one of four pneumaticcircuits behind the four-way relief valve.n Defect in the electrical part of thebrake system - in the ABS system.n Fault on the trailer connected.

Conclusionn Always prior to set out for the drive,remember to check a good function

of the brake system so that youwatch the indicator lights of thebrake system.n Check a good function of bulbs of thebrake system indicator lights by turningthe ignition key from "ACC" to "ON"position when the indicator lights mustcome on.n The indicator lights must go out afterseveral seconds.n After the indicator lights have goneout, you may move off.Brake system instrumentsThe vehicle user is obliged to carryout the continuous inspections of thebrake system to check its conditionand function. When some defect orsuspicion of the defect has beenfound out, have the diagnostics andpossible repair performed by theauthorized service station.

Parking brake

n The parking brake is of spring-loadedtype and acts on wheels of the rear axle.n The energy needful to brake up thevehicle is accumulated in the spring ofcombined brake cylinder being aircompressed.n The parking brake is controlled bymeans of the manual brake valve lever,which is located behind the gearshiftlever.Position of the parking brakelevern Parking position:To brake up the vehicle, it is necessaryto move the manual brake leverrearwards into the parking position(before the parking position is achieved,

FN0690a

drivingposition

parkingposition check

position


58

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 of towingonlyn Place the wheel chock to secure thevehicle against motion.n Turn the nut 1 to unscrew the stemout of spring-loaded cylinder.

you have to overcome a point ofpressure resistance and then the leveris automatically secured in the parkingposition).n Check position(it applies to some vehicle versionsonly)This position is designed to check ifthe parking brake system of the towingvehicle is capable to brake up thevehicle combination in a certaingradient in a safe manner. A function ofthe parking brake of the trailer brake isdisengaged after pushing the manualbrake lever and its displacing from theparking position rearwards into thecheck position; hereby the vehiclecombination will be braked up by theparking 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 and movethe lever forwards into a drivingposition.


59

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*indicates the minimum fluid level.n Use water with glass washer solventagent (e.g. Glacidet) to add the fluid. Inwinter keep the stipulated ratio not toallow the fluid will freeze up (followinstructions mentioned on theantifreeze 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 thewindshield - 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 aneedle.n The whole wiper arm body c/w jetscan be moved freely along the arm.


60

Tires and wheels

The service life of tiresdepends on:n way of driving and driving habitsn correct tires inflationn vehicle operating conditionsn geometry of front axlen proper distribution of load on theload space

Wheels and wheels dataWheels of the front axle - 2 balancedonesWheels of the rear axle - 4 non-balancedones

Spare wheel - 1 balanced one

Disc wheel 17,5 x 6,7519,5 x 6,75

Tires 245/70R 17,5(radial) 265/70R 17,5

245/70R 19,5265/70R 19,5ALL STEEL TUBELESS

n Check the tire pressures alwaysbefore you drive the vehicle. Rememberalso to check the tires if they are in agood condition (look for the tire repairshop if they have been damaged).n Tire 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 tire casing cord areallowed on tire treads or sides.n In case of the uneven wear of tiretreads on front axles, check and/oradjust the front axle wheels geometry.n The depth of tread grooves of tiresmust be 1.6 mm at least. If tires treads aremarked REGROOVABLE, the treads canbe cut through to make them deeper (onlya specialist may perform it).n Only balanced tires may be mountedon front wheels and all wheels must bein a good technical condition.n Only tires stated for the given type ofthe vehicle and recommended by thetire manufacturer may be used on thevehicle.n Protect tires against oils and fuel.n If the vehicle is put out of operation

for a long time, it should be slightlyraised to relieve the tires.n The dismounted wheels (tires)should be stored in a dry and darkplace.n Check the tightening-up of wheelnuts at intervals stipulated in theService Booklet.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 485 ± 35 Nm.


61

Transport of loads

Especially during the vehicle operationon highways and long-distance trans-port, follow the below-mentioned in-structions:n Do not exceed the maximum allow-able front axle load of 4,000 kgn Increase the tire inflation of the frontaxle by 80 to 100 kPa. However, do notexceed the maximum allowable tire

inflation pressures stated by the man-ufacturer.n Take care that the load is distribut-ed correctly on the load space of thevehicle:- place the load to the centre of the loadspace,- place the load evenly on the wholeload space.- keep a correct distribution of the

weight (1/3 to the front axle and 2/3 tothe rear axle)n If the tires should be replaced, it isnecessary to prefer:a) tires of higher capacityb) tires stated for the highway opera-tion by the manufacturer

OK OKOK

OK

FN0721


62

n Clamps of all electrical consumersof the vehicle must be connectedcorrectly 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 electricalequipment, 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 The electric arc welding outsidethe dealer's network is not allowed- danger of damage to alternator,engine control unit and ABS controlunit.

Warning!

Electrical equipment

n Secure the trailer rear wheels withchocks.n The front trailer axle must remainsteering.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 couplingheads and plug connectors of electricconductors.n Check the brake system and lightsfor a correct function.n Proceed very carefully when towinga trailer and do not exceed the allowableload limits.n When stopping during uphill ordownhill driving, check the manualbrake for a good efficiency. It must holdthe whole vehicle combination in agradient on the spot.

Basic rules for thetrailer coupling

Warning!n The pieces of informationmentioned in this chapter are thebasic ones only. You should abidemainly by the instructions given inthe Operation Manual for theconnected vehicle.


63

1

2

Location of battery

7

35

46

driving

directi

on

1 Plastic cover2 Holder clip3 Rubber holder4 Profiled battery holder5 Battery holder screw6 Fuse box7 Central ground point

FN0630cu


64

n Instructions for the operation andmaintenance are a part of the warrantycard delivered with the vehicle.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 batteryterminals, be sure to disconnect firstthe negative ("–") terminal. Proceed withcare during removal of battery terminalsnot to cause short-circuit between "+"battery terminal and vehicle ground.After cleaning and careful connectionof terminals connect the positiveterminal ("+") to the battery circuitbreaker again.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 toenvironmental regulations.

Warning!

Battery circuit breaker Alternator

With the engine running thealternator terminals must not bedisconnected and the batterycircuit breaker must not beswitched off - the alternator mustnot run without load.

Warning!

A

B

Battery

A circuit breaker onB circuit breaker off

FN0740

Warning!n Switch off the battery circuitbreaker only 30 seconds afterswitching off the ignition (to allowthe PC data processing).n Never shut the engine off by thebattery circuit breaker - this coulddamage the electrical equipmentand alternator.


65

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 light

10 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


66

Cleaning agentsn As far as the cleaning agents or otherchemical vehicle-care products areconcerned, you should follow themanufacturer´s directions when usingthem both for the vehicle interior or exterior.n The non-suitable cleaning agents mayimpair the value of vehicle components.n You should not use the volatile agents(acetone, diluents, gasoline), cleaning agents(wash powders) and bleaching or otheraggressive agents except for thoserecommended to remove spots from clothes.n Take care that the ventilation is enoughwhen working in interior (vapours of someagents 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 instructions,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-reased visibility with the tailgatetilted and standing on a road. Thespecial label inside the cabin beingvisible from the driver´s placereminds you of this obligation.

Warning!n The seat belts should be keptclean - dirt would affect the functionof retractor.n Before winding, the seat beltsmust be perfectly dry.n The seat belts must not becleaned chemically.


67

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 preserving area good protection of the vehicle againstnegative influences of the environment.n Regular care will contribute tomaintain the value of your vehicle.n It is important to use correct cleaningagents and procedures (see instructionsmentioned on packages of cleaningagents). When not observing theseinstructions, hard removable spots maystay on exterior surface materials aftercleaning.

Washing the vehiclen The best way how to maintain thepaint in a good condition is to wash it veryoften.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-washshampoo in ratio as mentioned on thepacking. It is necessary to rinse thesponge often during washing.n Use plenty of water to rinse thevehicle off after washing (do not allowthe agents to dry on the body paint) anddry it out with a chamois.

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

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

68

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

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 blowsimmediately again, have the vehicle checked at theauthorized service station

D) Fault: Charged batteryRemedy: Charge the battery according to instructionsmentioned in the 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

Engine

2. Starter cranks the engine but theengine cannot be started

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

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

F) Fault: Faulty neutral switchRemedy: Contact and have it repaired at the authorizedservice station

G) Fault: Faulty starterRemedy: Contact and have it repaired at an authorizedservice station

69


Engine

4. Engine will not reach the rated outputA) 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

5. Engine is knockingRemedy: 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 necessaryto stop the vehicle as soon as possible and to cooldown the engine by enhanced engine speed (1,200 ÷1,500 rpm).In any case do not shut the engine off after the coolingindicator light comes on.

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

70


8. "Engine - stop" indicator light ON

Fault: Serious engine defect (it may be probably thecoolant temperature, charge air temperature or oilpressure)Remedy: Stop the vehicle and shut the engine off.Carry out the diagnostic test (the diagnostic procedureis mentioned on the following page). If the light codelights up during this test, there is a serious defect inthe engine and it is necessary to contact the authorizedservice station. It is strictly prohibited to continue todrive the vehicle. However, when the indicator lights"engine - stop" and "engine - warning" light togetherpermanently during the diagnostic test, you cancontinue to drive the vehicle.

9. "Engine - warning" indicator light ON

Fault: Fault in the engine system or in the enginecomponentRemedy: The vehicle can be further operated, however,when you reach the nearest authorized service station,have this fault repaired - this situation is not consid-ered to be an emergency state.

10. "Engine - maintenance"indicator light ON

Fault: It notifies you of the necessary maintenance workRemedy: If it flashes during the start, it reminds you of thenecessary service job such as the engine oil change, etc.After, for example, the oil change has been performed,the re-start of the indication of this indicator light must becarried out - the authorized service station will perform it.

Engine

71


Engine

11. Diagnostic testFault: The indicator lights"engine - stop" "engine - warning" are ON

2B

FN075 3

2A

FN075 2

The fault code blinking repeatsitself continuously. It is neces-sary to put down the fault codenumber. To detect other faults, itis necessary to push the cruisecontrol switch (item 3) marked"+" and the procedure of faultcode blinking will begin to repeatitself - either the same fault codeappears (if there is no other faultcode) or another fault code dis-plays (put it down) and by repeat-ed pushing the cruise controlswitch "+" further blinking of thefault code will be activated - go onin that way until the first fault codeappears again.On termination of the diagnostictest, turn the diagnostics switchoff (item 4), move the ignition key(item 5) to position "ACC" andwait 30 seconds.

FN075 4

4

FN075 7

FN075 6

5

Warning!If the blue indicator light"engine - maintenance" comeson, contact the nearestauthorized service station.

FN075 1

1

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 2A) -orpush the engine diagnosticsswitch (item 2b) situated underthe glove box in the instrumentboard.3) The orange indicator light"engine - warning" will beginlighting and when it goes out,the red indicator light "engine -stop" will start blinking to showthe fault code.

3

72


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.

it comes on

- 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

Electrical equipment

1. The battery charging indicator light is on

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.

2. The battery charging indicator lightdoes not come ON when the ignition is ONRemedy: Contact and have it repaired at an authorizedservice station

73


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 instrumentsRemedy: Contact and have it repaired at an authorizedservice station

Brakes

1. The indicator light - brake systemmalfunction - is onFault: Low pressure in 1st or 2nd circuit of servicebrake or worn brake padsRemedy: Check the pressure in the pneumaticsystem on gauges on the instrument board. If the airpressure is too low, release the spring-loadedcylinders (see Chapter Parking brake) and have thevehicle towed to the authorized service station. In casethat the pressure is sufficient in the pneumatic system,dismount the glove box in the instrument board andinspect the module (1) for checking the brake padswear - see the figure. If the red diode lights on somemodule, the brake pads have been worn. Adapt thedriving to the situation and visit the authorized servicestation.

1 FN0759

74


4. The ASR indicator light is onRemedy: The equipment is not OK, the ASR system isnot working. It is necessary to visit the authorized servicestation.Note: When the ASR system is out of function, thecommon vehicle operation is not influenced.

2. The parking brake has been blocked,the air pressure gauge of brake systemindicates the pressure below the minimumvalue, the vehicle cannot be put in motionRemedy: Release the spring-loaded cylinders (seeChapter Parking brake) and have the vehicle towed tothe authorized service station.

3. The ABS indicator light is onRemedy: 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.

75

T R O U B L E S H O O T IN G

Towing

FN0770FN0760

A special hook to hold the rope for thevehicle recovery is welded to the frame.

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 propeller shaftn Secure the vehicle against motion.n Dismount bolts fixing the propellershaft to the axle final drive housingflange.n Attach the propeller shaft to thevehicle 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 thepropeller shaft not to damage thegearbox due to insufficient lubricationand release the spring-loaded cylinderin accordance with Chapter "Parkingbrake".n The ratio of the towed and towingvehicles weights must be 1.4:1 at least.

Vehicle recovery

76


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

77


Spare wheel holder (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 (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

78


Changing the wheel

Warning!With the vehicle lifted, never startthe engine.

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 fromholder.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 centimetresabove the ground by moving the lever (withthe 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.

n Open the jack valve slowly and care-fully lower the vehicle on ground.n Tighten the wheel nuts completely to485 ± 35 Nm.n Retighten the wheel nuts aftercovering 50 ÷ 100 km.

79


Replacing bulbs

n Prior to the bulb replacement, switchoff the respective light.n Replace the defective bulbs withbulbs of the same parametres(designation and parametres arementioned on the bulb).n Do not touch the halogen bulbglass with bare fingers - it would looseits efficiency 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 servicestation may adjust the main head-lamps.n A new bulb must correspond tothe specified bulb by its type andoutput.

FN0850

80


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

81


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 betteraccessible, 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 turnclockwise.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.

82


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

83


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

84


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.

85


Fuse box - cabin

Fuses

F1 10A stop lightsF2 10A cigarette lighterF3 10A audible hornF4 10A dome light and superstructure light*F5 10A radio / clockF6 25A 24 V / 12V voltage transformerF7 10A engine speed sensor / engine brake relayF8 10A engine control unit / glowing regulatorF9 10A differential lock / PTO / clock displayF10 25A superstructureF11 10A hazard warning lights (emergency flasher)F12 10A central door locking*F13 10A IGN relay control via ignition switch /

starter relay controlF14 10A tail fog lampsF15 10A openF16 10A windshield wipersF17 10A fan electric motorF18 10A turn signalsF19 10A reverse lights / "+" for instrumentsF20 10A brake pads wearF21 25A rear-view mirrorsF22 10A air-conditioning*F23 25A windows remote control*F24 10A air drierF25 10A high beam, LH + indicator light

F26 10A high beam, RH / R04 tail fog lampF27 openF28 10A low beam, LH + indicator lightF29 10A low beam, RH / R04 tail fog lampF30 10A main headlamps levelling deviceF31 10A side marker light, LH / auxiliary side

positioning light, RH / instrument board lightF32 10A side marker light, RH / auxiliary side

positioning light, LHF33 10A front fog lamps and tail fog lamps controlF34 10A controllers illuminationF35 10A front fog lamp, LH*F36 10A front fog lamp, RH*F37 openF38 openF39 10A ABS control unit / diagnostic connectorF40 10A ABS control unit

86


Relays

R01 rear-view mirrors heatingR02 openR03 stop lights - checkR04 tail fog lamps controlR05 turn signalsR06 ignition switchR07 windows control 1R08 openR09 windows control 3R10 openR11 side marker lightsR12 low beamR13 high beamR14 front fog lampsR15 openR16 openR17 wipersR18 wipers speed relayR19 wiper interval cycle switchR20 air-conditioningR21 emergency flasher 1R22 emergency flasher 2R23 stop lights - controlR24 open

FN0970

Replacing a fusen The fuse box is situated under theglove box in the instrument board.n Fuses are accessible after removalof the glove box bottom which wil bereleased by turning two rotary holders(sense of turning is illustrated on thecover).

n The individual electric circuits aresecured by fuses.n The blown fuse can be recognizedby the burnt metal strip.n Switch off the battery circuit breakerduring the fuse replacement.n A new fuse must have the sameampere value.n It is necessary to keep spare fuseson hand in vehicle.

87


Fuse box - under the battery cover

B

F

3

A

C

D

E

FN0980

1

2

4

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 vehiclerepaired at the authorized servicestation.n Never repair the blown fuses.n Do not use a screwdriver or othermetal object to remove the fuse.

A 80A air heatingB 30A starter electromagnetC 50A " + " ahead of ignition switchD 50A " + " behind ignition switchE 30A "+" permanent for the

engine control unitF 30A fuel heating1 20A " + " without circuit breaker

(permanent currentfor tachograph, clock,radio)

2 relay for starter electromagnet3 fuel heating relay4 starter relay - auxiliary

88


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.

Use of jumper cables to start the engine

Warning!The battery of the other vehiclemust have the nominal voltageof 24V.

FN0990

4

3

2

24V

5

1

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).

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 vehicleground because this could lead toshort circuit.

Warning!

89

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 designationCUMMINS ISBe 150 30 ISBe 170 30

Number of cylinders / valves 4 / 16 4 / 16

Cylinders bore 102 mm 102 mm

Pistons stroke 120 mm 120 mm

Displacement 3,922 cm3 3,922 cm3

Compression ratio 17.2 17.2

Maximum output 110 kW / 2,500 rpm 125 kW / 2,500 rpm

Maximum torque 550 Nm / 1,200 ÷ 1,600 rpm 600 Nm / 1,200 ÷ 1,600 rpm

Injection system CommonRail Bosch; CommonRail Bosch;electronic control unit electronic control unit

90


Propeller shaftn versions N, L, E with two-shaftarrangement and three cross-shapedjoints with one intermediate bearingand sliding splined adaptorn versions S,G with three-shaftarrangement and four cross-shapedjoints with two intermediate bearingsand sliding 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 barn fluid shock absorbers with lower stopn rubber upper stopn hypoid gears:

3.7 4.10 4.56

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

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

Front axlen rigid, with forged axle casingn parabolic spring suspension withstabilizer bar, shock absorbers withlower stop

91


Steeringn monoblock hydraulic power steeringn gear ratio from 14 to 16.6 -changeable during turning the steeringwheel between 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 (check data for adjust-ment of the brake pressure regulatorare stated on the plate situated in cab-in)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

92


Dimensions of chassis c/w cabin

FN1001

The tolerance ± 1 % holds for thedimensions if not statedotherwise.

93


Vehicle type D 100

Vehicle version N L E S G

kg

Curb weight chassis + cabin 3510 3560 3610 3660 3720

front axle 2230 2270 2310 2350 2390 Weight distribution:

rear axle 1280 1290 1300 1310 1330

Carrying capacity of chassis + cabin (c/w crew) 6490 6440 6390 6340 6280

Max. vehicle overall weight 10000 10000 10000 10000 10000

front axle 4000 4000 4000 4000 4000 Max. allowable weight distribution:

rear axle 6600 6600 6600 6600 6600

non-braked 750 750 750 750 750 Max. allowable trailer weight:

braked 3500 3500 3500 3500 3500

Max. allowable vehicle combination weight1 13500 13500 13500 13500 13500 1The individual maximum allowable weights must not be exceeded

Weights and axle loads

Warning!The distribution of the instanta-neous vehicleweight is allowed in ratio at least 30-35 % to thefront axle and 65-70 % to the rear axle.

The tolerance + 3 % holds for the weight data.

94


Vehicle type D 110


kg



rear axle 1280 1290 1300 1310 1330




rear axle 7400 7400 7400 7400 7400


braked 3500 3500 3500 3500 3500





95


Vehicle type D 120


kg



rear axle 1278 1288 1298 1308 1328




rear axle 7934 7904 7911 7908 7875


braked 6000 6000 6000 6000 6000





96


The plate with the tire inflation pressures issituated in the door space on the driver´sside.

Tires inflation pressures

Tire size

Front axle

Rear axle

Spare wheel

Air pressure (kPa)

245/70 R 17,5 245/70 R 19,5 750 800 800

265/70 R 17,5 265/70 R 19,5 650 675 675

97


Maximum speeds and climbing abilities

Engine Gearbox Disc dimension Rear axle ratio

Maximum theoretical

speed (km/h)

Maximum theoretical

climbing ability (%)

4,10 110 32 17,5x6,75

4,56 99 36,2 ZF 6 S 850

19,5x6,75 4,56 107 33,1

ISBe 150 30

ZF S5-42 17,5x6,75 4,56 103 30,1

3,73 121 32,1

4,10 110 35,9 17,5x6,75

4,56 99 40,6

4,10 119 32,9

ZF 6 S 850

19,5x6,75 4,56 107 37,1

4,10 115 29,8 17,5x6,75

4,56 103 33,6

ISBe 170 30

ZF S5-42

19,5x6,75 4,56 111 30,8

98


Engine oil 13 lCooling circuit c/w heater circuit 19 lGearbox ZF S5-42 3.2 lGearbox ZF 6 S 850 7.5 l (with PTO 8 l)Fuel tank capacity 120 lMinimum fuel reserve 16 lRear axle - 5.14 differential 4 l wheel body 0,25 lRear axle - 8.20 differential 8 l

wheel body 0,25 lMonoblock power steering 1.7 lWindshield washer tank 7.5 lHydraulic circuit for clutch release 0.5 lHydraulic circuit for cabin tilting 0.65 l

Operation fillings

99


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 v

ehicl

ewh

eelba

se (

N, L

, E,S

,G)

chas

sis n

umbe

r

Euro

peCz

ech

Repu

blic

year

of p

rodu

ction

man

ufac

turin

g pla

nt

V I N(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 plate of the right frame longitudinalbeam ahead of the shock absorberholder.The manufacturer´s plate VIN issituated also on the right door jambabove the door lock.

FN1020FN1010

Avia

Ash

ok Le

yland

Mot

ors s

.r.o.

100


Vehicle labels

On the left door jamb abovethe door lockn tires inflation pressures (F)n warning - information about alternator (G)

FN1040n

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

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)

FN1030n FN1053

n notice of air-conditioning (H)

101

A.............................................................Air filter ............................................... 48Air-conditioning* ............................... 22Alternator ........................................... 64Anti - blocking - system .................... 56Ashtray............................................... 31ASR .................................................... 56Axle (front) ......................................... 51Axle (rear) .......................................... 51

B.............................................................Basic rules for the trailer coupling .. 62Battery ............................................... 64Battery circuit breaker ...................... 64Battery location ................................. 63Belt tensioning ................................. 43Bonnet ............................................... 32Brake (emmergency) ....................... 57Brake (parking) ................................. 57Brake (service) ................................. 53Brake lining - checking .................... 55Brake system D100,110,120 ........... 52Brake system inspections ............... 55

C.............................................................Cabin interior lighting ...................... 29Cabin tilting ....................................... 34Cabin tilting at special versions ...... 35Cabin tilting (instructions) ............... 34Clothes,hooks,glove compartment 31

Clutch ................................................ 50Combined lever switch .................... 12Controllers ........................................ 14Cooling system ................................ 47Cruise control ................................... 16Cup holder ........................................ 31

D.............................................................Diagnostic socket ............................ 17Digital clock* ..................................... 30Doors .................................................. 6Draining the fuel filter ....................... 46During driving ................................... 40

E .............................................................Electrical equipment ........................ 62Electrically actuated windows* ......... 7Engine ............................................... 42

F .............................................................Fuel .................................................... 46Fuel tank ........................................... 46Fuse box - cabin ............................... 85Fuse box - under the battery cover .. 87

G.............................................................Gearbox ............................................. 49Gearshift lever .................................. 19

H.............................................................Head restraints ................................ 25

Headlamps and lights - location .... 65Headlamps leveling device ............. 29Heating and ventilation .................... 20

CH ..........................................................Changing the wheel ......................... 78Chassis 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

R.............................................................Rear-view mirrors ............................ 28Rear-viev mirrors remote control* .. 28Replacing bulbs ............................... 79

I N D E X

102

S .............................................................Seat belts .......................................... 26Seats ................................................. 24Sleep couch ...................................... 25Socket / cigarette lighter .................. 30Spare wheel holder (L, E, S, G) ....... 76Spare wheel holder (N) .................... 77Starting the engine ........................... 39Steering ............................................. 48Steering wheel adjustment ............. 19Stopping the engine ......................... 41Sun visors ......................................... 30

T .............................................................Technical data ......................................- Dimensions of chassis c/w cabin ........................................ 92- Engine ............................................. 89- Maximum speeds and climbing abilitie .............................................. 97- Operation fillings ............................ 98- Tires inflation pressures .............. 96- Undercarriage ................................ 90- Weights and axle load ................... 93Tires and wheels ............................. 60Tools and equipment ....................... 33Towing, vehicle recovery .................. 75Transport of loads ............................ 61Troubleshooting ...................................- Brakes ............................................. 73

- Electrical equipments .................... 72- Engine ............................................. 68- Monoblock hydraulic power steering ........................................... 73Turbocharger .................................... 45

U.............................................................Use of jumper cables to start theengine ............................................... 88

V .............................................................Vehicle care ...................................... 66Vehicle identification number .......... 99Vehicle labels .................................100Vehicle running-in ............................ 38

W ...........................................................Wheel chock (L, E, S, G) .................. 76Wheel chock (N) ............................... 77Windshield washer and wipers ...... 59

version 4a / 1/ 2007D100 / 110 / 120Alternations reserved

*

návod d120 str 1-3v

Documents