HD9 Use & Maintenance PDF [PDF]

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USE AND MAINTENANCE HANDBOOK



Euro 3



GB



The company ASTRA VEICOLI INDUSTRIALI reserves the right to make any modifications to vehicles for technical or commercial reasons at any time; the information, descriptions and illustrations contained in this publication are therefore correct at the time going to press. This Use and Maintenance Handbook deals with optional equipment which cannot be present on your vehicle, and alternative equipment as well (e.g. mechanical and automatic gearbox). Moreover, the regulations in force in certain countries affect the standard equipment of the vehicle. This publication could therefore contain information and illustrations not corresponding to the vehicle version provided on a particular market.



ASTRA Veicoli Industriali Product Logistics Via Caorsana, 79 --- 29100 PIACENZA (Italy) Tel. 0523/5431 --- Fax 0523/543459 Print cat. A3502196 First edition - DECEMBER 2011 Second edition - FEBRUARY 2012 Third edition - MAY 2012 Fourth edition - JULY 2012 Fifth edition - FEBRUARY 2013 Reproduction, whether total or partial, of the text and illustrations is strictly forbidden.



I



HD9 Euro3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX After sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI



TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 POSITION OF VEHICLE IDENTIFICATION DATA PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Model identification plate . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Imprinting of the vehicle chassis . . . . . . . . . . . . . . . . . . 1-3 Vehicle identification plate . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Chassis punching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Vehicle registration number . . . . . . . . . . . . . . . . . . . . . . . 1-4 Vehicle identification plate . . . . . . . . . . . . . . . . . . . . . . . . 1-5 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Engine IVECO F2B (Cursor 8) . . . . . . . . . . . . . . . . . . . . 1-6 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Engine IVECO F3B WG (Cursor 13) . . . . . . . . . . . . . . . . 1-7 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine IVECO F3B VGT (Cursor 13) . . . . . . . . . . . . . . . 1-8 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 1-9 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 AUTOMATIZED TRANSMISSION . . . . . . . . . . . . . . . 1-10 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . 1-11 ALLISON HD 4700 gear shift . . . . . . . . . . . . . . . . . . . 1-11 Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 TRANSFER DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . 1-12 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Front steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13



Front steering drive axle 9 ton . . . . . . . . . . . . . . . . . . . Front steering drive axle 10 ton . . . . . . . . . . . . . . . . . . Single rear drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem rear drive axles . . . . . . . . . . . . . . . . . . . . . . . . BRAKES (simplex without ABS) . . . . . . . . . . . . . . . . . BRAKES (duplex with ABS) . . . . . . . . . . . . . . . . . . . . ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicles without auxiliary cylinder . . . . . . . . . . . . . . . Vehicles with auxiliary cylinder . . . . . . . . . . . . . . . . . . Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oversize fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . VEHICLE OUTFITTING . . . . . . . . . . . . . . . . . . . . . . . . Set of keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle outfitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-13 1-13 1-14 1-14 1-15 1-16 1-16 1-17 1-18 1-18 1-18 1-19 1-19 1-19 1-20 1-21 1-21 1-21 1-22 1-24 1-24 1-24 1-24



INSTRUCTIONS FOR USE . . . . . . . . . . . . . . GENERAL INSTRUCTIONS FOR CORRECT USE OF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Night driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driving in rain, fog and snow . . . . . . . . . . . . . . . . . . . Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Snow chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-27 1-29 1-29 1-29 1-30 1-30 1-30 1-30 1-31



II Economic, ecological driving . . . . . . . . . . . . . . . . . . . Range of use of the engine . . . . . . . . . . . . . . . . . . . . . LEFT HAND DRIVE VEHICLES . . . . . . . . . . . . . . . . . CAB-EXTERNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . Front lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear lights --- Version with LED taillights . . . . . . . . . . DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central locking remote control . . . . . . . . . . . . . . . . . . Replacing remote control battery . . . . . . . . . . . . . . . . DRIVERS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTERNAL LIGHTING DEVICE . . . . . . . . . . . . . . . . . . Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL REAR VIEW MIRRORS . . . . . . . . . . . . . . Mirror selection and handling . . . . . . . . . . . . . . . . . . . SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fore and aft adjustment . . . . . . . . . . . . . . . . . . . . . . . . Cushion angle adjustment . . . . . . . . . . . . . . . . . . . . . Seat suspension adjustment . . . . . . . . . . . . . . . . . . . . Springing system adjustment . . . . . . . . . . . . . . . . . . . Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backrest angle adjustment . . . . . . . . . . . . . . . . . . . . . SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRIC WINDOW CONTROL . . . . . . . . . . . . . . . . Electric window risers control . . . . . . . . . . . . . . . . . . . HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPARTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESSORIES - DEVICES . . . . . . . . . . . . . . . . . . . . Sun blind tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



HD9 Euro3 1-31 1-32 1-33 1-33 1-34 1-34 1-35 1-36 1-37 1-39 1-40 1-42 1-44 1-44 1-45 1-46 1-48 1-48 1-48 1-48 1-49 1-49 1-49 1-50 1-52 1-52 1-53 1-54 1-54 1-54 1-55 1-55 1-55 1-55 1-56 1-56



Grip handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coat hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Volt current socket . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls on dashboard . . . . . . . . . . . . . . . . . . . . . . . . Module holder dashboard controls . . . . . . . . . . . . . . Steering wheel position control . . . . . . . . . . . . . . . . . . Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual transmission control . . . . . . . . . . . . . . . . . . . . Automated transmission control . . . . . . . . . . . . . . . . . Automatic transmission control . . . . . . . . . . . . . . . . . . RIGHT-HAND DRIVE VEHICLES . . . . . . . . . . . . . . . . CAB EXTERNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . Front lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear lights --- Version with LED taillights . . . . . . . . . . DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central locking remote control . . . . . . . . . . . . . . . . . . Replacing remote control battery . . . . . . . . . . . . . . . . DRIVERS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTERNAL LIGHTING DEVICE . . . . . . . . . . . . . . . . . . Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTERNAL REAR VIEW MIRRORS . . . . . . . . . . . . . . Mirror selection and handling . . . . . . . . . . . . . . . . . . . SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fore and aft adjustment . . . . . . . . . . . . . . . . . . . . . . . . Cushion angle adjustment . . . . . . . . . . . . . . . . . . . . . Seat suspension adjustment . . . . . . . . . . . . . . . . . . . . Springing system adjustment . . . . . . . . . . . . . . . . . . . Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backrest angle adjustment . . . . . . . . . . . . . . . . . . . . .



1-56 1-56 1-56 1-56 1-56 1-57 1-57 1-58 1-59 1-60 1-60 1-60 1-61 1-61 1-61 1-63 1-63 1-64 1-64 1-65 1-66 1-67 1-69 1-70 1-72 1-74 1-74 1-75 1-76 1-78 1-78 1-78 1-78 1-79 1-79 1-79



III



HD9 Euro3 SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRIC WINDOW CONTROL . . . . . . . . . . . . . . . . Electric window risers control . . . . . . . . . . . . . . . . . . . HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPARTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESSORIES - DEVICES . . . . . . . . . . . . . . . . . . . . Sun blind tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grip handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coat hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Volt current socket . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls on dashboard . . . . . . . . . . . . . . . . . . . . . . . . Module holder dashboard controls . . . . . . . . . . . . . . Steering wheel position control . . . . . . . . . . . . . . . . . . Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual gear shift lever . . . . . . . . . . . . . . . . . . . . . . . . . Automated transmission control . . . . . . . . . . . . . . . . . Automatic transmission command . . . . . . . . . . . . . . . ALL VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functions of instrument panel keys . . . . . . . . . . . . . . Warning lights panel A details . . . . . . . . . . . . . . . . . . . Warning lights panel B details . . . . . . . . . . . . . . . . . . . Warning lights panel C details . . . . . . . . . . . . . . . . . . Automated transmission display . . . . . . . . . . . . . . . .



1-80 1-82 1-82 1-83 1-84 1-84 1-84 1-85 1-85 1-85 1-85 1-86 1-86 1-86 1-86 1-86 1-86 1-86 1-87 1-87 1-88 1-89 1-90 1-90 1-90 1-91 1-91 1-91 1-92 1-92 1-92 1-94 1-95 1-96 1-97 1-98



Automated transmission indications on display . . . . 1-98 Automatic transmission display . . . . . . . . . . . . . . . . . 1-99 Automatic transmission indications on display . . . . . 1-99 Automatic transmission warning lights . . . . . . . . . . . 1-99 Warning light on dashboard --- Left---hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100 Warning light on dashboard --- Right---hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101 CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . 1-102 Position and headlight controls . . . . . . . . . . . . . . . . . 1-102 Headlight control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102 Direction indicator control . . . . . . . . . . . . . . . . . . . . . 1-103 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103 Windscreen washer/wiper control . . . . . . . . . . . . . . 1-104 Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105 Engine braking control - Vehicles without intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105 Engine braking control - Vehicles with intarder . . . . 1-105 Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106 Hazard light control . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107 Exhaust brake pre-selection . . . . . . . . . . . . . . . . . . . 1-107 Courtesy light switch . . . . . . . . . . . . . . . . . . . . . . . . . 1-108 Electro-pneumatic horn pre-selection . . . . . . . . . . . 1-108 Swivelling light control . . . . . . . . . . . . . . . . . . . . . . . . 1-109 Work light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 Fog light control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 Electric battery isolator control . . . . . . . . . . . . . . . . . 1-110 ASR off command . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111 ABS Off Road function control . . . . . . . . . . . . . . . . . 1-112 Distributor-reducer (transfer) . . . . . . . . . . . . . . . . . . . 1-113 Differential lock control (2 axle vehicles) . . . . . . . . . 1-114 Differential lock control (3-4 axle vehicles) . . . . . . . 1-116 Power take off control . . . . . . . . . . . . . . . . . . . . . . . . 1-118 Multipower PTO on flywheel . . . . . . . . . . . . . . . . . . . 1-119 P.T.O. manual transmission . . . . . . . . . . . . . . . . . . . . 1-120



IV P.T.O. on automated gearbox . . . . . . . . . . . . . . . . . P.T.O. on automatic transmission . . . . . . . . . . . . TACHOMETRIC SIMULATOR . . . . . . . . . . . . . . . . . . HEATING AND VENTILATION . . . . . . . . . . . . . . . . . Climate control system air vents . . . . . . . . . . . . . . . . Climate controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Most common control positions . . . . . . . . . . . . . . . . AUXILIARY HEATER (WEBASTO) . . . . . . . . . . . . . . AUXILIARY HEATER (WEBASTO) . . . . . . . . . . . . . . Auxiliary heater control panel . . . . . . . . . . . . . . . . . . Operation of the heater with key-off without programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USE OF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . Precautions for the initial period of use . . . . . . . . . . General checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . Checks before starting . . . . . . . . . . . . . . . . . . . . . . . . Starting from drivers cabin . . . . . . . . . . . . . . . . . . . . Starting from engine bay . . . . . . . . . . . . . . . . . . . . . . Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency electrical power . . . . . . . . . . . . . . . . . . . COLD START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with heater . . . . . . . . . . . . . . . . . . . . . . . . . . STOPPING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . Stopping from drivers cabin . . . . . . . . . . . . . . . . . . . Stopping from engine bay . . . . . . . . . . . . . . . . . . . . . MANUAL TRANSMISSION VEHICLES . . . . . . . . . . STARTING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . Splitter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLES WITH AUTOMATED TRANSMISSION



HD9 Euro3 1-121 1-122 1-123 1-125 1-125 1-126 1-128 1-132 1-133 1-133 1-135 1-137 1-137 1-137 1-138 1-139 1-140 1-140 1-141 1-141 1-142 1-144 1-145 1-146 1-146 1-147 1-149 1-149 1-150 1-152 1-152 1-153 1-154 1-155



(ASTRONIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EUROTRONIC TRANSMISSION . . . . . . . . . . . . . . . Changing to high gears . . . . . . . . . . . . . . . . . . . . . . . Shifting to lower gears . . . . . . . . . . . . . . . . . . . . . . . . STARTING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-up in automatic mode . . . . . . . . . . . . . . . . . . . . Start-up in manual mode . . . . . . . . . . . . . . . . . . . . . . DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . Forward movement in automatic mode . . . . . . . . . . Forward travel gear change in automatic mode . . . Shifting to next gear down . . . . . . . . . . . . . . . . . . . . Shifting to higher gears . . . . . . . . . . . . . . . . . . . . . . . Kick-down function . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining the selected gear . . . . . . . . . . . . . . . . . . Forward running in manual mode . . . . . . . . . . . . . . Shifting to next gear down . . . . . . . . . . . . . . . . . . . . Shifting to higher gears . . . . . . . . . . . . . . . . . . . . . . . Shift to neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . “LIMP HOME” function . . . . . . . . . . . . . . . . . . . . . . . STOPPING THE VEHICLE . . . . . . . . . . . . . . . . . . . . VEHICLES WITH AUTOMATIC TRANSMISSION . . STARTING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . Kick-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . N (Neutral) position . . . . . . . . . . . . . . . . . . . . . . . . . . R (Reverse) position . . . . . . . . . . . . . . . . . . . . . . . . . . Drive position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positions 6, 5, 4 and 3 . . . . . . . . . . . . . . . . . . . . . . . . Position 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . ALL VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEED PROGRAMMER . . . . . . . . . . . . . . . . . . . . . .



1-157 1-157 1-157 1-157 1-158 1-159 1-160 1-161 1-163 1-163 1-164 1-164 1-165 1-165 1-166 1-166 1-166 1-167 1-168 1-170 1-171 1-175 1-177 1-177 1-179 1-180 1-181 1-183 1-183 1-184 1-185 1-185 1-185 1-186 1-187 1-189 1-189



V



HD9 Euro3 Engine idle speed adjustment / memorising . . . . . Vehicle speed (Cruise Control) adjustment / memorising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Permanent disable . . . . . . . . . . . . . . . . . . . . . . . . . . . Temporary disable . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE BRAKE CONTROL SELECTION . . . . . . . Vehicles without intarder . . . . . . . . . . . . . . . . . . . . . . Vehicles fitted with intarder . . . . . . . . . . . . . . . . . . . . VEHICLE PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake --- vehicles without trailer . . . . . . . . . Parking brake --- vehicle with trailer . . . . . . . . . . . . . Parking brake efficiency check . . . . . . . . . . . . . . . . . Additional parking brake . . . . . . . . . . . . . . . . . . . . . . A.B.S. Anti-lock braking system . . . . . . . . . . . . . . . . SEMI-TRAILER COUPLING . . . . . . . . . . . . . . . . . . . Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS coupling (if foreseen) . . . . . . . . . . . . . . . . . . . . Pivoting fifth wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAILER HOOKING --- I type . . . . . . . . . . . . . . . . . . TRAILER HOOKING --- II type . . . . . . . . . . . . . . . . . . NORMS FOR TOWING TRAILER / SEMI-TRAILER Before hitching-up . . . . . . . . . . . . . . . . . . . . . . . . . . . After hitching-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAILER COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . Electric coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEMI-TRAILER COUPLING . . . . . . . . . . . . . . . . . . . Pneumatic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . Electric coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-189 1-191 1-193 1-194 1-195 1-195 1-196 1-196 1-198 1-200 1-200 1-201 1-201 1-202 1-203 1-205 1-205 1-206 1-206 1-206 1-207 1-208 1-209 1-210 1-210 1-210 1-210 1-211 1-211 1-211 1-211 1-211 1-211 1-211



TOWING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . Propeller shaft removal . . . . . . . . . . . . . . . . . . . . . . . Flanges to be removed . . . . . . . . . . . . . . . . . . . . . . . Spring cylinder emergency braking device . . . . . . . WHEEL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jacking up the vehicle . . . . . . . . . . . . . . . . . . . . . . . . Changing a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the spare wheel . . . . . . . . . . . . . . . . . . . . . DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTICS --- CONNECTIONS FOR CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . Use of jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-212 1-213 1-214 1-215 1-216 1-218 1-218 1-219 1-222 1-223 1-224 1-224



MAINTENANCE INSTRUCTIONS . . . . . . 1-225 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPENING RADIATOR GRILL . . . . . . . . . . . . . . . . . . TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN LEVELS CHECK . . . . . . . . . . . . . . . . . . . . . . . Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . Check engine coolant level . . . . . . . . . . . . . . . . . . . . Check windshield washer level . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing engine oil filter F2B . . . . . . . . . . . . . . . . . Replacing engine oil filter F3B . . . . . . . . . . . . . . . . . Engine oil vapour filter change . . . . . . . . . . . . . . . . . Accessory drive belts check . . . . . . . . . . . . . . . . . . . Intake-exhaust valve play adjustment . . . . . . . . . . . Injector-pump pre-load adjustment . . . . . . . . . . . . . VGT actuator grease application procedure . . . . . . FUEL FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . Bleed fuel tank condensation water . . . . . . . . . . . . .



1-227 1-228 1-229 1-229 1-230 1-232 1-232 1-233 1-233 1-234 1-234 1-236 1-237 1-238 1-239 1-240 1-240 1-240 1-241 1-241



VI Fuel tank water drain . . . . . . . . . . . . . . . . . . . . . . . . . Purging water from fuel decanter . . . . . . . . . . . . . . . Replacing fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel circuit bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake system seal check . . . . . . . . . . . . . . . . . . . . . Turbocompressor lubrication check . . . . . . . . . . . . . Intercooler external cleaning . . . . . . . . . . . . . . . . . . . Main filter element cleaning/change . . . . . . . . . . . . Safety secondary filter element replacement . . . . . Replacing the VGT piloting hoses filtering element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing engine coolant . . . . . . . . . . . . . . . . . . . . . Checking antifreeze concentration . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check clutch disengagement . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the hydraulic fluid . . . . . . . . . . . . . . . . . . . Air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MULTIPOWER PTO . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF NMV 221 POWER TAKE OFF --- TYPE I . . . . . . Oil level check/change . . . . . . . . . . . . . . . . . . . . . . . . Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Version without retarder . . . . . . . . . . . . . . . . . . . . . . . Version with retarder . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . AUTOMATED TRANSMISSION . . . . . . . . . . . . . . . .



HD9 Euro3 1-242 1-242 1-243 1-245 1-246 1-246 1-246 1-246 1-247 1-248 1-249 1-250 1-251 1-252 1-253 1-253 1-253 1-254 1-254 1-255 1-255 1-256 1-257 1-257 1-257 1-258 1-258 1-259 1-260 1-260 1-261 1-261 1-262 1-263 1-264



Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Version without retarder . . . . . . . . . . . . . . . . . . . . . . . Version with retarder . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot check (80-100 ˚C) on display . . . . . . . . . . . . . . Cold check (15-45 ˚C) . . . . . . . . . . . . . . . . . . . . . . . . Hot check (80-100 ˚C) . . . . . . . . . . . . . . . . . . . . . . . . Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . DISTRIBUTOR-TRANSFER (TRANSFER) --TYPE I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISTRIBUTOR-TRANSFER (TRANSFER) --TYPE II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPLITTER-REDUCER (TRANSFER CASE) --TYPE III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check differential oil level . . . . . . . . . . . . . . . . . . . . . Differential oil change . . . . . . . . . . . . . . . . . . . . . . . . Hub oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front axle - 10 ton version / K version . . . . . . . . . . . Checking differential oil level . . . . . . . . . . . . . . . . . . . Changing differential oil . . . . . . . . . . . . . . . . . . . . . . . Checking oil hub level . . . . . . . . . . . . . . . . . . . . . . . .



1-264 1-265 1-265 1-266 1-267 1-268 1-268 1-268 1-270 1-271 1-272 1-273 1-274 1-274 1-275 1-276 1-276 1-277 1-278 1-278 1-279 1-280 1-280 1-281 1-281 1-281 1-281 1-282 1-283 1-284 1-284 1-284 1-285



VII



HD9 Euro3 Changing hub oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front intermediate axle . . . . . . . . . . . . . . . . . . . . . . . Check differential oil level . . . . . . . . . . . . . . . . . . . . . Differential oil change . . . . . . . . . . . . . . . . . . . . . . . . Hub oil level check/change . . . . . . . . . . . . . . . . . . . . Rear intermediate axle . . . . . . . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leaf spring pins greasing . . . . . . . . . . . . . . . . . . . . . Carriage pin greasing on 3 and 4-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the hydraulic oil --- Vehicles without auxiliary cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding off air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the hydraulic oil for --- Vehicles with auxiliary cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding off air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stub axle greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering linkage grease application . . . . . . . . . . . . . 3-axle vehicles with auxiliary cylinder . . . . . . . . . . . . 4-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wheel toe-in check . . . . . . . . . . . . . . . . . . . . . . Front wheel toe-in check . . . . . . . . . . . . . . . . . . . . . . COMPRESSED AIR SYSTEM . . . . . . . . . . . . . . . . . . Tank visual inspection . . . . . . . . . . . . . . . . . . . . . . . .



1-286 1-287 1-287 1-287 1-287 1-288 1-288 1-289 1-290 1-290 1-291 1-292 1-292 1-293 1-294 1-294 1-295 1-295 1-295 1-296 1-297 1-297 1-297 1-298 1-299 1-300 1-301 1-301 1-301 1-302 1-303 1-304 1-304



Air dryer functionality check . . . . . . . . . . . . . . . . . . . Air dryer filter change . . . . . . . . . . . . . . . . . . . . . . . . . BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe-drum play check . . . . . . . . . . . . . . . . . . . . . . . Check pedal distributors . . . . . . . . . . . . . . . . . . . . . . TYRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . Checking wheels and tyres . . . . . . . . . . . . . . . . . . . . Inflating tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB TIPPING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . Oil level check / fluid change . . . . . . . . . . . . . . . . . . Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOWING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . Greasing the fifth wheel . . . . . . . . . . . . . . . . . . . . . . . Tow hook greasing --- Type I . . . . . . . . . . . . . . . . . . . Tow hook greasing --- Type II . . . . . . . . . . . . . . . . . . AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . Air-conditioner system maintenance . . . . . . . . . . . . System charge check . . . . . . . . . . . . . . . . . . . . . . . . SUPPLEMENTARY HEATER . . . . . . . . . . . . . . . . . . Replacing the supplementary heater fuel filter . . . . BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing front windscreen wiper blade . . . . . . . . . Windscreen washer reservoir . . . . . . . . . . . . . . . . . . Bodywork maintenance . . . . . . . . . . . . . . . . . . . . . . . Cleaning plastic parts . . . . . . . . . . . . . . . . . . . . . . . . Fabric panels cleaning . . . . . . . . . . . . . . . . . . . . . . . . Cleaning seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight/front sidelight bulb replacement . . . . . . . Headlight alignment . . . . . . . . . . . . . . . . . . . . . . . . . . Front direction indicator light bulb replacement . . . Side direction indicator bulb replacement . . . . . . . . Rear light bulb replacement . . . . . . . . . . . . . . . . . . . Front clearance light bulb replacement . . . . . . . . . . Rotary warning light bulb replacement . . . . . . . . . . Ceiling light bulb replacement . . . . . . . . . . . . . . . . .



1-305 1-306 1-307 1-307 1-307 1-308 1-308 1-308 1-309 1-309 1-310 1-311 1-311 1-312 1-312 1-313 1-313 1-314 1-315 1-315 1-316 1-316 1-316 1-317 1-317 1-317 1-317 1-318 1-318 1-319 1-320 1-320 1-321 1-322 1-322 1-322



VIII



HD9 Euro3



Replacing cab step light . . . . . . . . . . . . . . . . . . . . . . List of bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery maintenance (unsealed batteries) . . . . . . . . Recharge with external devices . . . . . . . . . . . . . . . . Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . Interconnection control unit (fuses and relays) . . . . Fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE / RELAYS HOLDER PLATE . . . . . . . . . . . . . . FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70005) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70601) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70602) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70401) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70402) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70403) not used . . . . . . . . . . . . . . . . . . RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional relays board . . . . . . . . . . . . . . . . . . . . . . . Supplementary flying fuse . . . . . . . . . . . . . . . . . . . . .



1-322 1-323 1-324 1-324 1-325 1-327 1-328 1-329 1-329 1-330 1-331 1-331 1-332 1-332 1-333 1-333 1-333 1-334 1-336 1-337



TABLE AND DIAGRAMS . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM . . 2-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . Engine F3B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine F2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . Automated/automatic transmission . . . . . . . . . . . . . Multipower/NMV 221 power take off . . . . . . . . . . . . Drive-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-339 1-341 1-342 1-342 1-334 1-346 1-348 1-348 1-350 1-352 1-354 1-354 1-356 1-358



Greasing transmission shafts . . . . . . . . . . . . . . . . . . Suspension geasing . . . . . . . . . . . . . . . . . . . . . . . . . Steering linkages, semi-trailer fifth wheel, tow hook greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . Checking, adjusting and cleaning operations . . . . . Lubrication and replacement operations --Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication and replacement operations --Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICANT AND HYDRAULIC FLUID TABLES . . .



1-360 1-362 1-364 1-366 1-368 1-368 1-370 1-371 1-372



APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-373 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEFT-HAND DRIVE VEHICLES . . . . . . . . . . . . . . . . Mirror selection and handling . . . . . . . . . . . . . . . . . . Automated transmission control . . . . . . . . . . . . . . . . RIGHT-HAND DRIVE VEHICLES . . . . . . . . . . . . . . . Mirror selection and handling . . . . . . . . . . . . . . . . . . Automated transmission control . . . . . . . . . . . . . . . . ALL VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functions of instrument panel keys . . . . . . . . . . . . . Warning lights panel A details . . . . . . . . . . . . . . . . . . Warning lights panel B details . . . . . . . . . . . . . . . . . . Warning lights panel C details . . . . . . . . . . . . . . . . . DISPLAY STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . Automated transmission display . . . . . . . . . . . . . . . Indications on the instrument display . . . . . . . . . . . Display operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display menu structure . . . . . . . . . . . . . . . . . . . . . . . KEY ON (CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-375 1-376 1-376 1-377 1-378 1-378 1-379 1-380 1-380 1-380 1-382 1-383 1-384 1-385 1-386 1-390 1-390 1-392 1-392 1-393 1-394 1-395



IX



HD9 Euro3 FRONT/REAR AXLES BRAKING SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL TEMPERATURE . . . . . . . . . . . . . . . . . RADIO --- CD PLAYER . . . . . . . . . . . . . . . . . . . . . . . . DIALOGUE MENU V . . . . . . . . . . . . . . . . . . . . . . . . . . SOUND SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRIP 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRIP 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PASSWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNCTIONS VIEWED ON THE DISPLAY . . . . . . . . CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . Position and headlight controls . . . . . . . . . . . . . . . . Headlight control . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction indicator control . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen washer/wiper control . . . . . . . . . . . . . . Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine braking control . . . . . . . . . . . . . . . . . . . . . . . Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard light control . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust brake pre-selection . . . . . . . . . . . . . . . . . . . Courtesy light switch . . . . . . . . . . . . . . . . . . . . . . . . . Electro-pneumatic horn pre-selection . . . . . . . . . . . Swivelling light control . . . . . . . . . . . . . . . . . . . . . . . . Work light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fog light control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric battery isolator control . . . . . . . . . . . . . . . . . ASR off command . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS Off Road function control . . . . . . . . . . . . . . . . . USE OF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . .



1-396 1-398 1-400 1-402 1-404 1-407 1-408 1-410 1-412 1-414 1-415 1-420 1-421 1-422 1-424 1-433 1-433 1-433 1-434 1-434 1-435 1-436 1-436 1-437 1-438 1-438 1-439 1-439 1-440 1-440 1-440 1-441 1-441 1-442 1-443 1-445



Precautions for the initial period of use . . . . . . . . . . General checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . Checks before starting . . . . . . . . . . . . . . . . . . . . . . . . Starting from the driver’s cab . . . . . . . . . . . . . . . . . . Starting from engine bay . . . . . . . . . . . . . . . . . . . . . . Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUTOMATED TRANSMISSION (ASTRONIC) Type II STARTING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-up in automatic mode . . . . . . . . . . . . . . . . . . . . Start-up in manual mode . . . . . . . . . . . . . . . . . . . . . . DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . Forward movement in automatic mode . . . . . . . . . . Upshifting and downshifting . . . . . . . . . . . . . . . . . . . Kick-down function . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining the selected gear . . . . . . . . . . . . . . . . . . Forward running in manual mode . . . . . . . . . . . . . . Shifting to higher gears . . . . . . . . . . . . . . . . . . . . . . . Shifting to lower gears) . . . . . . . . . . . . . . . . . . . . . . . Shift to neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engaging reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . OFF ROAD Function . . . . . . . . . . . . . . . . . . . . . . . . . Manoeuvring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEED PROGRAMMER . . . . . . . . . . . . . . . . . . . . . . Engine idle speed adjustment / memorising . . . . . Vehicle speed (Cruise Control) adjustment / memorising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Permanent disable . . . . . . . . . . . . . . . . . . . . . . . . . . . Temporary disable . . . . . . . . . . . . . . . . . . . . . . . . . . . A.B.S. Anti-lock braking system . . . . . . . . . . . . . . . .



1-445 1-445 1-446 1-447 1-448 1-450 1-450 1-452 1-454 1-454 1-455 1-456 1-457 1-458 1-460 1-462 1-462 1-463 1-463 1-464 1-464 1-464 1-465 1-466 1-466 1-467 1-468 1-469 1-470 1-470 1-472 1-474 1-475 1-476 1-477 1-478



X DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTICS --- CONNECTIONS FOR CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . Use of jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE / RELAYS HOLDER PLATE . . . . . . . . . . . . . . FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70005) . . . . . . . . . . . . . . . . . . . . . . . . . .



HD9 Euro3 1-479 1-482 1-482 1-483 1-484 1-484



Fuse holder (70601) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70602) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70401) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70402) . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse holder (70403) . . . . . . . . . . . . . . . . . . . . . . . . . . RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-485 1-485 1-485 1-486 1-486 1-487



XI



HD9 Euro3 INTRODUCTION This Use and Maintenance Handbook is divided into 4 parts, each of which systematically subdivided according to subject, for quick and easy consulting. 1)



Technical specifications: this contains all the characteristic data which should be read through at least once to acquire a working knowledge of the vehicle.



2)



Use of the vehicle and practical hints: this contains information relevant to the main controls and instruments, and the main rules to be followed especially for new vehicles.



3)



Maintenance instructions: this section contains the functional instructions for checking and maintaining the vehicle which must be implemented to ensure satisfying operation, cost-effective running and long life of the vehicle.



4)



Tables and diagrams: contains vehicle scheduled maintenance tables and diagrams.



In this Use and Maintenance Handbook there are texts that are highlighted in a particular manner: Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause injury. WARNING Standards for use of the AsTronic2 V35 version (recognisable by the pushbutton selector on the dashboard in lieu of the selection lever) are stated in the APPENDIX of this volume.



Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause damage to the vehicle. Procedures, technical information and precautions which must be highlighted. Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause environmental damages.



XII AFTER SALES SERVICE Warranty To comply to the warranty conditions, all the instructions for correct use and maintenance described in this manual are to be followed. After-sales service For any type of servicing the ASTRA V.I. Dealership is at the complete disposal of the Customer. Equipment and skilled staff are available for maintenance or repair jobs. The ASTRA V.I. Dealership is always willing to offer you hints and advice to ensure you get best performance from your vehicle. Spare parts Any spare parts used for replacements are to be “GENUINE ASTRA SPARES” which can be obtained from the dealer warehouses and authorised workshops. Remember that a correct order for spare parts must always include the following details: – type of vehicle; – chassis number; – reference and category numbers, to be found in the Spare Parts Catalogue. If the items are parts of a main group (engine, cab, axles, power steering, gearbox etc.) indicate also the group version and serial number.



HD9 Euro3



HD9 Euro3



XIII



WARNING The handbook contains use and maintenance instructions for all systems foreseen on the vehicle by the Manufacturer. Some systems described in the handbook may not be present on Your vehicle, according to the chosen version and market the vehicle is destined for. Assembly of accessories, additions and modifications on the vehicle are to be carried out in conformity with ASTRA directives. The specific document “Directive for conversion and outfittings” can be obtained as a guideline from the After Sales Service workshops. It is reminded that, especially regarding the electrical system. there are several electrical sockets available (standard or optionals) to simplify electrical operations carried out by the outfitters. For any exemption from the directives for the conversion it is necessary to have authorisation from ASTRA. It is strictly forbidden to make modifications or connections to the wiring of electronic control units. In particular the interconnection lines between control units (CAN lines) are never to be interfered with. Diagnostics and maintenance operations are to be carried out by skilled personnel using approved diagnostics equipment. Ignoring these afore-mentioned prescriptions will annul the contractual warranty .



XIV



HD9 Euro3



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1
1



HD9 Euro3



Technical data



1
2



HD9 Euro3



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1
3



HD9 Euro3



1A



1B



POSITION OF VEHICLE IDENTIFICATION DATA PLATES Model identification plate Located on the side walls of the cab (Fig. 1A vers. LHD, Fig. 1B vers. RHD, see arrow).



342BNU001L



2



356ADT101L



Imprinting of the vehicle chassis Punch marked at the front end of the right-hand side member (Fig. 2, see arrow). (see following page).



Vehicle identification plate Applied below the front grille on the right side for vehicle identification (Fig. 3A vers LHD, Fig. 3B vers RHD, see arrow). (see following page).



1
4



HD9 Euro3



b



1



Chassis punching (Fig. 1) a. right side member b. rear axle front leaf spring



2



Vehicle registration number (Fig. 2) 22) World–wide identification of manufacturers (Astra Veicoli Industriali S.p.A.) 23) Type of vehicle 24) Vehicle features 18) Year of construction 19) Production facility (P=Piacenza) 6) Chassis number



a



1
5



HD9 Euro3



1



3



357ADT201L



Vehicle identification plate (Fig. 3) 1. Approved type number marking 2. Vehicle chassis punching 3. Code of country issuing type approval 4. Not used 5. Full load maximum weight legally admissible 6. Full load maximum weight technically admissible 7. Assembly maximum weight legally admissible 8. Assembly maximum weight technically admissible 9. 1st axle maximum weight legally admissible 10. 1st axle maximum weight technically admissible 11. 2nd axle maximum weight legally admissible 12. 2nd axle maximum weight technically admissible 13. 3rd axle maximum weight legally admissible 14. 3rd axle maximum weight technically admissible 15. 4th axle maximum weight legally admissible 16. 4th axle maximum weight technically admissible 17. 5th axle maximum weight legally admissible 18. 5th axle maximum weight technically admissible 19. Axles unit maximum weight legally admissible 20. Axles unit maximum weight technically admissible 21. Vehicle commercial name 22. Lights inclination percentage 23. Distance between axles 24. Number of axles 25. Type of engine 26. Engine power 27. Smokiness index



1
6



HD9 Euro3



1



ENGINE Engine IVECO F2B (Cursor 8) (Fig. 1) 4-stroke Diesel, liquid cooled, variable geometry exhaust gas turbocharger. Main specifications



285ADT002L



Number of cylinders Bore Stroke Total displacement Compression ratio Injection order



mm mm cm3



6 115 125 7790 16.5 1-4-2-6-3-5



1
7



HD9 Euro3



1



ENGINE Engine IVECO F3B WG (Cursor 13) (Fig. 1) 4-stroke Diesel, liquid cooled, turbocharger with Wastegate pressure limiter. Main specifications



285ADT003L



Number of cylinders Bore Stroke Total displacement Compression ratio Injection order



mm mm cm3



6 135 150 12882 16.5 1-4-2-6-3-5



1
8



HD9 Euro3



1



ENGINE Engine IVECO F3B VGT (Cursor 13) (Fig. 1) 4-stroke Diesel, liquid cooled, variable geometry exhaust gas turbocharger. Main specifications



285ADT003L



Number of cylinders Bore Stroke Total displacement Compression ratio Injection order



mm mm cm3



6 135 150 12882 16.5 1-4-2-6-3-5



1
9



HD9 Euro3



1



MANUAL TRANSMISSION Clutch Dry single disk. Diameter 17”. Hydraulic control.



341BDT001L



Gear shift (Fig. 1) ZF 16 S 1620 TD, ZF 16 S 1820 TO, ZF 16 S 1920 TD, ZF 16 S 2220 TO, ZF 16 S 2220 TD, ZF 16 S 2320 TD, ZF 16 S 2520 TO, ZF 16 S 2720 TO Syncromesh manual with 8 forward gears, split into a low range group (1- 4) and a high range group (5 - 8), and 1 R.G, normal and low. Pneumatic servoshift device. Neutral switch for preventing starting the motor with gear engaged. Hydrodynamic retarder (intarder) mounted on gearbox output (optional). Ratios



1st 2nd 3rd 4th 5th 6th 7th 8th R.G.



Direct Drive Normal Low 13.80 16.41 9.49 11.28 6.53 7.76 4.57 5.43 3.02 3.59 2.08 2.47 1.43 1.70 1.00 1.19 12.92 15.36



R.G. = Reverse Gear



Over Drive Normal 11.54 7.93 5.46 3.82 2.53 1.74 1.20 0.84 10.80



Low 13.80 9.49 6.53 4.57 3.02 2.08 1.43 1.00 12.92



1
10



HD9 Euro3



1



AUTOMATIZED TRANSMISSION Clutch Dry single disk, Diameter 17”. Electro-pneumatic control. Gear shift ZF 16 AS 2601 OD Manual with 16 forward and 2 reverse gears. Electro-pneumatic servoshift. Automatic or manual mode selection. Version V33 (TYPE I): Lever selector Version V35 (TYPE I): Pushbutton selector Hydrodynamic intarder mounted on gearbox output (if present). Ratios 1st



14.12



9th



3.09



2nd



11.67



10th



2.55



3rd



9.53



11th



2.08



4th



7.88



12th



1.72



5th



6.52



13th



1.42



6th



5.39



14th



1.18



7th



4.56



15th



1.00



8th



3.77



16th



0.82



1 R.G.



13.07



2 R.G.



10.81



R.G. = Reverse Gear



1
11



HD9 Euro3



1



AUTOMATIC TRANSMISSION ALLISON HD 4700 gear shift Epicyclical automatic, 7 forward plus reverse. Hydrodynamic torque converter with free wheeldistributor . Automatic engage converter lock-up clutch. Hydrodynamic retarder built-in.



306ADT001L



Ratios 1st



1:7.63



2nd



1:3.51



3rd



1:1.91



4th



1:1.43



5th



1:1.00



6th



1:0.74



7th



1:0.64



R.G.



1:4.80



R.G. = Reverse Gear



1
12



HD9 Euro3



1



TRANSFER DISTRIBUTOR STEYR VG 2700/400 (Fig. 1) Transmission ratios: Normal (on road): 0.913 Low (off road): 1.407 Maximum torque at input: 30.000 Nm



283092101



IVECO ZF TC 2200 (Fig. 2)



2



Transmission ratios: Normal (on road): 1.0 Low (off road): 1.6 Maximum torque on input: 22.000 Nm STEYR VG 2000 (Fig. 3)



342ADT001L



3



Transmission ratios: Normal (on road): 0.89 Low (off road): 1.536 Maximum torque on input: 25.000 Nm



1
13



HD9 Euro3



1



2



3



AXLES Front steering axle (Fig. 1) In high strength drop-forged steel, steering type, not drive.



Front steering drive axle 9 ton (Fig. 2) With double reduction (central and final) in wheel hubs by means of epicyclical gear set. Drive shafts controlling front wheels equipped with Cardan joints.



Front steering drive axle 10 ton (Fig. 3) With double reduction (central and final) in wheel hubs by means of epicyclical gear set. Drive shafts controlling front wheels equipped with Cardan joints.



1
14



HD9 Euro3 Single rear drive axle (Fig. 1) With double reduction, central by pinion set and final in wheel hubs with epycicloid gear. Differential between wheels with pneumatic lock.



1



2



Tandem rear drive axles (Fig. 2) Two drive axles in tandem with double reduction, central with bevel gear and final in wheel hubs with epicyclical gear set. The tandem is provided with splitter between axles and pneumatic lock. Differential between wheels with pneumatic lock.



1
15



HD9 Euro3



1



BRAKES (simplex without ABS) Simplex wedge drum brakes (Fig. 1) on all axles. Brake adjustment is automatic and therefore maintenance free until total brake lining wear. Service brake: pneumatic operation with two independent sections for vehicles without tow bar, three independent sections for vehicles with tow bar. Parking and emergency brake: pneumatic operation acting on rear wheel brake drums through spring cylinder. Engine brake: built into engine. Retarder brake: hydraulic, installed on transmission. Auxiliary parking brake: pneumatic operation: must be engaged with engine running.



1
16



HD9 Euro3



1



BRAKES (duplex with ABS) Duplex wedge drum brakes (Fig. 1) on all axles. Brake adjustment is automatic and therefore maintenance free until total brake lining wear. Service brake: pneumatic operation with two independent sections for vehicles without tow bar, three independent sections for vehicles with tow bar. Parking and emergency brake: pneumatic operation acting on rear wheel brake drums through spring cylinder. Engine brake: built into engine. Retarder brake: hydraulic, installed on transmission. Auxiliary parking brake: pneumatic operation: must be engaged with engine running. ABS Wheel anti-lock system (ABS) with four channel electronic system and four solenoid valves that exercise the ABS function during the braking phase. Pulse generators and sensors on 1st and 2nd axles (2-axle vehicles). Pulse generators and sensors on 1st and 3rd axles (3-axle vehicles). Pulse generators and sensors on 2nd and 4th axles (2-axle vehicles).



1
17



HD9 Euro3 TYRES Front: Rear:



single (*) double (**) or single (*) DIMENSION



13R22.5



315/80R22.5



495/45R22.5 445/65R22.5



TYPE MICHELIN XZY2 MICHELIN XDY3 MICHELIN XZH PIRELLI AP05 PIRELLI AT75 PIRELLI AT99 PIRELLI FG85 PIRELLI TG85 PIRELLI FG88 PIRELLI TG88 CONTINENTAL HSC CONTINENTAL HDC MICHELIN XZY2 MICHELIN XDY3 MICHELIN XZE2 MICHELIN XDE2 MICHELIN XDE2+ PIRELLI AP05 PIRELLI AT75 PIRELLI FG85 PIRELLI TG85 PIRELLI FG88 PIRELLI TG88 CONTINENTAL HSR1 CONTINENTAL HDR MICHELIN XDA2 MICHELIN XZL



(*) bar 8 8 8 9 8.5 9 9 9 9 8.5 8.5 8.5 8.5 8.5 8 8 8 8 8.5 8.5 9 8



(**) bar 8 8 8 9 8.5 9 9 9 9 8 8 8 8 8 8 8 8 8 8.5 8.5 -



DIMENSION



12.00R20



315/70R22.5 325/95R24 20.00R20 385/68R22.5 365/85R20 365/80R20 16.00R20 14.00R20 24.00R20.5 385/95R24 385/55R22.5 525/65R20.5 395/85R20 525/80R25 24R21



TYPE MICHELIN XDY MICHELIN XZY2 MICHELIN XZL MICHELIN XZY PIRELLI AP05 PIRELLI AT75 PIRELLI FG85 PIRELLI TG85 MICHELIN XZE2TL MICHELIN XDE2TL PIRELLI FG88 PIRELLI TG88 CONTINENTAL MICHELIN XZY3 MICHELIN XFA1+ MICHELIN XZL MICHELIN XZL MICHELIN XZL MICHELIN XZL PIRELLI PS22 PISTA MICHELIN XS MICHELIN X MICHELIN XFA2 MICHELIN XS MICHELIN XZL MICHELIN XL MICHELIN XZL



(*) bar 8.5 8.5 8.5 8.5 9 9 9 9 9 9 9 9 8.5 7.5 6 7.6 7.6 7 6 9 9 8 8.5 7 6



(**) bar 8.5 8.5 8.5 8.5 8.5 9 9 9 9 9 9 7.6 7.6 7 9 -



1
18



HD9 Euro3



1



SUSPENSION Front (Fig. 1): Longitudinal single leaf springs. Telescopic duplex hydraulic shock absorbers and roll bar. Rear: 2-axle vehicles (Fig. 2): Longitudinal double leaf springs. Telescopic duplex hydraulic absorbers and roll bar.



2



345CDT001L



3



345FDT007L



shock



3 and 4 axle vehicles (Fig. 3): Single leaf springs, individual for the two rocking axles with rocker system. The torque bars between axle and central support counteract the axial thrust on acceleration and braking. Anti-roll bar on intermediate axle and on rear axle (upon request). Leaf spring: parabolic or semi-elliptic (upon request).



1
19



HD9 Euro3



1



STEERING ZF hydraulic ball bearing mounted power steering. Vehicles without auxiliary cylinder Type: 8098 (Fig. 1) Oil pump driven by engine. Emergency pump controlled by transmission (if present). Front wheel steering with quadrilateral kinetic motion assembly.



2 Vehicles with auxiliary cylinder Type: 8099 (Fig. 2) Oil pump driven by engine. Emergency pump driven by transmission. Front wheel steering with quadrilateral kinematic motion assembly. Auxiliary cylinder.



1
20



HD9 Euro3



1



ELECTRICAL SYSTEM Nominal voltage: 24 V Accumulators (Fig. 1) (n˚ 2): 12 V --- 170 Ah or 12 V --- 220 Ah Alternator: 28 V --- 90 A The characteristics of accumulators and alternator may change according to the outfitting and the destination market.



274CNU102



Starter motor 24V --- 4.5 kW (engine F2B) 24V --- 5 kW (engine F3B) Ground reference: negative pole.



1
21



HD9 Euro3



1



CHASSIS (Fig. 1) Built with rectilinear side members in high strength “C” section steel, connected by riveted or bolted cross-members. Standard fuel tank Steel, capacity 300 liters with level and reserve indicator. Oversize fuel tank Steel, capacity 600 liters with level and reserve indicator.



1
22



HD9 Euro3



TIGHTENING TORQUES Assembly Engine Multipower power take-off ZF manual transmission ZF iIntarder



ZF As-Tronic automated transmission



Allison automatic transmission IVECO splitter ZF splitter Wheels



Front axle (Iveco)



Element F2B engine oil magnetic drain plug F3B engine oil magnetic drain plug Magnetic oil drain plug Oil filler cap Oil drainage, level and filler caps Oil magnetic drain plug on clutch bell Oil filter cover fastening screw Oil drain plug Side oil drain plugs Bottom oil drain plug Filler and level cap Oil filter cover fastening screw Oil drain plug Filler and level cap Oil drain plug Magnetic oil drain plug Oil filler and level cap Oil drain plug Oil filler and level cap Fasteners (nut and washer) Fasteners (countersunk nut) Magnetic oil drain plug Oil filler and level plug Oil drain plug on transfer case Oil level plug on transfer case



Type



Torque (Nm)



M 38 x 1.5



25  30 80 140



M25x1.5



60



20  25 25  32 M14x1.5 M27x2 M22x1.5 M22x1.5 M22x1.5



54  66 90  110 63  77 60 60 580  650 380  450



1
23



HD9 Euro3



Assembly



Front intermediate axle (Iveco)



Rear intermediate axle (Iveco)



Rear axle (Iveco)



Front axle (Kessler)



Intermediate axle (Kessler)



Rear axle (Kessler)



Element Magnetic oil drain plug Oil filler and level plug Oil drain plug on transfer case Oil level plug on transfer case Magnetic oil drain plug Oil filler and level plug Oil drain plug on transfer case Oil level plug on transfer case Magnetic oil drain plug Oil filler and level plug Oil drain plug on transfer case Oil level plug on transfer case Magnetic oil drain plug Oil filler and level plug Oil drain plug on transfer case Oil level plug on transfer case Magnetic oil drain plug Oil filler and level plug Transfer case oil drainage cap Transfer case oil filler and level plug Oil drain plug on transfer case Oil level plug on transfer case Magnetic oil drain plug Oil filler and level plug Oil drain plug on transfer case Oil level plug on transfer case



Type



Torque (Nm) 72  88



100  120



36  44



M16x1.5 M30x1.5 M16x1.5 M24x1.5 M16x1.5 M30x1.5 M24x1.5 M24x1.5 M16x1.5 M24x1.5 M16x1.5 M30x1.5 M16x1.5 M24x1.5



60 160 60 120 60 160 120 120 60 120 60 160 60 120



1
24



HD9 Euro3



1



VEHICLE OUTFITTING Set of keys D Ignition/door/fuel tank keys. D Open/close doors remote control (if present). Documentation D USE AND MAINTENANCE manual.



357ADT001L



2



357ADT002L



Vehicle outfitting D Lifting jack (Fig. 1). D Jack levers/cab lifting/wheels wrench (Fig. 2).



1
25



HD9 Euro3



1



D Standard warning triangle (Fig. 1, ref. 1). In accordance with the laws of the individual Countries the warning triangle is an obligatory outfitting. D Tool box (Fig. 1, ref. 2). D 2 chocks (Fig. 2).



357ADT003L



2



357ADT004L



According to the outfitting the chocks may be contained in specific cages along the chassis.



1
26



HD9 Euro3



Page left intentionally blank



1
27



HD9 Euro3



Instructions for use



1
28



HD9 Euro3



Page left intentionally blank



HD9 Euro3



1
29



GENERAL INSTRUCTIONS FOR CORRECT USE OF THE VEHICLE Before driving Adjust the seat, steering wheel and rear-view mirrors to obtain a correct driving position. Check that there are no obstructions to pedal excursion, in particular the brake pedal. Check that the horn works correctly. Check that all external lights function correctly, and if necessary clean the lighting groups. Check, especially when travelling by night, that headlights are correctly aligned. Check that no oil or fluids are leaking from under the vehicle. Check that any cargo is correctly stowed. Check that the handbrake is on and that no dashboard warning light indicates a fault. To prevent accidental vehicle movements, disengage the handbrake with the brake pedal pressed. Do not apply transfers or stickers to the windscreen: these could distract or impair vision. When driving Long journeys should only be undertaken in ideal physical conditions. Light, easily digestible meals help in keeping reflexes ready as well as maintaining the concentration required for safe driving. Never drive for too many consecutive hours, but make frequent stops, taking the opportunity to stretch and generally refresh. Make use of the wide range of adjustments offered by the heating, ventilation or air-conditioning system to maintain constant cabin air change. The abuse of alcohol, drugs and or certain medicines is extremely dangerous. Never undertake a journey under the influence of alcohol, pharmaceuticals or drugs. Careful driving also means being in a condition to foresee the mistakes or carelessness of other drivers. Always observe speed limits and always drive in the slow lane on motorways. Always use indicators when changing direction or lane. Keep a safe distance from the vehicle in front. This distance varies according to speed, weather, traffic and road conditions. Never drive with the gearbox in neutral. Never freewheel downhill: With the engine off there is no engine braking, requiring greater force on the brake pedal. Use engine braking by engaging a low gear to avoid overheating the brakes. In case of breakdown, park the vehicle off the carriageway, switch on the hazard warning lights and set up the red reflecting triangle sign to warn other drivers. Always follow the Highway Code.



1
30



HD9 Euro3



Night driving Take special care, reducing speed if necessary, especially on unlit roads. Keep a greater safety distance than when driving by day: in effect it is more difficult to estimate the speed of an approaching vehicle when only its lights are visible. Stop and rest as soon as you feel tired. To continue would only be a hazard to yourself and others. Use high beams only outside built-up areas an only when you are sure they do not other drivers. Always dip headlights with oncoming traffic. Driving in rain, fog and snow If the road is wet the grip between the tyres and the road surface is significantly reduced, so braking distance is greater and grip when turning is reduced. Reduce speed and keep a greater distance from the vehicles in front. Heavy rain and fog reduce visibility. In compliance with the Highway Code, switch on dipped headlights even by day to render your vehicle more visible. Do not drive through puddles or flooded sections of road at high speed. Aquaplaning may cause loss of control. Use engine braking and in all cases avoid braking sharply. Set ventilation controls to ensure efficient windscreen demisting. Before starting out, check the condition of windscreen wipers. If temperature is below 0˚, or if it is snowing, check that the wiper blades and not frozen against the windscreenProceed with extreme caution in case of fog. Moderate speed and avoid overtaking if possible. Check that windscreen/headlight washer fluid contains antifreeze and anti-scale products. In winter, even apparently dry roads may have icy patches, especially sections in the shade or lined by trees or rocks. Parking Switch off the engine. Engage the parking brake. Engage 1st gear if the vehicle is parked on a slope or reverse gear if the vehicle is facing downwards (manual gearshift vehicles only). Never leave the key turned to MAR with the engine off to avoid flattening the batteries. Tyres Always reduce speed before taking on a tight bend, even if vehicle performance permits. Avoid sharp acceleration of heavy braking. Do not drive at constant high speeds for long periods, especially on uneven road surfaces. Make certain that wheels are correctly balanced and adjusted. Avoid violent impacts to tyre walls (for example when parking). Never tamper with tyre inflation valves.



HD9 Euro3



1
31



Do not insert any kind of tool between tyre and wheel rim. If the rim is damaged, replace it. If a tyre loses pressure for no apparent reason, replace the wheel and check the faulty tyre. Tyre pressures, including the spare, must always be as specified. Tyres that are old (over 6 years) or used should only be used in case of emergency and with due caution. Do not leave the vehicle parked for long periods on the edge of the kerb or similar irregularities on the road surface. Regularly check tyre tread depth, changing tyres when depth is less than the legal minimum. The vehicle mounts ’tubeless’ tyres, meaning without inner tube. Inner tubes must not be fitted to tubeless tyres. Certain types of tyres are fitted with wear indicators. They must be changed as soon as the indicators become visible on the tread. Aquaplaning is more likely with worn tyre treads. Snow chains The use of snow chains is governed by local law in each country. Chains should only be fitted to drive wheels. To prevent tyre damage, do not drive on clear roads with chains fitted. In extreme cases (tunnels, etc....) proceed at low speed and in any case remove the chains as soon as conditions permit. Maintain moderate speed with chains mounted, avoiding potholes and driving onto the kerb. Certain tyres of snow chain require tension adjustment after travelling a short distance. Economic, ecological driving Road conditions and driving style have a direct influence on fuel consumption and environmental impact. Carry out the maintenance operations described below at regular intervals and with care. Do not demand maximum power from the vehicle with the engine cold. Do not rev the engine when parked. Always avoid sharp acceleration and repeated braking/acceleration. Engage a higher gear as soon as conditions permit. If possible, avoid driving with side windows lowered. Use the air-conditioner/ventilation system to obtain the desired conditions in the cab. Engage a high gear whenever traffic and road conditions permit. Limit the use of high power absorption utilities (air-conditioner on full, for example) when driving in city traffic or behind slow moving vehicles. Revving the engine between gears or before stopping the engine serves absolutely no purpose. Avoid accelerating on full throttle. Fuel consumption will be significantly lower with gradual acceleration.



1
32



HD9 Euro3



1



Range of use of the engine The following table shows indications for correct engine use. a white sector: minimum, low use b green sector: economic running The best performance/consumption ratio is obtained when the engine rate is in the green sector. c d



yellow sector: maximum engine speed range red sector: runaway rate NEVER USE RED SECTOR.



Engine F2B/F3B



Tachometer sector (RPM) White



Green



Yellow



Red



0 - 1200



1200 - 1900



2400 - 3000



3000 - 3200



1
33



HD9 Euro3



1



342BNU001L



2



LEFT HAND DRIVE VEHICLES CAB-EXTERNAL The cab (Fig. 1) is hinged at the front and suspended both to front and rear on the chassis: D to the front by two longitudinal arms with springs, shock absorbers and buffers. D to the rear by two control arms with springs, shock absorbers and buffers. The cabin can be tipped forward by means of a manually controlled hydraulic cylinder. Always use the grips and steps (Fig. 2, see arrow) specifically designed to permit easy accessibility to get on and off the vehicle. Always keep handles and foot-boards clean to avoid slipping.



342BNU002L



1
34



HD9 Euro3



1



1



EXTERNAL LIGHTING Front lights (Fig. 1) 1. High beam 2. Parking light and headlight 3. Front direction indicator 4. Side direction indicator 5. Front clearance light 6. Rotary warning lights (if fitted)



342BNU009L



1
35



HD9 Euro3



1



1



228NU205



Rear lights (Fig. 1) 1. Direction indicator 2. Stop light 3. Side light 4. Fog warning light 5. Reversing light 6. License plate light (one side only) 7. Side clearance



1
36



HD9 Euro3



1



1



307HNU008L



Rear lights --- Version with LED taillights (Fig. 1) 1. Direction indicator 2. Side light/Stop light 3. Fog warning light 4. Reversing light 5. License plate light (one side only) 6. Side clearance



1
41



HD9 Euro3



Page left intentionally blank



1
37



HD9 Euro3



1



DOORS The vehicle has two doors symetrically placed at each side. The external door handle (Fig. 1, see arrow) can be locked from the outside with a key. To open the door pull down the external handle. D to block the lock, turn the key anticlockwise (Fig. 1, ref. 1); D to block the lock, turn the key clockwise (Fig. 1, ref. 2); D to open the door, pull handle downward.



342BNU004L



When the door is opened the cabin interior light comes on automatically, along with the cabin step lights.



1
38



HD9 Euro3



1



342BNU005L



The inner side of the door has the following controls (Fig. 1): 1. Door opening handle 2. Electric window control 3. Door closing handle 4. Knob for locking doors from the inside 5. Electric mirrors adjustment control (only driver’s door)



1
39



HD9 Euro3



1



272CNU001



Central locking remote control Briefly press the button (Fig. 1, ref. 1) on the remote control, while pointing the control in the direction of the vehicle, the direction indicators will flash simultaneously indicating that all doors are unlocked. To lock the doors press the button (Fig. 1 ref. 2) still while pointing the control in the direction of the vehicle, the direction indicators will flash simultaneously indicating that all doors are locked.



1
40



HD9 Euro3



1



272CNU002



Replacing remote control battery D Insert a small coin or screwdriver into the slot on the side of the remote control and open it (Fig. 2). D Replace the battery, paying attention to the polarity. D The remote control has a lithium battery. CR 2032 3V D Close the two halves of the remote control checking that they are correctly coupled. A reduction in range of the remote control is an indicator that the battery is almost exhausted. Exhausted batteries are harmful to the environment. Exhausted batteries must be disposed of as required by law. Or it can be handed over to the Service Network that will provide for correct disposal.



1
42



HD9 Euro3



DRIVERS SEAT



1



342BNU006L



HD9 Euro3 DRIVER’S SEAT (Fig. 1 previous page) 1. Driver’s seat adjustment controls 2. Steering wheel position control 3. Ashtray 4. Cigar lighter - 12 V power socket - Diagnostic socket 5. Gear lever 6. Differential lock / splitter / supplementary parking brake 7. Climate control system controls 8. Parking brake 9. Document holder 10. Controls lever Cruise control / retarder 11. Ignition switch 12. Dashboard 13. Steering wheel 14. Instrument panel 15. Controls lever lights / headlights / direction indicators / windscreen wiper controls 16. Pedal controls



1
43



1
44



HD9 Euro3



1



1



INTERNAL LIGHTING DEVICE Upper dashboard (Fig. 1) 1. Ceiling light Press button (Fig. 2) to switch on the ceiling light. Press again to switch off the ceiling light. 2. Access step lighting The light switches on when the door is opened.



342BNU007L



1



2



342BNU008L



1
45



HD9 Euro3



1



EXTERNAL REAR VIEW MIRRORS The vehicle is fitted with the following external rear view mirrors (Fig. 1, 2 and Fig. 3): 1 Left side wide-angle mirror 2 Main left side mirror 3 Right side wide-angle mirror 4 Main right side mirror 5 Right pull-in mirror



341DNU020L



1
46



HD9 Euro3



1



Mirror selection and handling This adjustment must be made with vehicle stationary.



342BNU050L



2



285ANU002L



Using the mirror selection control (Fig. 1, ref. 1) brings up a specific page on the techometer LCD (Fig. 2, ref. 1). Use the mirror adjustment control (Fig. 1, ref. 2) to adjust the selected mirror. Without remote control the driver has to adjust the mirrors manually.



1
47



HD9 Euro3



1



285ANU003L



2



284CNU004L



3



342BNU051L



The selected mirror is identified by the number on the LCD (Fig. 1, ref. 1) The selected mirror is graphically highlighted on the LCD (Fig. 1, ref. 2). The mirrors controlled by the system are (Fig. 2): 1. Main driver’s mirror 2. Driver’s wide-angle mirror 3. Main passenger side mirror 4. Passenger side wide-angle mirror Press the mirror heater button (Fig. 1, ref. 3) to rapidly demist the mirrors. Press the button to turn the mirror heating system on. Press the button again to turn the mirror heating system off.



1
48



HD9 Euro3



1



SEATS Fore and aft adjustment Lift lever (Fig. 1, ref. 1) to have the seat free to move backwards or forward. Release the lever and ensure the mechanism is fully. Cushion angle adjustment The cushion angle may be adjusted by lifting lever (Fig. 1, ref. 2) and pulling and pushing the backrest (12˚ max.). Release the lever after adjustment. Seat suspension adjustment Lift lever (Fig. 1, ref. 3) to lower and lock the seat; lower the lever to raise the seat (set beforehand with lever 5).



342BNU010L



1
49



HD9 Euro3



1



Springing system adjustment Springing system adjustment is obtained by lifting or lowering lever (Fig. 1, ref. 4): D Lever up = Maximum suspension effect. D Lever down = Minimum suspensions effect. With this device seat suspension is according to road surface and weight of the driver. The shock absorber has to be adjusted rigidly, to avoid that on rough surfaces the seat hits the end of stroke, jeopardising the spring system. Height adjustment Lift lever (Fig. 1, ref. 4) to raise the seat; release the lever after adjustment. Seat height is memorised automatically. Lower lever to lower the seat (100 mm max.) Backrest angle adjustment Lift lever (Fig.1, ref. 5) and set the backrest to the desired angle with your back. Release the lever to block the backrest.



342BNU010L



1
50



HD9 Euro3



1



178NU08



2



178NU09



3



178NU10



SEAT BELTS The vehicle is equipped with three-point seat belts and automatic reel (Fig. 1). D To fasten the belt grip the tab and insert it into the buckle until it clicks (Fig. 2). D To release the belt, press the button on the top of the buckle (Fig. 3). Do not adjust the mirrors while driving.



1
51



HD9 Euro3



1



178NU08



The belt does not need to be adjusted by hand: the webbing adjusts itself automatically to the length most suited to the driver allowing him freedom of movement provided that his movements are not abrupt. The belt mechanism is affected by changes in vehicle attitude and as a consequence the belt may lock in the following cases: D sudden braking or acceleration; D vehicle driving on a slope; D when cornering. The belt must not twist and must adhere to the hips, not the abdomen, to prevent the risk of slipping forwards. Occasionally check that the anchor bolts are fully tightened and that the belt itself is not cut or frayed. In case of accident of a certain gravity, replace the belt involved, even if it does not appear damaged. Do not make alterations likely to reduce seat belt efficiency



1
52



HD9 Euro3



1



ELECTRIC WINDOW CONTROL Electric window risers control Left side (Fig. 1) 1. Left side window control 2. Right side window control



342BNU011L



2



342BNU012L



3



342BNU013L



Right side (Fig. 2) 1. Right side window control. Press (Fig. 3, ref a) the switch to lower the glass. Pull the switch upward (Fig. 3, ref b) to raise the glass. The glass stops when the switch is released.



1
53



HD9 Euro3



1



178NU02



2



HATCH To open the hatch turn the handle (Fig. 1, ref. 1) anti-clockwise. To close the hatch proceed as follows: D Turn the handle clockwise until closing the hatch. D Return the handle to its original position (Fig. 2). D Turn the handle at most by a quarter turn until reaching the stop (Fig. 3, arrow). D Return the handle to closed position and lock it by tipping the knob. To escape from the cabin in an emergency turn the full release handles downward (Fig. 1, ref. 2) and push the hatch outwards.



272NU102X



3



272NU103X



1
54



HD9 Euro3



1



COMPARTMENTS Dashboard (Fig. 1) 1. Bottle/can holder 2. Mobile phone holder 3. Items tray (according to outfitting) 4. Gloves compartment 5. Compartment in front of passenger



342BNU014L



2



342BNU015L



Upper dashboard (Fig. 2) 1. Compartment in front of passenger (closed with lid). Act on button and raise lid to open. Lower lid and press until it clicks into place. 2. Loose items tray (according to outfitting)



1
55



HD9 Euro3



1



Door (Fig. 1) 1. bottle holder 2. pocket 3. pocket Tunnel (Fig. 2) 1. coin holder 2. loose items tray Seat (Fig. 3) 1. Compartment (closed with lid) Act on button and lower lid to open. Raise lid and press until it clicks to close. 2. items holder



342BNU016L



Rear wall (Fig. 4) 1. bottle holder 2. items compartment



2



3



4



342BNU017L



342BNU018L



342BNU019L



1
56



HD9 Euro3



1



ACCESSORIES - DEVICES Sun blind tabs (Fig. 1, ref. 1) Grip the front edge of the tab and turn downward. Bring to position by hand. Grip handle (Fig. 1, ref. 2) On passenger side. Coat hook (Fig. 1, ref. 2) On both sides of cab.



342BNU020L



2



Cigar lighter (Fig. 2, ref. 1) Press to activate cigar lighter: a click indicates it is ready for use. After use return to its seat without pressing. Ashtray (Fig. 2, ref. 2) On both sides of cab. Raise lid to open. Lower lid to close. 12Volt current socket (Fig. 2, ref. 3) Open cap and insert facility . After use close cap.



342BNU021L



1
57



HD9 Euro3



1



CONTROLS Controls on dashboard (Fig. 1) 1. Headlamps geometry adjustment 2. External lights switch 3. Hazard lights 4. Parking brake control



342BNU022L



1
58



HD9 Euro3



1



Module holder dashboard controls (Fig. 1) 1. Engine brake switch 2. Fog light switch 3. Rear fog light 4. Mirrors heating switch 5. Horn selector switch 6. Pivoting headlamps switch 7. Ceiling light switch 8. Not used 9. Not used 10. PTO activation switch 11. PTO 1 activation switch 12. PTO 2 activation switch 13. ABS switch (OFF-ROAD) 14. ASR switch 15. Additional parking brake switch 16. Work light switch 17. Electric battery master switch 18. Not used 19. Climate controls 20. 12 V current socket



1
59



HD9 Euro3



1



Controls on roof (Fig. 1) 1. Radio CD equipment housing 2. CB housing 3. Tachograph housing Controls on floor



342BNU024L



2



Steering wheel position control Steering wheel position adjustment is pneumatic, and can be regulated by means of the button on the floor at the base of the steering column, driver’s side (Fig. 2). Proceed as follows: D With the button pressed take the wheel in your hands and bring it to the required position. D Once in position, release the button. This operation can only be done with: D sufficient air pressure; D parking brake engaged.



357ANU101L



1
60



HD9 Euro3



1



272NU062X



Accelerator The accelerator is controlled by means of a pedal on the floor to be operated by the driver’s right foot (Fig. 1, ref. 1). Press the pedal to increase the torque output by the engine proportionally to the position of the pedal. Service brake The service brake is controlled by means of a pedal on the floor to be operated by the driver’s right foot (Fig. 1, ref. 2). Press the pedal to obtain a braking effect in proportion to the exerted pressure. Clutch The clutch is controlled by a pedal to be operated with the driver’s left foot (Fig. 1, ref. 3). Press the pedal to release the clutch. Only for manual trasmission vehicles.



1
61



HD9 Euro3



1



Manual transmission control Transmission is controlled by a manually operated lever. (Fig. 1, see arrow).



342BNU025L



2



Automated transmission control The selection of different operating modes is by means a multi-purpose lever with pushbuttons (Fig. 2).



357ANU102L



3



357ANU201L



Automatic transmission control The different functioning modes selection is through a selector lever with pushbuttons (Fig. 3).



1
62



HD9 Euro3



Page left intentionally blank



1
63



HD9 Euro3



1



357ANU202L



2



RIGHT-HAND DRIVE VEHICLES CAB EXTERNAL The cab (Fig. 1) is hinged at the front and suspended both to front and rear on the chassis: D to the front by two longitudinal arms with springs, shock absorbers and buffers. D to the rear by two control arms with springs, shock absorbers and buffers. The cabin can be tipped forward by means of a manually controlled hydraulic cylinder. Always use the grips and steps (Fig. 2, see arrow) specifically designed to permit easy accessibility to get on and off the vehicle. Always keep handles and foot-boards clean to avoid slipping.



357ANU203L



1
64



HD9 Euro3



1



1



EXTERNAL LIGHTING Front lights (Fig. 1) 1. High beam 2. Parking light and headlight 3. Front direction indicator 4. Side direction indicator 5. Front clearance light 6. Rotary warning lights (if fitted)



357ANU204L



1
65



HD9 Euro3



1



1



285ANU053L



Rear lights (Fig. 1) 1. Direction indicator 2. Stop light 3. Side light 4. Fog warning light 5. Reversing light 6. License plate light (one side only) 7. Side clearance



1
66



HD9 Euro3



1



1



307HNU009L



Rear lights --- Version with LED taillights (Fig. 1) 1. Direction indicator 2. Side light/Stop light 3. Fog warning light 4. Reversing light 5. License plate light (one side only) 6. Side clearance



1
71



HD9 Euro3



Page left intentionally blank



1
67



HD9 Euro3



1



DOORS The vehicle has two doors symetrically placed at each side. The external door handle (Fig. 1, see arrow) can be locked from the outside with a key. To open the door pull down the external handle. D to block the lock, turn the key anticlockwise (Fig. 1, ref. 1); D to block the lock, turn the key clockwise (Fig. 1, ref. 2); D to open the door, pull handle downward. When the door is opened the cabin interior light comes on automatically, along with the cabin step lights.



357ANU205L



1
68



HD9 Euro3



1



357ANU206L



The inner side of the door has the following controls (Fig. 1): 1. Door opening handle 2. Electric window control 3. Door closing handle 4. Knob for locking doors from the inside 5. Electric mirrors adjustment control (only driver’s door)



1
69



HD9 Euro3



1



272CNU001



Central locking remote control Briefly press the button (Fig. 1, ref. 1) on the remote control, while pointing the control in the direction of the vehicle, the direction indicators will flash simultaneously indicating that all doors are unlocked. To lock the doors press the button (Fig. 1, ref. 2) still while pointing the control in the direction of the vehicle, the direction indicators will flash simultaneously indicating that all doors are locked.



1
70



HD9 Euro3



1



272CNU002



Replacing remote control battery D Insert a small coin or screwdriver into the slot on the side of the remote control and open it (Fig. 1). D Replace the battery, paying attention to the polarity. D The remote control has a lithium battery. CR 2032 3V. D Close the two halves of the remote control checking that they are correctly coupled. A reduction in range of the remote control is an indicator that the battery is almost exhausted. Exhausted batteries are harmful to the environment. Exhausted batteries must be disposed of as required by law. Or it can be handed over to the Service Network that will provide for correct disposal.



1
72



HD9 Euro3



DRIVERS SEAT



1



357ANU207L



HD9 Euro3 DRIVER’S SEAT (Fig. 1 previous page) 1. Driver seat adjustment controls 2. Steering wheel position adjustment 3. Parking brake controls 4. Ignition key 5. Ashtray 6. Transmission controls 7. Cigar lighter 8. Differential lock / splitter / additional parking brake controls 9. Air conditioning controls 10. Cruise control / retarder controls lever 11. Ignition switch 12. Dashboard 13. Steering wheel 14. Instrument panel 15. Lights / headlights / turn signals / windscreen wiper controls lever 16. Pedal controls



1
73



1
74



HD9 Euro3



1



1



INTERNAL LIGHTING DEVICE Upper dashboard (Fig. 1) 1. Ceiling light Press button (Fig. 2) to switch on the ceiling light. Press again to switch off the ceiling light. 2. Access step lighting The light switches on when the door is opened.



357ANU208L



1



2



357ANU209L



1
75



HD9 Euro3



1



357ANU210L



EXTERNAL REAR VIEW MIRRORS The vehicle is fitted with the following external rear view mirrors (Fig. 1): 1 Left side wide-angle mirror 2 Main left side mirror 3 Right side wide-angle mirror 4 Main right side mirror 5 Right pull-in mirror



1
76



HD9 Euro3



1



Mirror selection and handling This adjustment must be made with vehicle stationary.



357ANU211L



2



285ANU002L



Using the mirror selection control (Fig. 1, ref. 1) brings up a specific page on the techometer LCD (Fig. 2, ref. 1). Use the mirror adjustment control (Fig. 1, ref. 2) to adjust the selected mirror. Without remote control the driver has to adjust the mirrors manually.



1
77



HD9 Euro3



1



285ANU003L



2



357ANU213L



3



342BNU051L



The selected mirror is identified by the number on the LCD (Fig. 1, ref. 1) The selected mirror is graphically highlighted on the LCD (Fig. 1, ref. 2). The following mirrors are handled by the system (Fig. 2): 1. Main driver mirror 2. Driver wide-angle mirror 3. Main passenger mirror 4. Passenger wide-angle mirror Press the mirror heater button (Fig. 2, ref. 3) to rapidly demist the mirrors. Press the button to turn the mirror heating system on. Press the button again to turn the mirror heating system off.



1
78



HD9 Euro3



1



SEATS Fore and aft adjustment Lift lever (Fig. 1, ref. 1) to have the seat free to move backwards or forward. Release the lever and ensure the mechanism is locked. Cushion angle adjustment The cushion angle may be adjusted by lifting lever (Fig. 1, ref. 2) and pulling and pushing the backrest (12˚ max.). Release the lever after adjustment. Seat suspension adjustment Lift lever (Fig. 1, ref. 3) to lower and lock the seat; lower the lever to raise the seat (set beforehand with lever 5).



357ANU214L



1
79



HD9 Euro3



1



Springing system adjustment Springing system adjustment is obtained by lifting or lowering lever (Fig. 1, ref. 4): D Lever up = Maximum suspension effect. D Lever down = Minimum suspensions effect. With this device seat suspension is according to road surface and weight of the driver. The shock absorber has to be adjusted rigidly, to avoid that on rough surfaces the seat hits the end of stroke, jeopardising the spring system. Height adjustment Lift lever (Fig. 1, ref. 5) to raise the seat; release the lever after adjustment. Seat height is memorised automatically. Lower lever to lower the seat (100 mm max.) Backrest angle adjustment Lift lever (Fig.1, ref. 6) and set the backrest to the desired angle with your back. Release the lever to block the backrest.



357ANU214L



1
80



HD9 Euro3



1



285ANU056L



2



178NU09



3



178NU10



SEAT BELTS The vehicle is equipped with three-point seat belts and automatic reel (Fig. 1). D To fasten the belt grip the tab and insert it into the buckle until it clicks (Fig. 2). D To release the belt, press the button on the top of the buckle (Fig. 3). The vehicle must be stationary to carry out this operation.



1
81



HD9 Euro3



1



285ANU056L



The belt does not need to be adjusted by hand: the webbing adjusts itself automatically to the length most suited to the driver allowing him freedom of movement provided that his movements are not abrupt. The belt mechanism is affected by changes in vehicle attitude and as a consequence the belt may lock in the following cases: D sudden braking or acceleration; D vehicle driving on a slope; D when cornering. The belt must not twist and must adhere to the hips, not the abdomen, to prevent the risk of slipping forwards. Occasionally check that the anchor bolts are fully tightened and that the belt itself is not cut or frayed. In case of accident of a certain gravity, replace the belt involved, even if it does not appear damaged. Do not make alterations likely to reduce seat belt efficiency



1
82



HD9 Euro3



1



ELECTRIC WINDOW CONTROL Electric window risers control Left side (Fig. 1) 1. Left side window control 2. Right side window control



357ANU215L



2



357ANU216L



3



357ANU217L



Right side (Fig. 2) 1. Right side window control. Press (Fig. 3, ref a) the switch to lower the glass. Pull the switch upward (Fig. 3, ref b) to raise the glass. The glass stops when the switch is released.



1
83



HD9 Euro3



1



178NU02



2



HATCH To open the hatch turn the handle (Fig. 1, ref. 1) anti-clockwise. To close the hatch proceed as follows: D Turn the handle clockwise until closing the hatch. D Return the handle to its original position (Fig. 2). D Turn the handle at most by a quarter turn until reaching the stop (Fig. 3, arrow). D Return the handle to closed position and lock it by tipping the knob. To escape from the cabin in an emergency turn the full release handles downward (Fig. 1, ref. 2) and push the hatch outwards.



272NU102X



3



272NU103X



1
84



HD9 Euro3



1



COMPARTMENTS Dashboard (Fig. 1) 1. Bottle/can holder 2. Mobile phone holder 3. Items tray (according to outfitting) 4. Gloves compartment 5. Compartment in front of passenger



357ANU218L



2



357ANU219L



Upper dashboard (Fig. 2) 1. Compartment in front of passenger (closed with lid). Act on button and raise lid to open. Lower lid and press until it clicks into place. 2. Loose items tray (according to outfitting)



1
85



HD9 Euro3



1



Door (Fig. 1) 1. bottle holder 2. pocket 3. pocket Tunnel (Fig. 2) 1. coin holder 2. loose items tray Seat (Fig. 3) 1. Compartment (closed with lid) Act on button and lower lid to open. Raise lid and press until it clicks to close. 2. items holder Rear wall (Fig. 4) 1. bottle holder 2. items compartment



357ANU220L



2



3



4



357ANU221L



357ANU222L



342BNU019L



1
86



HD9 Euro3



1



ACCESSORIES - DEVICES Sun blind tabs (Fig. 1, ref. 1) There are three sun blind tabs. Grip the front edge of the tab and turn downward. Bring to position by hand. Grip handle (Fig. 1, ref. 2) On passenger side. Coat hook (Fig. 1, ref. 3) On both sides of cab.



357ANU223L



2



Cigar lighter (Fig. 2, ref. 1) Press to activate cigar lighter: a click indicates it is ready for use. After use return to its seat without pressing. Ashtray (Fig. 2, ref. 2) On both sides of cab. Raise lid to open. Lower lid to close. 12Volt current socket (Fig. 2, ref. 3) Open cap and insert facility . After use close cap.



357ANU224L



1
87



HD9 Euro3



1



CONTROLS Controls on dashboard (Fig. 1) 1. Headlamps geometry adjustment 2. External lights switch 3. Hazard lights 4. Parking brake control



357ANU225L



1
88



HD9 Euro3



1



1



357ANU226L



Module holder dashboard controls (Fig. 1) 1. Engine brake switch 2. Fog light switch 3. Rear fog light 4. Mirrors heating switch 5. Horn selector switch 6. Pivoting headlamps switch 7. Ceiling light switch 8. Not used 9. Not used 10. PTO activation switch 11. PTO 1 activation switch 12. PTO 2 activation switch 13. ABS switch (OFF-ROAD) 14. ASR switch 15. Additional parking brake switch 16. Work light switch 17. Electric battery master switch 18. Not used 19. Climate controls 20. 12 V current socket



1
89



HD9 Euro3



1



Controls on roof (Fig. 1) 1. Radio CD equipment housing 2. CB housing 3. Tachograph housing Controls on floor



357ANU227L



2



Steering wheel position control Steering wheel position adjustment is pneumatic, and can be regulated by means of the button on the floor at the base of the steering column, driver’s side (Fig. 2). Proceed as follows: D With the button pressed take the wheel in your hands and bring it to the required position. D Once in position, release the button. This operation can only be done with: D sufficient air pressure; D parking brake engaged.



357ANU228L



1
90



HD9 Euro3



1



272NU062X



Accelerator The accelerator is controlled by means of a pedal on the floor to be operated by the driver’s right foot (Fig. 1, ref. 1). Press the pedal to increase the torque output by the engine proportionally to the position of the pedal. Service brake The service brake is controlled by means of a pedal on the floor to be operated by the driver’s right foot (Fig. 1, ref. 2). Press the pedal to obtain a braking effect in proportion to the exerted pressure. Clutch The clutch is controlled by a pedal to be operated with the driver’s left foot (Fig. 1, ref. 3). Press the pedal to release the clutch.



1
91



HD9 Euro3



1



Manual gear shift lever Gear shift is controlled by a lever used by the right hand (Fig. 1, ref. 1).



357ANU229L



2



Automated transmission control A multifunctional lever with buttons (Fig. 2) is used to select the various operating modes.



357ANU230L



3



357ANU231L



Automatic transmission command A selection lever (Fig. 3) is used to select the various operating modes.



1
92



HD9 Euro3



ALL VEHICLES INSTRUMENTS



Instrument panel (Fig. 1)



1



341DNU001L



HD9 Euro3



1
93



Instrument panel (Fig. 1) 1) Front axles brake wear warning light Red light indicates front brakes have reached the wear limit 2) Rear axles brake wear warning light Red light indicates rear brakes have reached the wear limit 3) Rear axle brakes air pressure indicator. 4) Front axle brakes air pressure indicator. 5) ABS failure warning light Yellow light indicates ABS system is not functioning 6) Braking system failure warning light Red light indicates there is a failure in the braking system 7) Rev counter 8) Digital speedometer 9) LCD screen with hour-counter and partial trip display 10) Partial trip reset button 11) Fuel level indicator 12) Fuel reserve warning light Red light indicates fuel tank level is in reserve 13) Engine water overheating Red light indicates the engine water is overheated 14) Engine water temperature indicator 15) Instruments illumination adjustment button A) Warning lights panel A B) Warning lights panel B C) Warning lights panel C See the below for further information regarding instrument panel.



1
94



HD9 Euro3



1



Functions of instrument panel keys Key 1 (Fig. 1, ref. 1): Instrument illumination adjustment. or Error memory display. Refer to the DIAGNOSTIC chapter for more information



1



2



285ANU009L



2



Key 2 (Fig. 1, ref. 2): Press key 2 for less than three seconds to display trip km or total km Trip odometer reset With trip odometer displayed on LCD (Fig. 2, ref. 1), press key 2 for more than three seconds to zero the indicated distance. Units of measure conversion (Km - miles) To convert the units of measure displayed on the LCD, proceed as follows: D With ignition key out, press both buttons (Fig. 1, ref 1 and 2). D Holding the buttons down, turn the key to MAR and wait 10 seconds.



1 285ANU010L



1
95



HD9 Euro3



1



Warning lights panel A details 1



341DNU002L



Automatic gear converter functioning warning light. Yellow light indicates lock-up clutch is not engaged. 2 Retarder on warning light. Yellow. Indicates that hydraulic retarder is active. 3 Engine brake engaged warning light. Yellow. Indicates that the engine brake is engaged. 4 Rear traverse differential locked warning light. Yellow. Indicates that the rear differential clamp is engaged. 5 Transfer box longitudinal differential locked warning light. Yellow. Indicates that the transfer box differential clamp is engaged. 6 Tandem longitudinal differential locked warning light. Yellow. Indicates that the tandem longitudinal differential is engaged. 7 External lights on warning light. Green. Indicates that the side lights (and dip headlights) are on. 8 Main beam on warning light. Blue. Indicates that main beam headlights are on. 9 Parking brake engaged warning light. Red. Indicates that the parking brake is engaged. 10 Left direction indicator warning light. Green. Indicates that the left direction indicator has been activated. 11 Power steering main circuit failure warning light. Red. Indicates there is a failure on the power steering main circuit. 12 Power steering emergency circuit failure warning light. Red. Indicates there is a failure on the power steering emergency circuit.



1
96



HD9 Euro3



1 1



2



4



3



Warning lights panel B details 1. Seat belt not fastened warning light Red. Indicates that the driver’s seat belt is not fastened. 2. Warning light Yellow. Indicates a general vehicle fault. 3. Preheating on warning light Yellow. Indicates that the engine preheating system is active. 4. ECM warning light Yellow. Indicates an ECM malfunction.



285ANU012L



1
97



HD9 Euro3



1



341DNU003L



Warning lights panel C details 1. Second speed limit engaged warning light. Yellow. This indicates that the second speed limiter is engaged. 2. ABS off warning light. Yellow. Indicates ABS off. 3. ASR off warning light Yellow. Indicates ASR off. 4. Engine oil temperature high warning light. Red. Indicates that the engine oil temperature is high. 5. Low trailer brake air pressure warning light. Red. Indicates trailer air brake malfunction. 6. Power steering oil level low warning light. Red. Indicates that the power steering oil level is insufficient. 7. Alternator warning light. Red. Indicates that the current delivered to the alternator is insufficient. 8. Water in fuel pre-filter warning light. Yellow. Indicates the presence of water in the fuel pre-filter. 9. Hazard lights on warning light. Red. Indicates that the hazard warning lights are on. 10. Right direction indicator warning light. Green. Indicates that the right direction indicator has been activated. 11. Cab unhooked warning light Red. Indicates that the cab has not been secured correctly. 12. Air filter clogged warning light Yellow. Indicates that the engine air filter is clogged.



1
98



HD9 Euro3



1



357ANU100L



2



228NUR24



Automated transmission display (Fig. 1) Automated transmission indications on display (Fig. 2) The display shows information on gearbox condition. A Gear engaged indicator (e.g. 1./.16 or N, RL and RH).999 Other information displayed: CH = system self-diagnosis, displayed when ignition is switched on. AL = insufficient air, shown alternating with usual indication. FP = bring accelerator pedal to idling position: if the indication on the display remains, there is a fault in the system and it is not possible to continue travelling. CL = shown in alternation with the current indication and indicates a clutch overload. CW = clutch worn. Replace as soon as possible. _ _ = gear shift. Displayed when changing gear. EE = displayed in case of dialogue error between display and electronic control unit. HT = electronic control unit temperature too high. nn = alphanumerical code identifying a fault detected by the control unit. For example: 68 = fault 68 detected in system. B Arrow up/down: along with number of bars displayed indicate the possible gear shifts. C Bars: along with arrows, indicate the number of possible gear changes or downshifts (max. 4). D Wrench: system error. Displayed when operation is only possible with certain limitations. Take vehicle to specialised garage as soon as possible. E STOP: displayed with previous indication: indicates that the vehicle must be stopped immediately due to serious fault in system.



1
99



HD9 Euro3



1



Automatic transmission display (Fig. 1) Automatic transmission indications on display The display shows information concerning transmission condition. A Indication of gear engaged (e.g. D, N, R or 26). B Alphanumeric code that identifies a fault detected by the control unit: (2 characters for 4 times, total 8 characters, e.g. d1/P_/07/22). To view the fault codes the relevant procedure has to be activated.



357ANU233L



2



357ANU239L



C Bolts wrench: system error. Go to the nearest authorised garage. Automatic transmission warning lights (Fig. 2) 1. automatic transmission failure warning light. 2. automatic transmission oil temperature high warning light.



1
100



HD9 Euro3



1



341DNU004L



Warning light on dashboard --- Left ---hand drive vehicles 1. PTO 1 on gearbox engaged warning light. Yellow light indicates that PTO 1 on gearbox is engaged. 2 PTO 2 on gearbox engaged warning ligh. Yellow light indicates that PTO 2 on gearbox is engaged. 3 PTO on flywheel engaged warning light. Yellow light indicates that PTO on flywheel is engaged. 4 Splitter unit reduced gear ratio engaged warning light. Green light indicates that splitter unit reduced gear ratio is engaged. 5 Low range engaged warning light. Green light indicates that the gear low range is engaged. 6 Trailer ABS failure warning light. Yellow light indicates that the trailer ABS system is not functioning. 7 Reduced gears engaged warning light. Green light indicates that the gearbox reduced gears are engaged. 8 Windshield washer liquid level warning light. Red light indicates that windshield washer liquid level is low. 9 Front transverse differential locked warning light. Yellow light indicates that front differential lock is engaged.



1
101



HD9 Euro3



1



356ANU101L



Warning light on dashboard --Right ---hand drive vehicles 1 Front transverse differential locked warning light. Yellow light indicates that front differential lock is engaged. 2 Windshield washer liquid level warning light. Red light indicates that windshield washer liquid level is low. 3 Splitter unit reduced gear ratio engaged warning light. Green light indicates that splitter unit reduced gear ratio is engaged. 4 Reduced gears engaged warning light. Green light indicates that the gearbox reduced gears are engaged. 5 Low range engaged warning light. Green light indicates that the gear low range is engaged. 6 Trailer ABS failure warning light. Yellow light indicates that the trailer ABS system is not functioning. 7 PTO on flywheel engaged warning light. Yellow light indicates that PTO on flywheel is engaged. 8 PTO 2 on gearbox engaged warning ligh. Yellow light indicates that PTO 2 on gearbox is engaged. 9. PTO 1 on gearbox engaged warning light. Yellow light indicates that PTO 1 on gearbox is engaged.



1
102



HD9 Euro3



1



CONTROL OPERATION Position and headlight controls (Fig. 1) The control has three positions: D position 0: off; D position 1: first click: position lights on; D position 2: second click: headlights on.



272NU043X



1



2



0



2 272NU044X



Headlight control (Fig. 2) The control has three positions. D position 0: normal headlights; D position 1 (light push forward): high beams; D position 2 (pull lever back): Beam flasher.



1
103



HD9 Euro3



1



1



0



2



272NU045X



2



1 2 272NU046X



Direction indicator control (Fig. 1) The control has three positions: D position 0 off; D position 1 (up) right direction indicators; D position 2 (down) left direction indicators. Horn (Fig. 2) The horn can be sounded by pressing the indicated points (Fig. 2, ref. 1, 2).



1
104



HD9 Euro3



3



1



2



1 0



272NU047X



2



272NU048X



3



272NU049X



Windscreen washer/wiper control The control (Fig. 1) has four positions: D position 0 = disengaged; D position 1 = intermittent; D position 2 = slow; D position 3 = fast. Pushing the end of the ring (Fig. 2, see arrow), the windscreen wiper makes one sweep. The windscreen washer is the button (Fig. 3, see arrow) on the control stick. Pressing the windscreen washer button also activates slow windscreen wiper operation. Releasing the washer button, the wiper makes three more cleaning strokes before stopping.



1
105



HD9 Euro3



1



Ignition switch (Fig. 1) The ignition switch has three positions: D position 0 (STOP): all off, key may be removed; D position 1 (MAR): ready to start, electrical power on, key locked in; D position 2 (AVV): starting engine. 272NU056X



22



Engine braking control The device is commanded by moving the lever (Fig. 2). The number of clicks available depends on vehicle outfitting.



272NU060X



1
106



1



HD9 Euro3 Cruise control The vehicle is fitted with an engine speed / vehicle speed control. Memory control (Fig. 1, ref. 1). RESUME: Engaging the lever calls up the stored configuration. OFF: Operate the lever to deactivate the clutch.



2



Speed setting control ON button (+): pressing the button (Fig. 2, ref. 1) increases the rpm / vehicle speed value. ON button (-): pressing the button (Fig. 2, ref. 2) decreases the rpm / vehicle speed value.



1
107



HD9 Euro3



1



1



272NU055X



2



Hazard light control Press the control (Fig. 1, ref. 1) to turn the hazard lights on. Press again to switch the hazard lights off. Exhaust brake pre-selection The control (Fig. 2) has three positions: D position 0: the exhaust brake is applied when the command is actuated; D position 1: the exhaust brake is applied when the accelerator pedal is released; D position 2: exhaust brake applied each time the brake pedal is pressed; All Cruise Control operations are deactivated when the exhaust brake is applied.



285ANU039L



1
108



HD9 Euro3



1



285ANU021L



2



285ANU022L



Courtesy light switch Press the button (Fig. 1) to turn the courtesy light on. Press the button again to turn the courtesy light off. Electro-pneumatic horn pre-selection Press the control (Fig. 2) to operate the electro-pneumatic horn by means of the horn control on the left steering stalk. Press the control again to operate the electric horn by means of the horn control on the left steering stalk.



1
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1



342ANU001L



2



Swivelling light control Press the button (Fig. 1) to turn the swivelling light on. The warning light (Fig. 1, ref. 1) indicates that the swivelling light is on. Press the button again to switch the swivelling light off. Work light Press the button (Fig. 2) to switch the work light on. The warning light (Fig. 1, ref. 1) indicates that the work light is on. Press the button again to switch the work light off. Rear fog light The rear fog light will only come on when the dipped beam headlights are switched on (light and headlight control in second position).



342ANU002L



3



342ANU003L



Press the button (Fig. 3) to switch the rear fog light on. The warning light (Fig. 3, ref. 1) indicates that the rear fog light is on. Press the button again to switch the rear fog light off.



1
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1



342ANU004L



2



306ANU002L



Fog light control Press the button (Fig. 1) to turn the fog lights on. The warning light (Fig. 1, ref. 1) indicates that the fog lights are on. Press the button again to switch the fog lights off. Electric battery isolator control Press the pushbutton (Fig. 2) to switch on the main power supply. This switch replaces the manual switch located near the battery case. After a certain time from activation or after the engine has been switched off, the batteries disconnect automatically.



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1



342ANU005L



ASR off command Press the button (Fig. 1) to turn the ASR system off. Press the button again to switch the ASR system off. Vehicle traction can be improved by pressing the ASR button in particular terrain conditions (deep snow, mud, etc.). The corresponding warning light will come on.



1
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1



342ANU006L



ABS Off Road function control Press the button (Fig. 1) to activate the ABS Off Road function. Press the button to restore the brakes anti --- lock device (ABS). Under certain road surface conditions (deep snow, mud, etc.) vehicle braking can be improved activating the ABS exclusion key. When this button is pressed the ABS system is: D cut out up to 15 km/h; D made less sensitive between 15 km/h and 40 km/h; D restored over 40 km/h. The driver is warned of activation by the related warning light . The ABS system is automatically restored at each engine re-start . Pressing this button with a normal road surface the wheels may lock in the case of braking.



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1



Distributor-reducer (transfer) Position knob (Fig. 1): D Position 0:travelling on road (normal ratios). D Position 1, “tortoise” symbol:off-road use (step-up ratios). Shift from one range to the other must take place with the vehicle stopped and gearbox in neutral. To shift from normal to reduced: D turn knob (Fig. 1) to position 1. For vehicles fitted with retarder ZF (Intarder3): with reduced gears engaged do not exceed MAXIMUM SPEED = 50 km. To pass from the step-up ratio to the normal ratio: D turn knob (Fig. 1) to position 0.



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1



Differential lock control (2 axle vehicles) Front transverse differential lock (4x4 vehicles only) (Fig. 1) 0) Lock disengaged. 1) Lock engaged. We recommend engaging the front transverse differential lock once the rear longitudinal and transverse differential locks are engaged.



2



Reat longitudinal distributor and transverse differential lock (4x4 vehicles only) (Fig. 2) 0) Lock disengaged. 1) Longitudinal differential distributor lock engaged. 2) Rear transverse differential lock engaged. The rear transverse differential only engages when the longitudinal lock is already engaged.



3



Rear transverse differential lock (4x2 vehicles only) (Fig. 3) 0) Lock disengaged. 1) Lock engaged.



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Differential lock engagement D To engage the lock, turn the knob to engage position. D Lock engagement is indicated by activation of the corresponding warning light. D To disengage the lock turn the knob to disengage position. D Lock disengagement is indicated by deactivation of the corresponding warning light. The differentials must be engaged with the vehicle stopped and with the wheels straight. If the lock does not disengaged immediately, change direction in order to eliminate any tension present. Proceed with caution when lock is engaged. Do not engage the lock on roads that do not require its use. In muddy or slippery conditions do not allow the wheels to slip when the differential lock is not engaged, as this will lead to serious damage to the gearing (a few seconds are enough). Do not engage the differential while a wheel is slipping as this will also cause serious damage to gearing. After use, always check that the locks are disengaged checking both the warning lights and the position of the control button.



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1



Differential lock control (3-4 axle vehicles) Front transverse differential lock 6x6, 8x6 and 8x8 vehicles only) (Fig. 1) 0) Lock disengaged. 1) Lock engaged. We recommend engaging the front transverse differential lock once the rear longitudinal and transverse differential locks are engaged.



2



Interaxle longitudinal differential lock and rear transverse differential lock (Fig. 2) 0) Lock disengaged. 1) Interaxle longitudinal differential lock engaged. 2) Rear transverse differential lock engaged. We recommend engaging the interaxle longitudinal lock after the longitudinal distributoir lock has already been engaged. The rear transverse differential lock only engages once the longitudinal lock has been engaged.



3



Longitudinal distributor differenital lock (6x6, 8x6 and 8x8 vehicles only) (Fig. 3) 0) Lock disengaged. 1) Lock engaged.



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Differential lock engagement D To engage the lock turn the know to engage position. D Engagement is indicated by the activation of the corresponding warning light on the cluster. D To disengage the lock turn the knob to disengage position. D Lock disengagement is indicated by deactivation of the corresponding warning light on the cluster. The differentials must be engaged with the vehicle stopped and with the wheels straight. If the lock does not disengaged immediately, change direction in order to eliminate any tension present. Proceed with caution when lock is engaged. Do not engage the lock on roads that do not require its use. In muddy or slippery conditions do not allow the wheels to slip when the differential lock is not engaged, as this will lead to serious damage to the gearing (a few seconds are enough). Do not engage the differential while a wheel is slipping as this will also cause serious damage to gearing. After use, always check that the locks are disengaged checking both the warning lights and the position of the control button.



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1



Power take off control The vehicle has the following power take offs: D P.T.O on flywheel (Multipower or NMV 221). D PTO on transmission.



A



285ANU023L



2 B



285ANU024L



3 C



285ANU025L



The power take offs are controlled by a switch on the dashboard. A. P.T.O I control on gearbox Power take-off activated is indicated by the warning light on the pushbutton (Fig. 1, ref. 1). B. P.T.O II control on gearbox Power take-off activated is indicated by the warning light on the pushbutton (Fig. 1, ref. 1). C. P.T.O control on flywheel Power take-off activated is indicated by the warning light on the pushbutton (Fig. 1, ref. 1). A maximum of 3 power take offs can be controlled simultaneously.



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1



1



Multipower PTO on flywheel Engage procedure: D Gearbox in neutral, vehicle stationary, engine off. D Turn ignition switch to MAR. Make sure that braking system low pressure warning light is off. If it is not, start the engine, wait until the warning light switches off then switch off the engine.



272NU087X



1



2



D Press the corresponding PTO button. D Wait for the yellow light on cluster. D Start the engine. In case of electrical or pneumatic command fault, the PTO can be engaged manually as follows: D Remove the Multipower connector ring (Fig. 1, ref. 1) or (Fig. 2, ref. 1) NMV 221; D Fully insert an M12x1.5 bolt.



228NMR32X



Disengage procedure: D Switch off the engine D Press the corresponding button. D Check that corresponding light goes out on cluster.



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1



P.T.O. manual transmission Engage procedure: D Gear idling, vehicle stationary, engine at minimum. Make sure that the braking system low pressure warning light is off. Otherwise wait until it switches off.



342ANU007L



2



342ANU008L



D Gearbox in neutral, vehicle stationary, engine idling. D Press the clutch pedal full down. D Press the corresponding PTO button (Fig. 1; Fig. 2). D Wait for the light to light up on cluster. D Release the clutch pedal. Disengage procedure: D Press the clutch pedal full down. D Press the corresponding PTO button (Fig. 1; Fig. 2). D Check on cluster that corresponding light goes out . D Release the clutch pedal.



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1



P.T.O. on automated gearbox Engage procedure: D Gearbox in Neutral, vehicle not moving, engine at minimum. Make sure that the braking system low pressure warning light is off. Otherwise wait until it switches off.



342ANU007L



2



D Press the relevant PTO button (Fig, 1, 2). D Wait for the cluster indicator light to switch on. Disengage procedure: D Press the relevant PTO button (Fig, 1, 2). D Check that the cluster indicator light has gone dark.



342ANU008L



With PTO engaged only manual transmission mode is available.



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1



P.T.O. on automatic transmission Engage procedure: D Gearbox in Neutral, vehicle not moving, engine at minimum. Make sure that the braking system low pressure warning light is off. Otherwise wait until it switches off.



342ANU007L



2



D Press the relevant PTO button (Fig, 1, 2). D Wait for the cluster indicator light to switch on. Disengage procedure: D Press the relevant PTO button (Fig, 1, 2). D Check that the cluster indicator light has gone dark.



342ANU008L



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1



TACHOMETRIC SIMULATOR The tachometric simulator (Fig. 1) permits correct electronic management of the cluster. For more information, refer to the corresponding publications.



285ANU026L



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1



HEATING AND VENTILATION Climate control system air vents (Fig. 1) 1. Windshield defrosting air outlets 2. Side ventilation air outlets 3. Door windows de-frosting air outlets 4. Central ventilation air outlets 5. Foot ventilation air outlets



j cool air J warm air



342BNU43L



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1



342BNU44L



Climate controls (Fig. 1) 1. Temperature adjustment control: 2. Four-speed electric fan control 3. Air distribution control knob (see symbols) 4. Internal recirculation control: - not pressed: external air inlet - pressed: internal recirculation 5. Conditioner control with incorporated warning light (only climate control version) not pressed: off pressed: engaged Symbols



Ventilation outlets Foot cooling/outlets Foot cooling Foot cooling/windshield Windshield de-misting and side vent windows Climate control Recirculation



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Proceed as follows (figure on previous page): For all versions: D start engine; D turn the knob (Fig. 1, ref. 1) of fan control, to set the required ventilation level; D turn the knob (Fig. 1, ref. 2) to set the required temperature inside the passenger compartment; D turn the knob (Fig. 1, ref. 3) to the required position according to the climate control requirements (feet-outlets-windshield, see also next page). D if there is heavy environment pollution press pushbutton (Fig.1, ref. 4) to activate internal recirculation. Only for versions with climate control: D press the switch (Fig. 1,ref. 5) to start the air conditioner; D to disengage the air conditioner, press the switch again. With the knob (Fig. 1, ref. 1) in position 0 (off) there is no electrical enable to the conditioner control. Hints for use: D keeping permanently in recirculation position can cause misting of the windows. Periodically press button (Fig 1, ref. 4) to ensure a change of air. D Do not keep the conditioner on for long times with the fan (Fig. 1, ref. 1) at minimum to avoid ice forming on the evaporator. D If the cab is overheated (vehicle has remained parked for a long time under the sun) turn the knob (Fig. 1, ref. 1) anticlockwise , and the knob (Fig. 1, ref. 2) clockwise, switch on the conditioner and keep the windows open for a few minutes. D In the case of a very humid environment switch on the conditioner and fully turn the knob (Fig. 1, ref. 3) clockwise; if necessary adjust the temperature with the knob (Fig. 1, ref. 2), using the conditioner as a dryer. D Run the system for a few minutes to ensure full efficiency at least once a week, regardless of the temperature. Any water dripping from under the vehicle with the air-conditioner on is due to normal condensation discharge.



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1



342BNU45L



Most common control positions Normal temperature position



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1



De-misting -de-frosting position To obtain a rapid increase in air temperature, press the recirculation start button: however, it is not advisable to keep this position for a long time.



342BNU46L



1
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1



342BNU47L



Maximum heating position



1
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1



Maximum cooling position For versions with air conditioner press the start button.



342BNU48L



1
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1



357ANU103L



AUXILIARY HEATER (WEBASTO) The vehicle is equipped with a hot air generator (Fig. 1, see arrow) to heat the passenger compartment with engine off. To activate the generator, proceed as follows: D Enable the heater by means of the wheel (Fig. 2, ref. 1). D Start the auxiliary heater moving the knob (Fig.1, ref. 2) clockwise from position ”0”. Continuing to turn the knob clockwise increases the air temperature. Continuing to turn the knob anticlockwise reduces the air temperature.



2 Proceed as follows to disconnect the generator: D Set the knob on ”0”. D Deactivate the heater by means of the wheel (Fig. 1, ref. 1).



357ANU104L



1
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1



357ANU105L



6 87



1



9 10 11



2



3



4



2



5



285ANU043L



AUXILIARY HEATER (WEBASTO) The vehicle is provided with an auxiliary heater for heating the engine coolant when the engine is off. Ignition of the heater can be programmed by means of a display for setting the required parameters (Fig. 1). Auxiliary heater control panel (Fig. 2) 1. Time 2. Programming 3. Heating 4. Back 5. Forward 6. Stored 7. Remote control symbol 8. Day of the week or programmed day 9. Current time or programmed time 10. External temperature 11. Operation indicator



1
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6 87



1



9 10 11



2



3



4



1



5



285ANU043L



Before setting the time and day of the week Briefly press the button (Fig. 1, ref. 1). 12:00 will blink on the display. Set the current time during the buttons (Fig. 1, ref. 4 and 5). The digits will stop blinking when the time is stored. The day of the week will blink on the display. Set the day using the buttons (Fig. 1, ref. 4 and 5). The day will be stored when the indication stops blinking. The indication will light up when the key is inserted. It will go out 10 seconds after removing the key. How to set the time and day of the week Hold the button (Fig. 1, ref. 1) pressed until the time starts blinking. Adjust as described for the first setting. To set the time only, press the button twice (Fig. 1, ref. 1) after setting the time to skip setting the day. After changing the day of the week, press the button (Fig. 1, ref. 1) to make the day blink for less time.



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6 87



1



9 10 11



2



3



4



1



5



285ANU043L



Operation of the heater with key-off without programming Symbol (Fig. 1, ref. 11) heater working. Turning the heater on Briefly press the button (Fig. 1, ref. 3). Symbol (Fig. 1, ref. 11) and the heating time will appear. The default setting is 120 minutes. It may be modified temporarily or permanently. Temporarily changing the heating time Press button (Fig. 1, ref. 4) after turning on to shorten the operation time (down to 1 minute). Press the button (Fig. 1, ref. 5) to extend the heating time (up to 120 minutes). Permanently changing the heating time Do not turn the heater on. Press the button (Fig. 1, ref. 4) and hold it pressed for approximately 3 seconds until the indication blinks on the display. Release briefly. Set the heating time (from 10 to 120 minutes) using the buttons (Fig. 1, ref. 4 and 5). The new setting will be stored when the indication disappears from the display. Turning the heating off Briefly press the button (Fig. 1, ref. 3). The symbol (Fig. 1, ref. 11) disappears from the display. The heater will continue to operate for a few minutes to allow the device to cool down correctly (wash-out step).



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6 87



1



9 10 11



2



3



4



1



5



285ANU043L



Operation of the heater with key-on without programming Symbol (Fig. 1, ref. 11) heater working. Turning the heater on Briefly press the button (Fig. 1, ref. 3). The symbol (Fig. 1, ref. 11), the time and day of the week will appear. The heater will work until the key is on. At key off, the remaining heating time (15 minutes) may be extended (up to 120 minutes) by pressing the button (Fig. 1, ref. 5) or shortened (down to 1 minute) by pressing the button (Fig. 1, ref. 4). Turning the heater off Briefly press the button (Fig. 1, ref. 3). The symbol (Fig. 1, ref. 11) disappears from the display. The heater will continue to operate for a few minutes to allow the device to cool down correctly (wash-out step).



1
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1



342BNU001L



USE OF THE VEHICLE Precautions for the initial period of use When the vehicle is new a brief running-in period of at least 150/200 hours is required: Observe the following precautions during this time: D do not demand maximum engine power; D after starting, warm the engine slowly; avoid driving at high revs too soon; D frequently check the oil level; D check the tightening of the wheel bolts. General checks Before starting to use the vehicle, check: D tyre conditions; D correct functioning of all lights, headlights and windshield wiper; D fuel level in tank; D any faults or low levels indicated on the instrument board; D check service brake and parking brake efficiency. Visually inspect the vehicle, checking working conditions and for damage/problems which may cause damage to the vehicle or injury to operators.



1
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Refuelling Put out naked flames while refuelling. Do not smoke.



342BNU001L



Proceed as follows: D clean the filler area, open the filler cap (Fig. 1, ref. 1) with the key and refuel with the specified fuel type; D close the filler cap carefully. Keep the fuel tank as full as possible. Use fuels of the specified types supplied by petroleum companies. Do not use other than specified fuels. Use of other than specified fuels can cause severe engine damage.



1
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STARTING ENGINE Exhaust gases are poisonous. Check for adequate ventilation before starting the engine in a confined space. Always engage the handbrake before starting the engine.



272CNU093



2



272BNU079



Checks before starting Check that the main switch (Fig. 1) is on. A: power off B: power on Make all the required daily checks (for more information see MAINTENANCE INSTRUCTIONS). Especially check: D engine oil level; D engine coolant level; D tyre condition; D tow-hook /semi-trailer fifth wheel condition. Power up the vehicle electrical system turning the ignition switch to MAR (Fig. 2, ref. 1) and check: D fuel level; D lights, warning light, horn and windscreen wiper function;



1
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Starting from drivers cabin Proceed as follows: D Check that the parking brake is engaged; D turn the ignition key to MAR (Fig. 1, ref. 1); D wait until the engine pre-heating light (Fig. 2) goes out. If the key is not turned to start the engine within a few econd, the key must be turned to STOP (Fig. 1, ref. 3) and the procedure repeated.



272BNU100



2



D turn the ignition key to AVV (Fig. 1, ref. 2) and release it as soon as the engine starts. Do not press the accelerator pedal while starting the engine. If the engine does not fire immediately, do not insist on the starter motor for more than 15 seconds.



356ANU001L



Do not leave the engine idling for a prolonged period of time, whether cold or hot. After starting the engine, drive the vehicle gently for a certain period, with medium to low engine revs, to allow it to warm up.



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Starting from engine bay The engine can be started with the cabin tipped in the following way: D Turn the ignition switch (Fig. 1, ref. 1) to MAR position; D tip the cabin and press the starter button (Fig. 2, see arrow). Engine starting is only possible if: D gearbox is in neutral; D parking brake is engaged.



272BNU079



2 Tow starting The engine cannot be started in any case in presence of a battery fault, because the control units are not powered.



178NU47



Manual transmission vehicles Proceed as follows: D turn the ignition switch (Fig. 1) to MAR; D engage a medium-low gear according to working conditions. Vehicles with hydro-mechanical/automatic/automated transmission The engine cannot be started by towing.



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1



4



Emergency electrical power When the batteries are discharged, connect the vehicle to external batteries to restart it.



3



2



The vehicle is equipped with a 24 volt electrical system with negative and earth. Only use 24 volt batteries to jump start the engine.



1



238NU44



Proceed as follows: D lay the cables on the ground ensuring that the terminals do not touch metal parts or each other; connect one end of the red cable (A) to the POSITIVE terminal (Fig. 1, ref. 1) of the flat battery; D connect the other end of the red cable (A) to the POSITIVE terminal (Fig. 1, ref. 2) of the external battery; D connect one end of the black cable (B) to the NEGATIVE terminal (Fig. 1, ref. 3) of the external battery; D connect the other end of the black terminal (B) to any point of the chassis of the vehicle (Fig. 1, ref. 4) to be started which is certainly connected to earth.



1
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1



4



3



2



Select a connection point as distant as possible from the vehicle batteries. Make sure that the two vehicles do not come into contact. Respect the sequence of the operation. Do not reverse the polarity when making the connection. Use cables with a suitable cross-section area. Never use a battery charger to start the engine. Do not disconnect the accumulators even if they are discharged.



1



238NU44



The use of a booster is permitted following the use instructions of the said instrument.



Always start the engine a previously described. After starting the engine, disconnect the cables by reversing the connection sequence. The vehicle electrical system must work in presence of battery, even if flat. In any case verify the causes of the batteries discharge.



1
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COLD START The following table shows the precautions to be adopted for starting the engine at temperatures lower than 0 ˚C. For more information on fluids, refer to the MAINTENANCE INSTRUCTIONS chapter. Temperature [˚C]



Operations Starting procedure Fuel



From 0 to -19 normal



From -19 to -25 with heater



Lower than -25 with heater



replace with Artic diesel fuel



replace with suitable fuel



add suitable percentage of additive



wash out the engine and auxiliary heater feeding circuit



Engine oil



no replacement needed



replace with suitable type



Engine coolant



appropriate percentage of antifreeze



Transmission oil



no replacement needed



Power steering steering fluid



no replacement needed



Windscreen washer fluid



appropriate percentage of antifreeze



Batteries



check maximum charge by measuring electrolyte density



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1



357ANU105L



2



Starting with heater Proceed as follows: D Start the supplementary heater (Fig. 1) as described above. D Let the heater run for at least 60 minutes. D Start the engine (Fig. 2) as described above. D Check that the oil pressure reaches the maximum value within thirty seconds: otherwise stop the engine, start the auxiliary heater for at least 10 minutes and start the engine again. D After starting the engine, keep the heater running to warm up the engine faster. The vehicle can be used at maximum power only after the liquid temperature.



272BNU100



1
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1



272BNU091



STOPPING ENGINE Stopping from drivers cabin To stop the engine, proceed as follows: D bring the engine to idle speed for a few minutes to reached steady state temperature and ensure turbocompressor lubrication; D turn the ignition switch to STOP (Fig. 1, ref. 0) and remove the key. DO NOT switch off the engine with the vehicle in motion to prevent loss of power steering. DO NOT remove the key from the ignition switch with vehicle in motion to prevent locking the steering. Vehicles with automated transmission: if the gearbox is not in neutral when the engine is stopped, the system automatically sets this position when the key is removed from the switch. In this condition there is no mechanical connection between engine and wheels, and the vehicle may roll forward if the parking brake is not applied.



1
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1



After switching off the engine the engine control unit has to carry out a series of diagnostic procedures that require electrical power for a few seconds. For this reason, before cutting out the batteries wait at least 10 seconds. Premature deactivation of the electric power through the circuit breaker (Fig. 1, position A) can cause considerable operating problems on the engine control system. Therefore this manoeuvre is only to be performed in cases of extreme necessity. After five (5) consecutive engine emergency switch-off operations, on the next start the engine starts normally but is unable to provide power and remains at idle speed. To restore complete function, contact the Service Network.



272CNU093



2



178NU45



3



306ANU002L



Stopping from engine bay To stop the engine, proceed as follows: D press the button (Fig. 2, see arrow) until the engine stops. After using the vehicle, always disconnect the accumulators through the circuit breaker (Fig. 1, position A) or by acting on the switch (Fig. 3).



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1 1



178NM81



2



MANUAL TRANSMISSION VEHICLES STARTING THE VEHICLE Before starting the vehicle, make sure that the tractor brake low pressure warning lights and trailer brake low pressure warning lights (if fitted ) are off, and that brake air pressure has reached 6 bar (Fig. 1). If necessary wait a few minutes for the compressor to charge the air tanks. To start the vehicle proceed as follows: D press the clutch pedal (Fig. 2, ref. 3); Press the pedal full down to fully disengage the clutch to prevent premature wear to synchronisers.



285ANU027L



D engage a low gear (1st to 3rd according to gradient); D release the parking brake, then release the clutch while pressing the accelerator pedal (Fig. 2, ref. 1).



3



The vehicle must be started in the right gear, especially if loaded and/or on a hill to prevent premature clutch wear. Proceed to engage the next gear pressing the clutch down before selecting the gear.



272NU062X



1
150



HD9 Euro3



1



2



1



DRIVING THE VEHICLE In normal driving conditions the danger warning lights (RED) must be off. If one or more warning lights come on, stop the vehicle and ascertain the cause. When driving, check that: D fuel level(Fig. 1, ref. 1) is not at minimum; Never totally empty the fuel tank to prevent any deposits or condensation water from the tank reaching the injectors.



285ANU028L



2



285ANU045L



D engine coolant temperature light (Fig. 1, ref. 2) remains at around 90˚ C; D the engine oil pressure (Fig. 2) is suitable; the warning light will go out after the engine has started;



1
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1 1



2



285ANU046L



2



285ANU030L



D the rear (Fig. 1, ref. 1) and front (Fig. 1, ref. 2) brake air pressure is suitable (max. 12 bars, min. 5.5 bars). D the alternator warning light (Fig. 2) is off. Do not exceed maximum engine speed, especially on downhill stretches. Never run down hill in neutral or with clutch disengaged. Use auxiliary brakes for long downhill stretches (engine brake, intarder) to prevent service brakes from overheating. Do not for any reason use the parking brake when travelling (except in emergency).



1
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1



178NU52



GEARBOX The operations to control the gearbox are the same as those on traditional type synchronised gearboxes, i.e. without requiring doubling of the clutch when changing up and without intermediate acceleration when changing down. The individual gears can be engaged only when the parts to be mated reach the same speed. It is therefore important to press the gear lever evenly until the gear is engaged.



2



341DNU005L



To avoid damaging the toothing of the gear, reverse should only be engaged when the vehicle is stationary. Gearbox control (Fig. 1) When the low range group is selected (“Tortoise” on warning light, Fig. 2, ref. 1) and the gearbox is in neutral, the gear lever is positioned between 3rd and 4th gear whereas when the high range group is selected (“Tortoise” off warning light, Fig. 2, ref. 1) and the gearbox is in neutral, the lever is positioned between 5th and 6th. To engage 1st and 2nd and 7th and 8th, the gear lever must be moved towards the left or right to overcome the slight resistance of the positioning springs. The selections 3rd/4th and 5th/6th are separated by a harder spring click.



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1



178NU52



2



341DNU006L



3



272GNU0099



Strike rapidly with the palm of your hand to overcome elastic resistance to shift range. The lever will position itself automatically for the desired selection of 3rd/4th and 5th/6th (Fig. 1). During change-over the gear shift automatically activates, indicated by the relevant LOW SPLIT warning light (Fig. 2).that switches on or off. To protect the clutch, the engine and the gearbox against run-away speed rates, SPECIAL CARE MUST BE TAKEN TO AVOID ERRONEOUS OPERATIONS when a lower gear is engaged. In particular: D A lower gear must be engaged only when the vehicle speed is lower than the maximum speed of the gear . D Shift from range 5/6 to range 3/4 only if the vehicle speed is slower than approximately 30 km/h. D Do not shift up or down more than two ratios (four half ratios) at a time. Any passage from the high range to the low range other than the passage 5th and 4th used for normal driving conditions must be avoided. The lever should not be used to set the low range even when the vehicle is momentarily in neutral. Operating the clutch The clutch pedal (Fig. 3, ref. 1) must be fully depressed each time a gear is changed. Changed gear effected only if the clutch is completely disengaged.



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1



178NU53



2



341DNU006L



Splitter control The splitter control which makes it possible to divide each of the eight gears (and reverse) occurs via the pre-selection valve located in the control lever and operated by the pre-selection lever (Fig. 1): D lever upwards (position A) = > normal gears D lever downwards (position B) = > step-up gears To control the splitter the lever should be worked and the clutch pedal fully depressed. A valve activated by the clutch pedal commands the splitter control cylinder, so that switching is obtained. To obtain correct splitter operation, engagement and disengagement movements must not be abrupt. Engagement of reduced gears is indicated by the relevant LOW SPLIT warning light (Fig. 2) that switches on. The use of the splitter is particularly useful in certain cases, for example: D to exploit the maximum power of the engine when difficulty is experienced when driving off, overtaking or travelling uphill; D when travelling in urban areas or when travelling in a queue when you wish to maintain the engine at an economical rpm.



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272NU062X



STOPPING THE VEHICLE To stop the vehicle proceed as follows: D release the accelerator pedal (Fig. 1, ref. 1) and gradually press the brake pedal (Fig. 1, ref. 2); D when the vehicle is drawing to a halt, depress the clutch pedal (Fig. 1, ref. 3) and move the gear lever to neutral; D when the vehicle has come to a halt, engage the parking brake. DO NOT switch off the engine with the vehicle in motion to prevent loss of power steering. DO NOT remove the key from the ignition switch with vehicle in motion to prevent locking the steering.



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VEHICLES WITH AUTOMATED TRANSMISSION (ASTRONIC) EUROTRONIC TRANSMISSION



357ANU106L



2



The ZF AsTronicselection system isacombination of an electro-pneumatic engagement transmission with an automated clutch. Gear change is facilitated by an electronically controlled gear selector (joy-stick, Fig. 1). It is also possible to set a completely automatic selection mode. F N R



function key idle position pushbutton reverse gear lock ring. After each action the selection lever returns to the initial position.



147NU10



3



Changing to high gears D With a step in (+) direction (Fig. 2, ref. a) the gear shifts by one higher gear. D With two steps in (+) direction (Fig. 2, ref. b) the gear shifts by two higher gears. Shifting to lower gears D With one step and movement in (---) direction (Fig. 3, ref. a) the gear shifts to a lower gear. D With two steps and movement in (---) direction (Fig. 3, ref. b) the gear shifts by two lower gears.



147NU12



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357ANU107L



2



357ANU108L



STARTING UP When the engine has been started the display shows the symbol N (Fig. 1). The system is in manual mode. Start-up is only enabled after sufficient air pressure has been reached. If the pressure is not sufficient the display shows the symbol AL. If, stopping the vehicle, due to low air pressure the clutch does not disengage, the engine stops. If gear shift takes place with air pressure too low, the gear may remain in idle, and no motion is transmitted. Moreover, there is no braking effect of the engine brake. If engine start-up is not possible because a gear has remained engaged and it is not possible to select idle position due to insufficient air pressure, it is necessary to autonomously supply air to the transmission from an external source.



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Start-up in automatic mode D start engine; D press the function key (F) (Fig. 1); The system sets the best take-off gear that is shown on the display (Fig. 2, for example 3rd gear); Each time the F key is pressed the system changes from manual mode to automatic and vice-versa.



147NU11



2



For start ---up with inclines greater than 10%, especially at full loads, the manual mode MUST be engaged. D release the parking brake pressing the accelerator pedal at the same time (Fig. 3, ref. 1); the clutch engages and the vehicle starts.



357ANU109L



3



272NU005MY



If the accelerator pedal is not (sufficiently) pressed during these manoeuvres, the vehicle may move backwards. In this case the clutch engages and disengages at brief intervals (misfiring). This also occurs when moving forward with reverse gear engaged travelling downhill. Avoid that the vehicle can move in the opposite direction to that of the engaged ratio. If the vehicle moves forward without a gear engaged, the engine brake action is not available.



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357ANU110L



Start-up in manual mode D start engine; D move the gearshift by one position (Fig. 1) pushing in (+) direction. The system sets the best take-off gear that is shown on the display (Fig. 2, for example, 3rd gear); D if necessary change the required starting gear moving the lever forward (+) or backward (---); For start ---up with inclines greater than 10%, especially at full loads, you MUST: D to select the take-off gear, D do not change gear when driving uphill.



2 D release the parking brake and at the same time press the accelerator pedal (Fig. 2, ref. 1); the clutch engages and the vehicle starts. 357ANU117L



3



272NU005MY



If the accelerator pedal is not (sufficiently) pressed during these manoeuvres, the vehicle may move backwards. In this case the clutch engages and disengages at brief intervals (misfiring). This also occurs when moving forward with reverse gear engaged travelling downhill. Avoid that the vehicle can move in the opposite direction to that of the engaged ratio. If the vehicle moves forward without a gear engaged, the engine brake action is not available.



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2



1



DRIVING THE VEHICLE In normal driving conditions the danger warning lights (RED) must be off. If one or more warning lights come on, stop the vehicle and ascertain the cause. When driving, check that: D fuel level(Fig. 1, ref. 1) is not at minimum; Never totally empty the fuel tank to prevent any deposits or condensation water from the tank reaching the injectors.



285ANU028L



2



285ANU045L



D engine coolant temperature light (Fig. 1, ref. 2) remains at around 90˚ C; D the engine oil pressure (Fig. 2) is suitable; the warning light will go out after the engine has started;



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2



285ANU046L



2



285ANU030L



D the rear (Fig. 1, ref. 1) and front (Fig. 1, ref. 2) brake air pressure is suitable (max. 12 bars, min. 5.5 bars). D the alternator warning light (Fig. 2) is off. Do not exceed maximum engine speed, especially on downhill stretches. Never run down hill in neutral or with clutch disengaged. Use auxiliary brakes for long downhill stretches (engine brake, intarder) to prevent service brakes from overheating. Do not for any reason use the parking brake when travelling (except in emergency).



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147NU11



Forward movement in automatic mode Running in automatic mode takes place: D when the vehicle has been started in automatic mode; D when with the vehicle in manual mode the function key (F) is pressed (F) (Fig. 1). Forward travel gear change in automatic mode Gear changes take place automatically according to these parameters: D running situations; D full load; D accelerator pedal position; D vehicle speed; D engine speed. When running the display shows the gear set.



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The gear set by the system can be changed by acting on the lever without exiting from automatic mode: Shifting to next gear down D With one step and shift in (---) direction (Fig. 1, ref. a) shifts to a lower gear. D Two steps and movement in (---) direction (Fig. 1, ref. b) shifts two gears down.



147NU12



2



147NU10



Shifting to higher gears D One step in (+) direction (Fig. 2, ref. a) shifts to a higher gear D With two steps in (+) direction (Fig. 2, ref. b) shifts two gears up.



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147NU11



Kick-down function Pressing the accelerator pedal beyond the hard limit stop point causes the control system to set POWER mode. Before shifting up, each gear is maintained up to the corresponding maximum engine speed, downshifting in case of sharp acceleration. The system remains in automatic mode during kick-down. Maintaining the selected gear In automatic mode, if the current gear has to be maintained (for example to accelerate before beginning a climb), press function button F without moving the lever. The system shifts to manual mode: no further gear shifts are possible except those made by means of the lever. To return to automatic mode, press function button F again without moving the lever.



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Forward running in manual mode Running in manual mode takes place: D when the vehicle has been started in manual mode; D with the vehicle in automatic mode the (F) function key is pressed (Fig. 1). Shifting to next gear down



147NU11



2



D With one step and shift in (---) direction (Fig. 2, ref. a) shifts to a lower gear. D Two steps and movement in (---) direction (Fig. 2, ref. b) shifts two gears down. Shifting to higher gears D One step in (+) direction (Fig. 3, ref. a) shifts to a higher gear D With two steps in (+) direction (Fig. 3, ref. b) shifts two gears up.



147NU12



3



147NU10



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Shift to neutral D Press the function key (N) (Fig. 1). The N symbol appears on the display. Manual mode is enabled. It is also possible to shift to neutral while driving. Shifting to neutral interrupts the dynamic coupling of the driveline. Engine braking in this case is not enabled.



147NU09



It is possible to shift to neutral at any time and from any gear, even with the vehicle moving. Simply shift the lever in the required direction or press the function key (F). To avoid holding the clutch disengage system operating during stops longer than 1 or 2 minutes with the engine running (for example in a traffic jam or at a level crossing) it is advisable to shift to neutral by pressing function key (N). This avoids unnecessary use of the disengage system.



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Reverse gear Reverse gear is only available in manual mode. The system is equipped with two reverse gears: RL = slow reverse RH = fast reverse



147NU15



2



Engaging reverse The vehicle has to be stationary. Proceed as follows: D Stop the vehicle completely. If the vehicle is still moving the reverse gear engagement does not take place. It is not important whether the gear is in idle position or a forward gear is engaged.



147NU16



D Slow reverse: pull the collar (R) upward and shift the lever one click in direction (---) (Fig. 1). D Fast reverse: pull the collar (R) upward and shift the lever two clicks in direction (---) (Fig. 2). With the vehicle stationary and already in reverse it is still possible to shift from RL to RH and vice-versa. Push the lever with the collar pulled up and shift respectively: D one click in direction (---) for RL; D two clicks in direction (---) for RH.



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Reverse gear disengagement Proceed as follows: D Stop the vehicle completely. If the vehicle is still moving the reverse gear disengagement does not take place.



147NU17



2



D Pull the collar (R) upward and move the lever by one position in (+) direction (Fig. 1). or D Press the function key (N) (Fig. 2). The display will show the symbol N. Manual mode is activated. Any forward gear can be selected.



147NU09



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CL



Protection functions Clutch protection If the clutch overheats (for example due to many consecutive starts at short intervals, or with low speed gear selected for too long) the CL symbol appears on the display and an alarm will sound. In this situation the driver must perform a manoeuvre that eliminates the overload (for example accelerating the vehicle to engage the clutch, stopping the vehicle or start-out selecting a low gear). If the accelerator is pressed the system will engage the clutch regardless of the overload signal, worsening the condition of the clutch itself (except in 1st and RL). This may cause the clutch to slip with engine over-revving and may even allow the vehicle to slip backwards if starting out on a hill. Engine over-rev protection The system does not permit engagement of gears not compatible with engine sped and load conditions.



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“LIMP HOME” function The LIMP HOME function is useful in emergency conditions. The system will not work in the usual manner in these conditions. Proceed with the utmost care. Check that the air pressure is maximum. Check vehicle performance under control: the gear indicator may show a different gear from the one actually engaged in some conditions.



307HNU004L



2



147NU04



Use The symbol LH will blink on the display when the LIMP HOME function is working (Fig. 1). Activation by driver D stop the engine; D turn the key to the MAR position; D within 5 seconds, press the function button (Fig. 2, ref. N) and hold it pressed for at least 5 seconds. Symbol LH (Fig. 1) blinking D LIMP HOME function on; D gearbox in neutral; D clutch disengaged.



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147NU04



2



307HNU005L



Gearbox lever functions D for shifting one gear at time up (+) o down (---); D all forward gears and one reverse are available; D function button (Fig. 1, ref. F): engage/disengage clutch. Clutch state display D Clutch engaged: bar with arrow pointing downward (Fig. 2, ref. 1). D Clutch disengaged: bar with arrow pointing upward (Fig. 2, ref. 2). D The indicator will stop blinking during a gear shift. It will resume blinking after the gear is engaged.



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Operation D Activate emergency mode and start the engine. D Press and release the brake. D Engage the required gear by repeated operating the gear lever (Fig. 2): (a) forward (+) to shift up (b) backward (---) to shift down The gears to be used in LIMP HOME mode must be selected when the vehicle is stationary only. Movements of the gear lever while the system is travelling will not be taken into account by the system.



147NU04



2 D Engage the clutch: hold the button (Fig. 1, ref. F) pressed until the bars and downward pointing arrow appears (Fig. 3, ref. 1). 307HNU005L



3



307HNU006L



The clutch may be engaged with delay or suddenly.



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147NU04



Uphill starting D If the clutch is engaged by means of the button (Fig. 1, ref. F) when the brake is pressed, release the brake pedal briefly in order to be able to disengage the clutch with the accelerator again. Driving downhill D The clutch will be automatically engaged when the vehicle is travelling downhill with a gear engaged. Restoring normal operation (RESET) D Turn the key to the STOP position and wait for the indicator to go out. D Turn the key back to the MAR position.



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272NU005MY



STOPPING THE VEHICLE With the accelerator pedal (Fig. 1, ref. 1) released, decelerate the vehicle with the service brakes (Fig. 1, ref. 2) until stopping. During this operation the clutch automatically disengages before the vehicle stops, preventing the engine from stalling. When the vehicle stops, if a higher gear than the last selected pick-up gear is engaged, the system will automatically shift to the last selected pick-up gear. When the vehicle stops, if a lower gear than the last selected pick-up gear is engaged, that gear is maintained. Always shift to neutral by pressing function button (N) for stops longer than 1-2 minutes with the engine running.



With the vehicle stationary, engine running and gear engaged, simply press the accelerator to move off with the vehicle. Always shift to neutral (N) and engage the parking brake before exiting the vehicle with the engine running. If the transmission is not in neutral (N), a buzzer will sound if the driver attempts to exit the vehicle. Pulling the handbrake when driving on slippery roads may stall the engine. In this event power steering is NO LONGER AVAILABLE!



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178NM81



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357ANU201L



3



272NU005MY



VEHICLES WITH AUTOMATIC TRANSMISSION



STARTING THE VEHICLE Before starting the vehicle, check that the warning lights indicating low tractor brake air pressure and low trailer brake air pressure (if present) are off, and that the brake air pressure has reached 6 bars (Fig. 1): if required, wait for a few minutes for the compressor to adequately recharge the air reservoirs. To drive off proceed as follows: D release the parking brake and press the brake pedal (Fig. 3, ref. 2); D take the lever (Fig. 2) to D position (drive); D wait for 1-2 seconds to enable gear engagement; D release the brake pedal and press the accelerator (Fig. 3, ref. 1): vehicle will start off smoothly.



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357ANU201L



The automatic transmission will select the most suitable gear for vehicle running conditions (engine speed and load). Driving off can also take place with gear lever in intermediate positions (1, 2, 3). In these positions, the gearbox excludes the gears higher than the selected one (e.g. when selecting position 2, the transmission will exclude engagement of gears higher than second gear). Run engine idle with gearbox in position N (neutral) for at least 5 minutes when driving off temperature is below ---15˚C.



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2



1 285ANU028L



DRIVING THE VEHICLE Under normal conditions the danger warning lights and danger display indications (RED) should be off. If one or more of the warning lights/indications should come on, stop the vehicle and find the cause. When driving check that: D the fueltank level(Fig. 1, ref. 1)isnotminimum; Never fully drain the fuel tank to prevent dirt and condensation on the bottom of the tank from reaching the injection system.



2 D the engine coolant temperature (Fig. 1, ref. 2) should remain about 90˚C; D the engine oil pressure (Fig. 2) is suitable; the warning light will go out after the engine has started; 285ANU045L



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D the rear (Fig. 1, ref. 1) and front (Fig. 1, ref. 2) brake air pressure is suitable (max. 12 bars, min. 5.5 bars); D the alternator warning light (Fig. 2) is off. Do not exceed maximum engine speed, especially downhill. Never travel with the transmission in Neutral. Avoid using the auxiliary brakes (engine brake, intarder) on long downhill stretches to prevent overheating the service brakes. Never use the parking brake (expect in an emergency) when travelling.



357ANU238L



2



285ANU030L



Kick-down The kick down device operation (i.e. depress accelerator pedal beyond limit stop) enables the driver to “force” down-shifting when running. This device can be used to have higher vehicle pickup after a moderate slowing down (i.e. not causing automatic shifting to a lower gear). Do not use this device continuously because it causes rough use of the transmission, stresses the assembly and leads to higher fuel consumption.



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Automatic transmission 1. Safety button to be pressed to allow selector lever movement. 2. MODE button : to choose a second setting of the automatic transmission control unit. PERFORMANCE mode: default setting, button not pressed, LED off. ECONOMY mode: second setting, button pressed, LED on. The MODE button incorporates a warning light (ref. 3) that switches on when the button is pressed.



357ANU234L



3. Display: Shows the ratio engaged when vehicle is travelling, and fault codes when requested. 4. DIAGNOSTIC button: to view fault codes on the display.



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It is not possible to shift from position N to position D or R if the parking brake is applied. Positions N, D and R can only be selected and released by pressing the safety button (Fig. 1, see arrow).



357ANU235L



Only the positions Neutral, Reverse, 2 can be used when the oil temperature is colder than 7˚C (19˚F). All other positions will not be available even if they are selected. Forward or reverse must only be engaged when the vehicle is stationary. Never idle the vehicle with reverse engaged for longer than 5 minutes to prevent damage to the transmission.



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The selection lever has the following positions: N (Neutral) position This position must be selected: D to start the engine; D to operate the power take-off; D when the vehicle is momentarily left with the engine running. R (Reverse) position This position must be used for reversing the vehicle. An external buzzer will sound when Reverse is selected.



357ANU236L



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Drive position This position must be used for driving the vehicle in the normal conditions. Automatic transmission control system selects the most suitable gear and controls engagement of converter automatic lock-up clutch according to engine speed and load. The automatic transmission may keep shifting down and up when travelling uphill (“gear hunting”). In this case, it is advisable to manually select the lower gear and reduce speed.



357ANU236L



The control system tends to shift to higher gears to decrease engine load when travelling downhill. This decreases the engine brake effect and increases speed. In this case, select a more suitable gear to prevent speeding up.



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Positions 6, 5, 4 and 3 These positions should be used occasionally when selection should be limited to the first three gears, cutting out the higher gears and first gear, due to particular load or road conditions. The lower is the selected position, the higher is engine braking effect, since higher gears engagement is progressively excluded. Position 2 This position must be used to control vehicle speed uphill and especially downhill on particularly steep roads.



357ANU236L



Position 1 There transmission does not shift and outputs maximum torque to wheels.



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Fault The “Check Trans” warning will on the side panel (Fig. 1, ref. 1) will light up to indicate a possible automatic transmission fault. The error code will appear on the display by the side of the selection lever (Fig. 2, see arrow). If the “check trans” warning light comes on, park the vehicle by the side of the road in a safe place and call a Service workshop as soon as possible.



272NU005AL



2



357ANU237L



High automatic transmission oil temperature is indicated by the corresponding warning light on the side panel (Fig. 1, ref. 2).



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Stopping the vehicle To stop the vehicle proceed as follows: D Release the accelerator pedal (Fig. 1, ref. 1) and press the brake pedal (Fig. 1, ref. 2). D When the vehicle is drawing to a halt, move the gear lever to N (Neutral). The torque converter permits keeping the vehicle stationary with the selection lever in any position by pressing the brake pedal. Avoid however to maintain this position for long periods since it causes a sudden gearbox oil temperature increase.



272NU005MY



D When the vehicle has come to a halt, engage the parking brake.



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ALL VEHICLES SPEED PROGRAMMER Engine idle speed adjustment / memorising The speed programmer is a device that acts on the engine power supply management system, controlling rotation speed both with vehicle stationary and in motion, so that certain conditions are met. Keep the brake pedal pressed throughout the operation. Conditions: D engine at idle speed; D engine at temperature over 30 ˚C.



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Proceed as follows: D Action the Cruise Control lever (Fig. 1, ref. 1) toward the steering wheel (RESUME) until engine speed reaches the basic stabilised rate (approx 550 rpm); D Adjust speed as required using ON + (Fig. 1, ref. 2) or ON --- (Fig. 1, ref. 3) (pivoting head key). Each touch of the ON key increases or decreases engine speed by circa 20 rpm. Engine idle speed must be between the following values: D minimum value: 550 rpm D maximum value: 750 rpm Adjust idle speed according to needs (noise, vibration, etc.). D When required speed is reached, move the Cruise Control lever again toward the steering wheel (RESUME) for about 5 seconds. D Release the brake pedal. This will memorise the new speed even after stopping the engine, and the new setting will be valid for all subsequent restarts. If the procedure is not carried out correctly and/or problems are encountered during it, the previously memorised speed is maintained.



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HD9 Euro3 Vehicle speed (Cruise Control) adjustment / memorising



The Cruise Control must not be used in heavy traffic conditions or on roads where constant speed adjustment is necessary. If the set speed is no longer achievable the device cuts-out automatically. If vehicle speed increases by more than 2 kph over the set value (e.g. on descending road) to slow the vehicle and maintain set speed, engine braking is automatically engaged. If vehicle speed increases more than 4 km/h also the retarder (if present) engages. Vehicles with automated transmission: if the vehicle speed exceeds 6 km/h, the transmission will shift down (automatic mode only). The automated transmission, in automatic mode, will shift down whenever necessary (increase coolant flow rate).



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Conditions: D engine brake lever/retarder not engaged; D vehicle moving with gear engaged; D vehicle speed greater than 20 kph; D brake pedal not pressed; D clutch pedal not pressed. Control ON + ON --RESUME OFF



Vehicle speed regulation Increases speed Decreases speed Selects last set speed Cancels speed regulation



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Enable Proceed as follows: The function can be enabled only if the brake pedal has been pressed at least once after starting the vehicle. D Bring the vehicle to the steady speed to maintain with the accelerator pedal; D Press the ON button (+) (Fig. 1, ref. 2) once: the speed value is automatically memorised; D Release the accelerator pedal.



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Changing setting Proceed as follows: D after activating the function press ON (+) (Fig. 1, ref. 2) to increase vehicle speed; or D after activating the function press ON (---) (Fig. 1, ref. 3) to decrease vehicle speed. Tip Function Briefly press the ON (+) or ON (---) button to vary speed by steps of 1 km/h. Ramp Function Pressing down the ON (+) or ON (---) buttons changes speed continually.



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Permanent disable Proceed as follows: D Engage the Cruise Control lever towards the dashboard (OFF) (Fig. 1, ref.1). or D Operate the brake or engine brake pedal; or D Press/turn the accelerator pedal (demanding a higher speed than set) for more than 60 seconds. After disengage, it is possible to revert to the previous configuration by moving the Cruise Control lever towards the steering wheel (RESUME). If the set speed is no longer achievable the device cuts-out automatically. To prevent disabling the engine brake or intarder on downhill stretches, the Cruise Control remains active if the brake pedal is pressed at speed over 4 kph. Temporary disable Proceed as follows: D Operate the clutch pedal (if present) the system shifts to stand-by. After disengaging the clutch the vehicle returns to the cruising speed set previously. D Press/turn the accelerator pedal for more than 60 seconds. As soon as the accelerator is released the function automatically resumes at the last set value.



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ENGINE BRAKE CONTROL SELECTION Vehicles without intarder The device is controlled by moving the steering column right lever (Fig. 1) and can be set in one of three positions(from 0 to 2): D position 0: disabled; D position 1: 50% engine braking; D position 2: 100% engine braking. For the same lever positions, maximum engine braking effect is achieved by engaging lower gears, since braking is proportional to engine revs. Engine brake engagement disables all cruise control operations Whatever the setting, the function is disabled as soon as the accelerator pedal is pressed.



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To enable the device: D not press the switch (Fig. 1 item 0); D move the lever (Fig. 2) to the desired braking position. To disable the device: D shift the lever (Fig. 2) back to position 0. Use the retarder to reduce vehicle speed on turns or downhill, to prevent overheating the brakes.



284CNU014L



21



3



272GNU104



Function warning light (Fig. 3) switches on: D bringing the ignition switch to MAR (RUN) for three seconds (test); D in fixed mode until the retarder performs its braking action; D flashing if there is a system fault.



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Vehicles fitted with intarder The device is controlled by moving the steering column right lever (Fig. 1) and can be set in one of seven positions (from 0 to 6) corresponding progressively to greater breaking forces as in the table (Fig. 2).



2



228NUR53



For the same lever positions, maximum engine braking effect is achieved by engaging lower gears, since braking is proportional to engine revs. Engine brake engagement disables all cruise control operations Whatever the setting, the function is automatically disabled as soon as the accelerator pedal is pressed.



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To enable the device: D not press the switch (Fig. 1, item 0); D move the lever (Fig. 2) to the desired braking position. To disable the device: D shift the lever (Fig. 2) back to position 0. Vehicles with automated gearbox (in automatic mode): with the lever in position 6, the transmission automatically shifts to the lower gear whenever this is needed to ensure maximum efficiency of the exhaust brake.



284CNU014L



2



1



272GNU105



Function warning light (Fig. 3) switches on: D bringing the ignition switch to MAR (RUN) for three seconds (test); D in fixed mode until the retarder performs its braking action; D flashing if there is a system fault.



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B



A



1



VEHICLE PARKING Parking brake --- vehicles without trailer The parking brake (Fig. 1) has two positions: D position A: engaged, vehicle braked; D position B: disengaged, vehicle NOT braked. To engage the parking brake bring the lever to position A. To disengage the parking brake raise the collar and bring the control lever to position B. Never use the parking brake (unless in an emergency) when the vehicle is running. The parking brake must be engaged in the following situations: D temporary or prolonged parking of the vehicle; D when loaading/unloading the vehicle.



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B



1



Parking brake --- vehicle with trailer The parking brake (Fig. 1) has two positions: D position A: engaged, vehicle braked; D position B: disengaged, vehicle NOT braked. To engage the parking brake bring the lever to position A. To disengage the parking brake raise the collar and bring the control lever to position B.



A



Never use the parking brake (unless in an emergency) when the vehicle is running. The parking brake must be engaged in the following situations: D temporary or prolonged parking of the vehicle; D when loaading/unloading the vehicle.



2



Parking brake efficiency check Proceed as follows: D bring the vehicle (tractor + trailer) on an appropriate slope; D set the lever in position A (Fig. 1); D press and push (Fig. 2) the lever keeping it in position: the vehicle must not move. In this position the trailer parking brake is excluded. Any movement of the vehicle indicates an insufficiency of the TRACTOR parking brake. When released, the lever returns to position A.



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Additional parking brake The additional parking brake (Fig. 1) has two positions: D position 0: off; D position 1: on. To engage the additional parking brake, turn the knob to position 1 and wait for 5 to 6 seconds. The additional parking brake is of the non-proportional type and can be engaged only after engaging the parking brake. Since it is pneumatically operated, it must be used only with running engine and for short periods of time.



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2



A.B.S. ANTI-LOCK BRAKING SYSTEM The A.B.S. system provides optimal braking and perfect vehicle control in all conditions. in particular: D it prevents wheel locking while braking in any road conditions; D it reduces stopping distance; D increases safety for the driver who can maintain vehicle stability and direction. Functioning check or any faults on the ABS system are indicated with the ignition key on “MAR”. 1. Tractor ABS (yellow) (Fig. 1); also the generic warning light switches on. This indicates a fault on the tractor ABS system. 2. Trailer ABS (yellow) (Fig. 2); also the generic warning light switches on. This indicates a fault on the trailer ABS system. When there is an A.B.S. circuit fault. the vehicle braking related to that circuit takes place in normal mode. In any case it is necessary to go as soon as possible to the nearest After Sales dealership .



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JSK38-50_03



2



SEMI-TRAILER COUPLING Coupling Proceed as follows to open the fifth wheel: D raise the safety lever (Fig. 1, ref. 1); D move the bolt (Fig. 2, ref. 2) forwards to release the first stop notch (Fig. 3, see arrow); D pull the bolt fully to the second stop notch (see arrow). Proceed as follows to couple the semi-trailer: D immobilise the semi-trailer; The semi-trailer skid plate should be approx. 5 cm lower than the top of the fifth wheel.



JSK38-50_05



3



309FNU005L



D reverse the tractor so that it is in line with the semi-trailer, the locking mechanism functions automatically; D drive the tractor forwards to check that the semi-trailer is hooked-up correctly; D check the closure as shown below; D lift the supporting legs; D connect the electric and pneumatic connections.



1
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Check closure D check that the safety lever (Fig. 1, ref. 1) is in the lower position; D the back plate must uniformly rest on the fifth wheel (see arrow). Uncoupling Proceed as follows: D immobilise the vehicle; D lower the supporting legs; D disconnect the pneumatic and electric connections; D open the fifth wheel as described above; D move the tractor forwards. When the coupling pin is released the locking mechanism will automatically rearmed and the fifth wheel will be in coupling position.



309FNU006L



1



2



178NU85



ABS coupling (if foreseen) When using a tractor without a semi-trailer, particular attention should be paid to reconnecting the ABS coupling in its seating. After inserting it, press hard on the bracket (Fig. 2) until it locks into position. If this is not carried out water may get into the system causing corrosion and malfunctioning of the device.



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1



Pivoting fifth wheel Crosswise pivoting movements may be enabled for off-road use only. Crosswise pivoting must be blocked for safety reasons when travelling at high speed on roads.



307FNU007AL



2



307FNU007BL



How to enable crosswise pivoting D Loosen the hexagonal head screws (Fig. 1, ref. 1) on each side. D Extract the two lock teeth (Fig. 1, ref. 2) to reach end of travel in the slot (see arrow). D Fasten the hexagonal head screws again (Fig. 1, ref. 1) at a tightening torque of 80 Nm. How to lock crosswise pivoting D Loosen the hexagonal head screws (Fig. 2, ref. 1) on each side. D Insert the two lock teeth (Fig. 2, ref. 2) to reach end of travel in the slot (see arrow). D Fasten the hexagonal head screws again (Fig. 2, ref. 1) at a tightening torque of 80 Nm.



1
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1



307HNU002L



2



307HNU003L



TRAILER HOOKING --- I type Proceed as follows: D ensure that the chocks are positioned under the rear wheels; D the front axle can still be moved; D adjust the height of the trailer draw bar to that of the pintle hook; D lift the lever (Fig. 1, see arrow); D hook the trailer to hook (Fig. 1, ref. 1); D reverse the tractor and insert the trailer eyebolt in the bell-shaped head: the lever will snap down; D check coupling by checking that the lever is down (Fig. 2, see arrow) and the safety pins are retracted (detail).



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1



2



TRAILER HOOKING --- II type Proceed as follows: D secure the trailer with chocks under the rear wheels, so that the front axle can be manoeuvred; D adjust the height of the trailer draw bar to that of the pintle hook; D pull the lever outwards (Fig. 1, ref. 2) and at the same time raise the lever (Fig. 1, ref. 3) so as to lower the hook (Fig. 1, ref. 1); D connect the trailer to the hook (Fig. 2, ref. 1) checking that the safety lever (Fig. 2, ref. 2) has entered into its housing.



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NORMS FOR TOWING TRAILER / SEMI-TRAILER Before hitching-up Before reversing with the tractor, make sure no people are standing in the immediate area



228NUR61



After hitching-up Engage the parking brake. Check that the coupling has been made correctly. Connect the air lines and electrical cables. Check the brakes and lights. Check correct function of the safety device. When driving Proceed with care while towing a trailer/semi-trailer. Never exceed the maximum admissible weight. In case of stops on hill, check that the parking brake functions correctly. It must be capable of holding the vehicle stopped.



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HD9 Euro3



4



3



2



1



Pneumatic coupling (Fig. 1) 1. Automatic (red) 2. Adjustable (yellow) Electric coupling (Fig. 1) 3. 15 pin coupling (ISO 12098) 4. ABS



1



228NUR60



TRAILER COUPLING



2



SEMI-TRAILER COUPLING Pneumatic coupling (Fig. 2) 1. Automatic (red) 2. Adjustable (yellow) Electric coupling (Fig. 2) 3. 15 pin coupling (ISO 12098) 4. ABS



272NU107X



3



LADDER Use the specific ladder (Fig. 3, ref. 1) to access the electric and pneumatic connections of the tractor. Keep the steps clean at all times to avoid slipping.



1



272NU108X



1
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HD9 Euro3



1



228NUR72



TOWING THE VEHICLE The towing of the vehicle is to be carried out using the specific hook for this purpose (see arrow). Proceed as follows: D free the split pin and withdraw the locking pin; D insert the end of the towbar into the seat; D insert the locking pin and fasten it with the cotter pin. If present, remove the protection hood before starting towing operations. Always use a suitably anchored rigid bar. Do not use cables or chains. Insert the key into the ignition switch to release the steering lock. The towing vehicle must have: D a total weight comparable to that of the vehicle being towed; D traction power sufficient to tow the convoy up the hills along the way; D braking power sufficient to slow the convoy down the hills along the way.



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Operating instructions Proceed as follows: D release the parking brake spring cylinders operating as described in the relevant section. If there is suspicion of internal transmission failures, or when driving long distances, it is necessary to remove the propeller shaft.



228NUR61



Manual transmission vehicles D Check that the gears high range is inserted (5th --- 8th ratio). D Bring the lever to idle position. D Start towing keeping MAXIMUM SPEED at 40 KM/H. It is advised not to exceed a maximum distance of 200 km. Automated transmission vehicles D Insert the gears high range proceeding as follows: --- check the gear pneumatic and electrical supply; --- move the ignition switch to position 1; --- check there are no error messages on the display. D Select Neutral position. D Start towing, maintaining a MAXIMUM SPEED of 25 km/h for a MAXIMUM DISTANCE of 100 km. Vehicles with automatic Allison transmission Remove the propeller shaft.



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1



357ANU110L



Propeller shaft removal To remove (Fig. 1, version 6x4) proceed as follows: D for the moment, fasten the shaft to the chassis; D make a reference mark on the coupling flange to be able to refit in the same position; D unscrew the fastening bolts and place them in the cab; D retract the end of the shaft and secure it to the chassis so as to avoid interference with the axle flange and other moving parts. Flanges to be removed to avoid dragging of the transmission (splitter unit and gearbox) (Fig. next page). To lift the front of the vehicle, remove the rear flange. A. 2-axle vehicles B. 3-axle vehicles If the steering does not have hydraulic servo control (engine off) much more force is required on the steering wheel. C. 4 axle vehicles If the steering does not have hydraulic servo control (engine off), steering is almost impossible. In this case the front of the vehicle has to be lifted.



HD9 Euro3



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215



Fig. 1 - Flanges to be removed



357ANU113L



1
216



HD9 Euro3



1



Spring cylinder emergency braking device In the event that compressed air does not reach the parking brake circuit, the vehicle is automatically braked by the spring cylinders. To enable the vehicle to be towed, the brake must be released with the mechanical release device. Mechanical disengagement To do this, proceed as follows OPERATING ON BOTH CYLINDERS: D place chocks under the wheels; D engage the hand brake; D turn the central screw located on the rear part of the cylinder (Fig. 1) anticlockwise from position 1 to position 2.



238NU56



After intervention of the emergency release device, the vehicle must only be towed and must under no circumstances circulate autonomously. Before using the vehicle normally again, return both the spring cylinders to position 1.



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HD9 Euro3



1



228NUR62



Compressed air discharged If the vehicle has not been used for a long period and the comprssed air system is discharged, it can be re-charged from an external source through the connector (Fig. 1, see arrow). This operation also releases the spring cylinders.



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1



285ANU038L



2



1



2 178NU91



WHEEL CHANGE Jacking up the vehicle To use the jack: D remove the cab jack (Fig. 1, ref. 1) from its housing behind the passenger seat by loosening the retainer screw (Fig. 1, ref. 2) from the bracket; D take the rod supplied; D check, that the hydraulic valve (Fig. 2, ref. 1) of the jack is rotated clockwise (hydraulic circuit under pressure); D position the jack at the raising points specified in the following page; D insert the rod into the bush (Fig. 3, ref. 2) and work the pump until lifting the wheel; D after replacement, SLOWLY turn the jack control hydraulic valve anticlockwise; D remove the jack and press the top part of jack cylinder with your foot to fit it back into seat. Strictly comply with instructions indicated on the label attached to the jack to use it correctly. The wheels should be changed when the vehicle is on level ground and unloaded with the hand brake engaged and chocks placed against the wheels which remain on the ground.



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4



1



272NU006MY



2



272NU007MY



3



272NU008MY



272NU008MY



Changing a wheel To change a wheel: D use the wheel brace provided to loosen the wheel bolts on the wheel to be changed; D raise the vehicle until the wheel is off the ground and set the jack at the following points: Figure 1: axle; Figure 2: front axle; Figure 3: intermediate axle; Figure 4: rear axle.



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1



The vehicle may be provided with spacers in some cases: D between rim and hub (Fig. 1); D between rim and fastening nuts (Fig. 2). Take note of the position if the spacer is removed to refit it correctly. Do not eliminate the spacer.



2



309FNU008L



1
221



HD9 Euro3



1



272NU010MY



D unlock the fastening nuts completely and remove them, then withdraw the wheel, taking care not to damage the stud bolt threads; D clean the threads of the screws and the nuts and the rim and hub stops; D fit the spare wheel or the repaired wheel; D fasten the nuts slightly until the wheel is correctly coupled to the hub; D lower the vehicle; D tighten the wheel fastening nuts to the specified torque (see TECHNICAL DATA section) in the order indicated (Fig. 1). Putting the weight of the body (approx 70 daN) on the end of the lever supplied, obtain a torque that is approximately equal to the specified value. Check the torque of the wheel fastening nuts after travelling about 20-40 km and then again after travelling 100 km. Do NOT lubricate the contact zones between nut and rim. A torque that is too tight could cause damage: therefore do not use pipes or extensions that have not been specifically supplied Do not use wheels and fastening devices different to the originals.



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1



178NU96



Handling the spare wheel Replacing a front or rear wheel with a spare does not create problems even if the profile of the thread is different. A tyre with the same profile should however be reintegrated as soon as possible. To remove the wheel proceed as follows: D unscrew the nuts (Fig. 1, ref. 1) fastening the wheel to the support bracket; D free the handle (Fig. 1, ref. 2) and take it in job position; D turn the crank until sufficiently lowered to remove the wheel. To replace the wheel, reverse the above procedure.



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1



2



DIAGNOSTICS The odometer display shows errors present in the vehicle control system memory. The warning light related to the concerned system will appear to indicate that errors are present. The control systems are indicated by four letters (Fig. 1, see table). Proceed as follows if one or more warning lights come on (see table, Fig. 1): D Turn the ignition switch to MAR; D Hold the button pressed for at least 5 seconds (Fig. 2, ref. 1). The error situation when the request was made will appear on the display (Fig. 2, detail). a error sequential number b total number of errors present c error code d ECU type (Fig. 1, see table). The errors present at the time of the request are displayed. The displayed error list is not refreshed. Each error is displayed for 5 seconds: the display goes back to the basic function after the last error.



307ANU100L



1
224



HD9 Euro3



1



357ANU240L



2



DIAGNOSTICS --- CONNECTIONS FOR CONTROL SYSTEMS Use of jack 1 30---pole connector For connection with the specific IVECO diagnostics tool. There are the following diagnostics systems: D ECM (engine control unit); D ABS (brakes/traction control unit); D UDS (AdBlue additive dosing unit); D VCM (vehicle control unit); D IBC (body computer control unit); D ETC (automated transmission control unit); D EST (intarder control unit). 2 ALLISON connector For connection with the specific Allison automatic transmission diagnostics tool.



356ANU102L



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Maintenance Instructions



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INTRODUCTION Properly dispose of replaced material (brake pads, filters, etc.) and materials resulting from maintenance operations and repairs (material soaked in fuel, oil, powder, etc.) according to the laws in force, diversified from normal waste. Collect and dispose of used lubricants and fluids, according to the laws in force. Collect and dispose of used batteries according to the laws in force. Drain and recharge the air conditioning system using the specific devices, according to the laws in force. All level checks must be carried out with vehicle parked on flat and handbrake engaged. Wait a few minutes for the level to stabilise before checking. Observe scrupulous cleanness of oil and fluid containers when refilling. Before injecting grease, or checking levels, carefully clean the pressure fittings and the areas around the level and filling caps. Use oil and fluid of the same type used before in the various assemblies when topping up. Never tamper with valves, regulators or other devices, unless specified in the handbook, to prevent damage to vehicle components and consequent hazards for persons. Technical information on maintenance (intervals, type and number) is given in TABLES AND DIAGRAMS.



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342BNM001L



OPENING RADIATOR GRILL To open the radiator grill, lift it (Fig. 1, see arrow): two gas springs hold it open. To close the radiator grill, lower it until flush.



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1



TILTING THE CAB The vehicle’s cab can be tilted forward via a hydraulic cylinder driven by the oil pressure supplied by a manually operated pump. Always apply the parking brake and set the shift lever to neutral before starting any job. Before tipping open the front grill to prevent damage.



272NM001MY



2



272NM002MY



Lifting the cab Proceed as follows: D take the rod supplied; D using the lever (Fig. 1, ref. 1) turn the pawl to the circuit pressure position (to right); D insert the lever into the seat provided (Fig. 2, ref. 1) and pump until the cabin is fully tipped. Never leave the cab in a partially tilted position. Never work under a partially tilted cab. Do not stand in front or behind the cab when it is being tilted. Keep the front grill fully open throughout the operations. If there is an anomaly affecting the hydraulic system, the cab can be tilted with mechanical means (e.g. with a crane).



1
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HD9 Euro3



1



272NM003MY



2



272NM002MY



3



272GNM001



Lowering the cab Proceed as follows: D using lever (Fig. 1, ref. 1) turn the pawl (Fig. 1, ref. 2) to the circuit decompression position (to the left); D insert the lever provided into the appropriate seating (Fig. 2, ref.1) and down until the cab has been tilted; D check that the cab is fully lowered and warning light and cluster (Fig. 3) is off. Tipping can be interrupted by turning the pawl (Fig. 1 ref. 2). Leave the pawl (Fig. 1, ref. 2) in decompression position until the next tipping operation.



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Page left intentionally blank



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MAIN LEVELS CHECK All the fluids indicated have a level sensor. However it is a good rule to periodically check the levels visually, also to ensure the correct functioning of the sensor.



342BNM002L



2



Check engine oil level Proceed as follows: D open the cowl; D with the engine off and cold, remove the oil dipstick (Fig. 1, see arrow) and check that the level is included between the references on the dipstick (Fig. 2). Reposition the dipstick; If the engine is warm, stop the engine and wait for 10 minutes for the oil to drain into the sump. Do not use the vehicle if the oil level is either under or over the limits. Lack of lubricant or excessive lubricant can damage the engine.



156NM11



D if required, top up using oil of the same type contained in the oil sump.



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1



342BNM003L



2



342BNM004L



Check engine coolant level Proceed as follows: D open the cowl; D with engine cold check that the liquid level is at a distance of 1-2 (cm) from the cap (Fig. 1, see arrow); D top up using fluid of the same type contained in the reservoir, if required; Check windshield washer level Proceed as follows: D open the cowl; D check that the liquid level is at a distance of 2-3 (cm) from the cap (Fig. 2, see arrow); D if necessary top up the level, using an appropriate mixture of water and detergent.



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HD9 Euro3



1



178NM10



ENGINE Changing engine oil Proceed as follows: D stop the warm engine and waitfor the coolant temperature to drop to 60 ˚C; D tilt the cab; D arrange a suitable sized container and remove the dipstick; D clean the cap area, loosen the drain cap (Fig. 1) and drain all the oil for the time required; D clean the drain plug, check that the thread is in good condition, replace the O-ring and close it;



1
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HD9 Euro3



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178NM11



2



156NM11



D clean the filler area and pour in the specific amount of lubricant through the filler (Fig. 1, see arrow); D close the filler and arrange the dipstick in the housing; D start the engine and warm it up. Stop the engine and wait for a few minutes; D remove the oil dipstick and check that the level is included between references on the dipstick (Fig. 2); D top-up the level if necessary. Do not use the vehicle if the oil level is either under or over the limits. Lack of lubricant or excessive lubricant can damage the engine.



1
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1



Replacing engine oil filter F2B Replace the oil filter at the frequency shown. If the filter is clogged up, the bypass valve will permit lubrication of the engine, but the circulating lubricant will not be filtered.



342BNM005L



2



Proceed as follows: D stop the warm engine and waitfor the coolant temperature to drop to 60 ˚C; D loosen the filtering cartridge (Fig. 1, see arrow) using the specific tool and accurately clean the housing; D fasten the cartridge by hand until the seal comes into contact with the housing, then turn by another 3/4 of a turn (Fig. 2). Do not fasten the cartridge excessively. This could damage the seal. Observe the specifications provided by the supplier.



342BNM006L



D start the engine for a few minutes and check for leakage of lubricant; D check engine oil level and top up, if required.



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1



Replacing engine oil filter F3B Replace the oil filter at the frequency shown. If the filter is clogged up, the bypass valve will permit lubrication of the engine, but the circulating lubricant will not be filtered.



178NM12



2



Proceed as follows: D stop the warm engine and waitfor the coolant temperature to drop to 60 ˚C; D loosen the filtering cartridge (Fig. 1, see arrow) using the specific tool and accurately clean the housing; D fasten the cartridge by hand until the seal comes into contact with the housing, then turn by another 3/4 of a turn (Fig. 2). Do not fasten the cartridge excessively. This could damage the seal. Observe the specifications provided by the supplier.



178NM13



D start the engine for a few minutes and check for leakage of lubricant; D check engine oil level and top up, if required.



1
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HD9 Euro3



1



Engine oil vapour filter change Proceed as follows: D loosen the screws of the cover (Fig. 1) and remove it; D remove the filter (Fig. 2, ref. 1); When refitting, position the filter with the support brackets (Fig. 2, see arrow) pointing toward the cover.



228NM221



1



2



228NM222



3



228NM223



D replace the cover; D check that the breather pipe (Fig. 3, see arrow) is not kinked or bent.



1
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HD9 Euro3



1



178NM14



Accessory drive belts check The engine has two accessory drive belts (Fig. 1): 1. alternator/fan/water pump drive belt 2. climate control compressor drive belt (only clima-version). Each belt has an automatic take-up device and does not require adjustment. Proceed as follows: D tilt the cab; D when the engine is cold, check that the belt (Fig. 2) is not frayed or cracked (small crosswise cracks are allowed); D otherwise replace the belt; This operation must be carried out by adequately trained personnel. For further information contact your Dealer.



2 D press with the hand on the longer branch to check the take-up device is functioning properly.



178NM05



1
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HD9 Euro3



1



Intake-exhaust valve play adjustment (Fig. 1) This operation must be carried out by adequately trained personnel. For further information contact your Dealer. Play is adjusted by means of the screw with lock nut, at the head of each rocker.



178NM18



Injector-pump (Fig. 2)



pre-load



adjustment This operation must be carried out by adequately trained personnel. For further information contact your Dealer.



2 Adjust the pre-load by means of the screw with lock nut on the head of each rocker arm (contact the dealership for further information). 178NM19



3



284CNM001L



VGT actuator grease application procedure Proceed as follows: D tilt the cab; D clean the concerned fitting (Fig. 3, see arrow); D inject grease of the specified type in the fitting. Inject lubricant until it pours out of the lubricated points to ensure efficient lubrication. Use a manual grease dispenser only. Never use a high pressure grease dispenser.



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1



FUEL FEED SYSTEM Bleed fuel tank condensation water Proceed as follows: D loosen the drain cap (Fig. 1, see arrow) and let a little fuel out to drain the residues and condense which normally is formed in the tank.



272CNU099



Keep the fuel tank as full as possible. Use fuels of the specified types supplied by petroleum companies. Do not use other than specified fuels. Use of other than specified fuels can cause severe engine damage.



1
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1



357ANM100L



Fuel tank water drain Proceed as follows: D with engine off disconnect the electric connector (Fig. 1, ref. 1); D loosen the filter ring a few turns (Fig. 1, ref. 2) and drain the fuel; D tighten the ring nut without excessive torque when water-free fuel flows out; D connect the electric connector. This operation must be carried out if the fuel filter water warning light comes on (Fig. 2).



2



272NU007MY



3



285ANM002L



Purging water from fuel decanter Proceed as follows: D fasten on end of a rubber pipe to the connector (Fig. 3, ref. 1); D insert the other end of the pipe into a container; D loosen the vent screw (Fig. 3, ref. 3); D open the valve (Fig. 3, ref. 2) and drain off the water and any impurities trapped in the decanter; D close the valve and remove the pipe.



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357ANM101L



Replacing fuel filters The vehicle has two groups of fuel filtration: D fuel prefilter (on chassis; Fig. 1, see arrow); D fuel filter (on engine; Fig. 2, see arrow). Proceed as follows: D with engine off disconnect the electric connector (Fig. 1, ref. 1); D with the engine stopped, loosen the filtering cartridge using the specific tool and carefully clean housing and engine; Do not fill the new filter with fuel to prevent foreign matter entering the injection system.



2 D hand-tighten the cartridge until the seal comes into contact with the support, then tighten it by ¾ of a turn;



Do not fasten the cartridge excessively. This could damage the seal. Observe the specifications provided by the supplier.



206NM08



D connect the electric connector (Fig. 1, ref. 1); D bleed the air from the fuel circuit as indicated in the following pages; D start the engine for a few minutes and check for leakage of lubricant.



1
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1



2



1



3



Replacing fuel decanter filter Proceed as follows to replace the fuel separator filter cartridge: D Stop the engine. D Close the on-off valve (if present). D Loosen the securing screws and remove the cover (Fig. 1, ref. 1). D Remove the spring (Fig. 1, ref. 2). D Remove the cartridge (Fig. 1, ref. 3) and replace it. D Refit the spring. D Refit the lid and check that the seal is intact and correctly positioned: replace it required. D Open the on-off valve (if present). D Start the engine and check for leakage. Bleed the feed system, if required.



285ANM003L



1
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HD9 Euro3



1



272NM006MY



1



2



Fuel circuit bleeding Proceed as follows: D tip the cabin; D fit suitable pipes to the bleed nipples and lead them to a container; D loosen the bleed nipples by a few turns. Prefilter D Pump the priming pump (Fig. 1, see arrow) until fuel flows out from the nipple (Fig. 1, ref. 1) without air bubbles, then tighten the nipple. Filter D Repeat the operation for this nipple (Fig. 2, ref. 1); Cylinder head bleed nipple D Remove the soundproofed cover; D Repeat the operation for this nipple (Fig. 3, ref. 1).



206NM03



3



1 178NM119



Absolutely avoid smearing fuel on the accessory drive belts to prevent damage. Use suitable receptacles to prevent fuel leakage into the environment.



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1



INTAKE SYSTEM Intake system seal check Proceed as follows: D tip the cabin; D check the intake system seals and connectors (Fig. 1, see arrow). Turbocompressor lubrication check Proceed as follows: D tip the cabin; D inspect the delivery pipes (Fig. 2, ref. 1) and return pipes (Fig. 2, ref. 2) to check absence of leaks or faults that could cause decreased oil flow to the turbo. Given the high turbocompressor operating speed, any reduction in oil supply will result in damage.



272NM007MY



2 1 2 269NM193



Intercooler external cleaning Clean the radiator using compressed air to remove accumulated debris (leaves, insects). To remove hardened debris, brush the radiator with a water/detergent solution then use steam to remove any residue.



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1



Main filter element cleaning/change Clean the main filter element at most 6 times, after which it must be changed.



174NM26



2



Proceed as follows: D release the retainer springs (Fig. 1, see arrow) and remove and thoroughly clean the cover; D extract the primary cartridge (Fig. 2, see arrow); D dust removal using compressed air at maximum 3 bar pressure, blowing air from inside filter element outwards (Fig. 3); Keep the air jet at a few centimeters from the filter pack to prevent damage. Never clean the filter by beating on a hard surface.



174NM27A



3



156NM52



D thoroughly clean the inside of the filter box with a vacuum cleaner. Take care not to allow the dust enter the intake hose. Do not start the engine without the air filter.



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1



Carry out the following checks before refitting the filtering element: D check conditions of O-rings and plastic tabs. Replace the filtering element, if required; D check integrity of filtering element by placing a source of light inside (Fig. 1); light will filter from even the smallest cracks, indicating that the filter must be replaced;



156NM53



Make sure the temperature does not exceed 60˚C if a light source outputting heat (e.g. a lamp bulb) is used.



2 D clean the rubber drain valve, check integrity and replace it if required.



174NM29A



Safety secondary filter element replacement Proceed as follows: D remove the main filter; D remove the element (Fig. 2, see arrow). The secondary element cannot cleaned. It can only be replaced.



be



1
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HD9 Euro3



1



178NM88B



2



178NM88



Replacing the VGT piloting hoses filtering element Engine F2B (Fig. 1) Engine F3B (Fig. 2) Proceed as follows: D with a cold engine, loosen the filtering cartridge (see arrow) using the specific tool and accurately clean housing and engine; D fasten the cartridge by hand until the seal comes into contact with the housing, then turn by another 3/4th of a turn. Do not fasten the cartridge excessively. This could damage the seal. Observe the specifications provided by the supplier.



1
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1



342BNM007L



COOLING SYSTEM Never remove the cap (Fig. 1, ref. 1) when coolant is hot to avoid: D scalding; D damage to the engine, in that the system comes under pressure only with coolant heating from engine cold. Always top up the system with engine off and cold.



1
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HD9 Euro3



1



Replacing engine coolant The system pressure regulator valve (Fig. 1, ref. 2) is sealed and must not be removed for any reason.



342BNM007L



2



228NMR01



Proceed as follows: D turn the cab heater cock to maximum heat; D position a container with adequate capacity then remove the cap (Fig. 1, ref. 1) on the expansion chamber (Fig. 1, ref. 2); D disconnect the radiator hose (Fig. 2, see arrow), then wait for coolant to fully drain off; D refit the hose; D pour the coolant very slowly into the expansion tank until full; D start the engine and run it slightly faster than idle speed for about 5 minutes; D stop the engine and top-up expansion chamber coolant level; D start the engine, warm it up and allow it to run until the coolant in the chamber does not produce air bubbles; D check that the system pressure regulator valve opens at the specified pressure value: otherwise replace it.



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1



156NM61



Checking antifreeze concentration A 50-50 mixture of water and specific antifreeze is required to protect the system from corrosion. The minimum concentration of antifreeze depends on the temperature where the vehicle is in use (Fig. 1). antifreeze water Check the concentration of antifreeze in the engine coolant. Always respect the supplier’s mixing specifications if particular additives are used.



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1



342BNM008L



CLUTCH Check clutch disengagement Proceed as follows: D run the engine at idle and depress the clutch; D after approx. 10/12 seconds, slowly engage reverse gear. If the toothing “grates” (grating noise of engagement of front teeth) the clutch must be checked and/or bled. Oil level check Proceed as follows: D open the radiator grill; D visually check that oil level (Fig. 1, see arrow) is not below the minimum level; D if necessary, top-up the level as shown in the following paragraph. The fluid is corrosive: always wear protective gloves. Use only the specified type of fluid for topping up. The fluid will corrode any paintwork it comes into contact with.



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254



HD9 Euro3



1



342BNM008L



2



272NM004X



Changing the hydraulic fluid Proceed as follows: D prepare a suitable container, unscrew tank cap (Fig. 1, see arrow) and unscrew drain pipe (Fig. 2, ref. A), draining off oil completely; D seal drain pipe and fill tank with oil to the max. level; D bleed out air from the system. Air bleeding Proceed as follows: D check whether reservoir is full; D use a transparent tubing and insert one end into the drain valve union (Fig. 2, ref. B) and the other end into a clean container; D press clutch pedal and keep it in position; D open the drain valve a little to allow oil and air bubbles to come out and close it after a few seconds; D release clutch pedal completely; D repeat operation until oil without air bubbles comes out of the drain valve.



1
255



HD9 Euro3



1



285ANM001L



MULTIPOWER PTO Oil level check Proceed as follows: D with the engine off remove the dipstick (Fig. 1, ref. 1) and check that oil level is between the notches on the dipstick, then replace it; D if necessary, top-up the level as shown in the following paragraph.



1
256



HD9 Euro3



1



285ANM002L



2



228NM226



Oil change Proceed as follows: D place a suitable container, clean the area around the level plug and remove it (Fig. 1, ref. 1); D remove the drain plug (Fig. 2, ref. 1) fully drain off the oil; D clean the drain plug, check that the thread is in good condition, replace the O-ring and close it; D fill with the required quantity of fluid as shown on the cap (Fig. 1, ref. 1); D clean the filler cap, check that the thread is in good condition, replace the O-ring and close it; D test drive then check level again, removing the screw (Fig. 2, ref. 2) waiting for oil to stop draining then replacing the screw; D top-up the level if necessary. Clean the filter on the intake pipe after the first 25 hours of use, proceeding as follows: D remove the filter unscrewing the retaining cap (Fig. 2, ref. 3), clean it with diesel oil and dry with compressed air. If exhausted, replace it; D check gaskets and replace them if necessary.



1
257



HD9 Euro3



1



ZF NMV 221 POWER TAKE OFF --- TYPE I Oil level check/change The power take off uses the same oil as the gearbox. For further information regarding oil level checks and oil replacement, see the following pages. For oil level check/oil change operations refer to the instructions for the gearbox. The quantity of oil required in addition to that of the gearbox is circa 2 litres.



228NMR32



2 2 1



Oil filter change (Fig. 1) Change the filter only after having drained off oil. Oil may leak during these operations.



3



228NMR02



Proceed as follows: D position a suitable container then remove the cover (Fig. 2, ref. 1); D remove the filter (Fig. 2, ref. 2) and recover the seal (Fig. 2, ref. 3); D refit the filter following above instructions in reverse order.



1
258



HD9 Euro3



1



TRANSMISSION Versions with power take-off NMV 221 --type I only.



228NM227



Oil level check Proceed as follows: D clean the area around the cap and and open the level cap (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D close the level plug. Check that the breather is perfectly clean and functioning.



1
259



HD9 Euro3



1



228NM227



2



228NM228



Oil change Proceed as follows: D place a suitable container, clean the area around the level plug and remove it (Fig. 1, ref. 1); D remove the drain plug (Fig. 2, ref. 1) fully drain off the oil; D clean the drain plug, check that the thread is in good condition, replace the O-ring and close it; D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1); D clean the level plug, check that the thread is in good condition, replace the O-ring and close it; D carry out a test drive then re-check level at plug (Fig. 1, ref. 1); D if necessary, top-up with specified oil until it flows from the hole, repeat the test drive and check the level again.



1
260



HD9 Euro3



1



GEARBOX Oil level check If transmission is fitted with retarder, do not use it just before stopping the vehicle. The check is to be made with transmission cold (< 40 ˚C).



342BNM009L



Proceed as follows: D clean the area around the cap; then open the level/filler cap (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D replace the cap.



1
261



HD9 Euro3



1



342BMM009L



2



342BMM011L



Oil change Version without retarder Proceed as follows: D clean the level/filler cap zone (Fig. 1, ref. 1) then remove the cap; D prepare an appropriate container and remove the drain cap (Fig. 2, ref. 1) ; D clean the drain cap, check that the threading is in good condition, replace the sealing ring with a new one and close the drain cap; D fill with prescribed lubricant through the level/filler cap (Fig. 1, ref. 1) until it overflows; D clean the level/filler cap, check that the thread is in good condition, replace the o-ring and close the cap; D run a road test, check the level through the cap (Fig. 1, ref. 1); D if required, top up oil of the specified type until it spills out of the hole. Repeat the road test and check the level again.



1
262



HD9 Euro3



1



342BMM009L



2



Version with retarder Proceed as follows: D clean the level cap zone (Fig. 1, ref. 1) then remove the cap; D prepare an appropriate container, remove the drain caps (Fig. 2, ref. 1) and (Fig. 2, ref. 2) emptying out all the lubricant; D clean the drain caps, check that the threading is in good condition, replace the o-ring with a new one and close the drain caps; D fill with prescribed lubricant through the filler cap (Fig. 3, ref. 1) until it overflows from the level cap (Fig. 1, ref. 1); It is also possible to fill through the level cap (Fig. 1, ref. 1) except in the case of a first filling after an overhaul.



357ANM102L



3



357ANM103L



D clean the level and filler cap, check that the thread is in good condition, replace the o-ring and close the caps; D run a road test, check the level through the cap (Fig. 1, ref. 1); D if required, top up oil of the specified type until it spills out of the hole. Repeat the road test and check the level again.



1
263



HD9 Euro3



1



Replacing the oil filter Empty the oil before this operation. During this operation further oil may spill out. Proceed as follows: D prepare an appropriate container; D unscrew the fastening screws (Fig. 1, ref. 1) and remove the cover (Fig. 1, ref. 2); D remove the filter (Fig. 1, ref. 3) from the cover; When refitting, lubricate the O-rings (Fig. 1, ref. 4) of the filter. D refit the filter following the operations in reverse.



357ANM104L



1
264



HD9 Euro3



1



AUTOMATED TRANSMISSION Checking oil level If the transmission is equipped with retarder do not use it prior to stopping the vehicle. The test is to be carried out with transmission cold (< 40 ˚C).



357ANM105L



Proceed as follows: D clean the area around the cap; then open the level/filler cap (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top up the oil level as shown in the following paragraph; D close the cap.



1
265



HD9 Euro3



1



357ANM105L



2



357ANM107L



Changing oil Version without retarder Proceed as follows: D clean the level/filler cap zone (Fig. 1, ref. 1) then remove the cap; D prepare an appropriate container and remove the drain caps (Fig. 1, ref. 2) and (Fig. 2, ref. 1) emptying out all the lubricant; D clean the drain caps, check that the threading is in good condition, replace the o-ring with a new one and close the drain caps; D fill with the specified oil until it flows from the level/filler cap (Fig. 1, ref. 1); D clean the cap, check that the threading is in good condition, replace the O-ring with a new one and close the cap; D run a road test, check the level through the cap (Fig. 1, ref. 1); D if required, top up oil of the specified type until it spills out of the hole. Repeat the road test and check the level again.



1
266



HD9 Euro3



1



357ANM106L



2



Version with retarder Proceed as follows: D clean the level cap zone (Fig. 1, ref. 1) then remove the cap; D prepare an appropriate container and remove the drain caps (Fig. 1, ref. 1) and (Fig. 2, ref. 1 and ref. 2) ; D clean the drain caps, check that the threading is in good condition, replace the o-ring with a new one and close the drain caps; D fill with prescribed lubricant through the filler cap (Fig.3, ref. 1) until it spills out from the level cap (Fig. 1, ref. 1); It is also possible to fill through the level cap (Fig. 1, ref. 1) except in the case of a first filling after an overhaul.



357ANM102L



3



357ANM103L



D clean the level and filler cap, check that the thread is in good condition, replace the o-ring and close the caps; D run a road test, check the level through the cap (Fig. 1, ref. 1); D if required, top up oil of the specified type until it spills out of the hole. Repeat the road test and check the level again.



1
267



HD9 Euro3



1



Replacing the oil filter Empty the oil before this operation. During this operation further oil may spill out. Proceed as follows: D prepare an appropriate container; D unscrew the fastening screws (Fig. 1, ref. 1) and remove the cover (Fig. 1, ref. 2); D remove the filter (Fig. 1, ref. 3) from the cover; When refitting lubricate the O-rings (Fig. 1, ref. 4) of the filter. D refit the filter following the operations in reverse.



357ANM104L



1
268



HD9 Euro3



1



AUTOMATIC TRANSMISSION Checking oil level The correct oil level is essential for good operation of the transmission. Insufficient oil can cause irregular operation and damage the converter. Excessive oil can cause the formation of foam and overheat the transmission. Hot check (80-100 ˚C) on display Proceed as follows: D let the engine idle with the gearshift in Neutral position for a few minutes; D apply the parking brake; D press the DIAGNOSTIC button (Fig. 1, ref. 1); D carefully observe the display (Fig. 1, ref. 2): the information are shown on pages in sequence, two characters at a time.



357ANM201L



1
269



HD9 Euro3



1



357ANM201L



The following cases may occur: D Correct oil level: oL oK appears on the display D Low oil level: oL Lo XX will appear on the display, where xx is the missing amount of oil expressed in quarters of a gallon D High oil level: oL Hi XX will appear on the display, where xx is the amount of oil in excess expressed in quarters of a gallon D Procedure error: oL --- xx will appear where xx shows the error code The errors are: D oL --- --- 0X : insufficient waiting time D oL --- --- EL : engine speed too low D oL --- --- EH : engine speed too high D oL --- --- SN : selector not in neutral D oL --- --- TL : low oil temperature D oL --- --- TH : high oil temperature D oL --- --- SH : vehicle moving D oL --- --- FL : faulty level sensor



1
270



HD9 Euro3



1



274NM0D1



Cold check (15-45 ˚C) Proceed as follows: D start the engine and let it idle with transmission in Neutral for approximately one minute; engage reverse once or twice and then Drive to bleed the hydraulic circuit; D clean the filler zone, then release the grip by one or two turns and remove the dipstick inserted in the filler (Fig. 1), clean it and re-introduce it; D remove the dipstick and check that the oil level is comprised between the COLD ADD and the COLD FULL notches; D then top up or empty to the required level; then reposition the dipstick and refasten the grip; D do a hot check as soon as possible.



1
271



HD9 Euro3



1



274NM1B2



2



Hot check (80-100 ˚C) Proceed as follows: D let the engine idle with the gearshift in Neutral position; D clean the filler zone, then release the grip by one or two turns and remove the dipstick inserted in the filler (Fig. 1), clean it and re-introduce it; D remove the dipstick and check that the oil level is comprised between the HOT ADD and the HOT FULL notches; D top up or empty as required; then reposition the dipstick and fasten the grip; Repeat the level check at least twice to make sure that the value is correct: check the correct operation of the breather if this does not occur.



274NM1B3



D check the breather (Fig. 2, see arrow) which must be perfectly clean and functioning.



1
272



1



274NM1C1



HD9 Euro3 Changing the oil Proceed as follows: D take a suitably sized container, clean the filler area, loosen the handle by two or three turns and remove the dipstick; D remove both drain cap (Fig. 1, arrow) and drain all the oil; D clean the drain cap, check that the threading is in good conditions and close; D pour in the specified amount of lubricant through the filler and reposition the dipstick by screwing back the handle; D check the level after a test run.



1
273



HD9 Euro3



1



Replacing the oil filter The filters may be replaced after draining the lubricant oil.



274NM1C2



Proceed as follows: D arrange a container of appropriately capacity, clean the area around the flanges and then loosen the fasten screws (Fig. 1, ref. 1) and remove the flange (Fig. 1, ref. 2) and the seals (Fig. 1, ref. 3); D remove the cartridge (Fig. 1, ref. 4); Oil may leak out during these operations.



D insert the new cartridge in the housing, fit the new seal and the corresponding flange and then fasten the screws; D fill will lubricant as described above; D at the end, start the vehicle and check for leakages of lubricant.



1
274



HD9 Euro3



1



238NM10



DISTRIBUTOR-TRANSFER (TRANSFER) --- TYPE I Oil level check Proceed as follows: D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D close the level plug. Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.



1
275



HD9 Euro3



1



238NM10



2



238NM11



Oil change Proceed as follows: D place a suitably sized container, clean the area around the plugs then remove the level plug (Fig. 1, ref. 1); and filler cap (Fig. 1, ref. 2); D unscrew the plugs (Fig. 2, ref. 1) and fully drain off the oil; D clean the drain plug, check that the thread is in good condition, replace the O-ring and close it; D prepare 6.5 litres of fresh oil; D fill through the filler cap (Fig. 1, ref. 2) until oil flows from the level plug (Fig. 1, ref. 1); D clean the filler cap and level plug, check that the thread is in good condition, replace the O-rings and close them; D drive the vehicle for a few minutes to allow oil to reach all transfer components, then stop and wait ten minutes for the oil to settle; D remove the level plug (Fig. 1, ref. 1): oil should flow from the hole. If not, top up level exclusively through the cap (Fig. 1, ref. 2) until oil flows from the level plug (Fig. 1, ref. 1); D close both the level plug and filler cap.



1
276



HD9 Euro3 DISTRIBUTOR-TRANSFER (TRANSFER) --- TYPE II



1



Checking oil level Proceed as follows: D Clean the area around the filler/level plug then open it (Fig. 1, ref. 1): oil should arrive at the edge of the hole; D Top up with the specified lubricant, if necessary, through the same hole; D Close the plug; D Check that the breather (Fig. 1, see arrow) is perfectly clean and functional.



272CNU101



1
277



HD9 Euro3 Changing oil Proceed as follows: D Place a suitably sized container, clean the area around the plug then remove the level plug (Fig. 1, ref. 1); D Remove the drain plug (Fig. 1, ref. 2) and fully drain the oil; D Clean the drain plug, check that the thread is in good condition, replace the o-ring and close it. D Fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1); D Clean the level plug, check that the thread is in good condition, replace the o-ring and close it; D Carry out a test drive then re-check level at plug (Fig. 1, ref. 1); D If required, top up with oil of the specified type, repeat the road test and check the level again.



1



272CNU101



1
278



HD9 Euro3



1



SPLITTER-REDUCER (TRANSFER CASE) --- TYPE III Checking oil level Proceed as follows: D clean the cap area and open the level cap (Fig. 1, ref. 3): the lubricant must reach the edge of the hole; D top up, if required, with oil of specified type through the same hole; D close the cap; D check the breather (Fig. 1, see arrow): it must be perfectly clean and functioning.



307HNM001L



1
279



HD9 Euro3



1



Changing the oil Proceed as follows: D arrange a suitably sized container, clean the cap area and remove the filler cap (Fig.1, ref.1) and level cap (Fig. 1, ref. 3); D remove both drain caps (Fig. 1, ref. 2) and drain all the oil; D clean the drain caps; check that the threading is in good condition, replace the o-ring and close them; D fill with oil of the specified type through the cap hole (Fig. 1, ref. 1) until oil flow out from the cap hole (Fig. 1, ref. 3); D clean the filling and level caps; check that the threading is in good condition, replace the o-ring and close them; D run a road test, check the cap level (Fig. 1, ref. 3); D if required, top up oil of the specified type, repeat the road test and check the level again. 307HNM001L



1
280



HD9 Euro3



1



TRANSMISSION SHAFTS Greasing Proceed as follows: D clean the joint concerned; D Inject grease into the universal joint grease nipples (Fig. 1, see arrow) each transmission shaft has two or three greasing points.



178NM46



Inject grease until it seeps from the grease nipples to ensure efficient lubrication A hand pump must be used for greasing, and never a high pressure grease gun.



1
281



HD9 Euro3



1



AXLES Front axle



228NM230



Check differential oil level Proceed as follows: D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D close the level plug. Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning. Differential oil change Proceed as follows: D place a suitable container, clean the area around the level plug (Fig. 1, ref. 1) and remove it; (Fig. 1, ref. 1); D remove the drain plug (Fig. 1, ref. 2) fully drain off the oil; D clean the drain plug, check that the thread is in good condition, replace the O-ring and close it; D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1); D clean the level plug, check that the thread is in good condition, replace the O-ring and close it; D carry out a test drive then re-check level at plug (Fig. 1, ref. 1); D if necessary, top-up with specified oil until it flows from the hole, repeat the test drive and check the level again.



1
282



HD9 Euro3



1



Hub oil level check This must be checked separately on both hubs.



178NM50



Proceed as follows: D turn the plug (Fig. 1, ref. 1) such that the reference mark is horizontal; D clean the plug zone and open the plug (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D close the level plug.



1
283



HD9 Euro3



1



Hub oil change This must be checked separately on both hubs.



178NM50



Proceed as follows: D turn any of the screws (Fig. 1, ref. 2) in the lowest position, until the cap is situated aloft; D clean the area around the cap, then open it (Fig. 1, ref. 1); D place a suitably sized container, clean the area around the level plug (Fig. 1, ref. 2) and remove it fully draining off the oil; D tighten the screw; D position cap hole (Fig. 1, ref. 1) in horizontal position; D fill up with new oil until it overflows from hole (Fig. 1, ref. 1); D clean the drain plug, check that the thread is in good condition, replace the O-ring and close it; D repeat operation for the other hub; D carry out a test drive, then re-check the level at plug (Fig. 1, ref. 1); D if necessary, top-up with specified oil until it flows from the hole, repeat the test drive and check the level again.



1
284



HD9 Euro3



1



285BNM001L



2



1



285BNM002L



Front axle - 10 ton version / K version Checking differential oil level Proceed as follows: D clean the cap area and open the level cap (Fig. 1, ref. 1): lubricant should drip out of the hole; D top up the level as shown below, if required; D close the filler cap. Check the breather which must be clean and functioning. Changing differential oil Proceed as follows: D arrange a container of appropriately capacity, clean the area around the caps and then remove the filler cap (Fig. 1, ref. 1); D remove the drain cap (Fig. 2, ref. 1) and drain all the oil; D clean the drain cap; check that the threading is in good condition, replace the o-ring and close it; D fill until oil spills out the of the hole on the cap (Fig. 1, ref. 1); D clean the filler cap; check that the threading is in good condition, replace the o-ring and close it; D run a road test, check the cap level (Fig. 1, ref. 1); D if required, top up oil of the specified type until it spills out of the hole. Repeat the road test and check the level again.



1
285



HD9 Euro3



1



Checking oil hub level The operation must be carried out separately on both axles.



276NM019T



Proceed as follows: D adjust the cap (Fig. 1, ref. 1) so that it is arranged in horizontal position; D clean the cap area and open the level cap (Fig. 1, ref. 1): the lubricant must flow out of the hole; D top up the level as shown in the following paragraph, if required; D close the filler cap.



1
286



HD9 Euro3



1



Changing hub oil The operation must be carried out separately on both axles.



276NM019T



Proceed as follows: D take any of the screws (Fig. 1, ref. 2) to the lowest position, so that the cap (Fig. 1, ref. 1) is facing upwards; D clean the cap area and open the cap (Fig. 1, ref. 1); D arrange a suitably sized container, clean the screw area and remove it (Fig. 1, ref. 2) and drain the lubricant completely; D tighten the screw; D adjust the cap (Fig. 1, ref. 1) so that it is arranged in horizontal position; D fill until oil spills out the of the hole on the cap (Fig. 1, ref. 1); D clean the cap, check that the threading is in good condition, replace the o-ring and close it; D repeat the procedure on the other hub; D run a road test, check the cap level (Fig. 1, ref. 1); D if required, top up oil of the specified type until it spills out of the hole. Repeat the road test and check the level again.



1
287



HD9 Euro3



1



228NM230



2



228NM231



Front intermediate axle Check differential oil level Proceed as follows: D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D close the level plug. Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning. Differential oil change Proceed as follows: D place a suitable container, clean the area around the level plug (Fig. 1, ref. 1) and remove it (Fig. 1, ref. 1); D remove the drain plug (Fig. 2, ref. 1) and fully drain off the oil; D clean the drain plug, check that the thread is in good condition, replace the O-ring and close it; D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1); D clean the level plug, check that the thread is in good condition, replace the O-ring and close it; D carry out a test drive then re-check level at plug (Fig. 1, ref. 1); D if necessary, top-up with specified oil until it flows from the hole, repeat the test drive and check the level again. Hub oil level check/change Proceed as described for the front axle hubs.



1
288



HD9 Euro3



1



228NM232



Rear intermediate axle Oil level check Proceed as follows: D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D close the level plug. Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.



1
289



HD9 Euro3



1



228NM232



2



Changing oil Proceed as follows: D on either of the hubs, turn any of the screws (Fig. 2, ref. 1) in the lowest position; D position a container with adequate capacity, clean the zone around the plugs and then remove the level plug (Fig. 1, ref. 1); D remove the drain plug (Fig. 1, ref. 2) and (Fig. 3, ref. 1) and both the screws (Fig. 2, ref. 1) and completely drain off the oil, then refasten the screws; D clean the drain plugs, check that the thread is in good condition, replace the o-rings and close them; D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1); Re-fill gradually to give the oil time to reach the hubs. The operation is finished when the level does not drop for at least five minutes.



178NM51



3



228NM233



1



D clean the level plug, check that the thread is in good condition, replace the o-ring and replace it; D carry out a test drive, then re-check the level (Fig. 1, ref. 1); D if a top-up is necessary, after topping up repeat the test drive and level check.



1
290



HD9 Euro3



1



228NMR09



Rear axle Oil level check Proceed as follows: D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the hole; D if necessary, top-up the level as shown in the following paragraph; D close the level plug. Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.



1
291



HD9 Euro3



1



228NMR09



2



Changing oil Proceed as follows: D on either of the hubs, turn any of the screws (Fig. 2, ref. 1) to the lowest position; D position a container with adequate capacity, clean the zone around the plugs and then remove the level plug (Fig. 1, ref. 1); D remove the drain plug (Fig. 1, ref. 2) and both the screws (Fig. 2, ref. 1) and fully drain off the oil, then refasten the screws; D clean the drain plug, check that the thread is in good condition, replace the o-ring and refit the plug. D fill with the specified oil until it flows from the plug hole (Fig. 1, ref.; 1); Re-fill gradually to give the oil time to reach the hubs. The operation is finished when the level does not drop for at least five minutes.



178NM51



D clean the level plug, check that the thread is in good condition, replace the o-ring and replace it; D carry out a test drive, then re-check the level (Fig. 1, ref. 1); D if a top-up is necessary, after topping up repeat the test drive and level check.



1
292



HD9 Euro3



1



SUSPENSIONS Leaf spring pins greasing Fig. 1: Support pin Fig. 2: Support plate



342BNM012L



2



342BNM013L



Proceed as follows: D clean the relevant union; D inject grease in the pressure unions of leaf spring joints (see arrow). To ensure efficient lubrication, inject lubricant until it pours out of the lubricated points. Use a manual grease dispenser only. Never use a high pressure grease dispenser.



1
293



HD9 Euro3



1



342BNM014L



2



342BNM015L



3



342BNM016L



Carriage pin greasing on 3 and 4-axle vehicles Proceed as follows: D open the cover (Fig.1) remove grease and fill the cover with prescribed lubricant ; D clean union (Fig. 2, see arrow); D inject grease in pressure union until it flows out from the bearing (fig.3); D close the cover. To ensure efficient lubrication, inject lubricant until it pours out of the lubricated points. Use a manual grease dispenser only. Never use a high pressure grease dispenser.



1
294



HD9 Euro3



1



STEERING SYSTEM Oil level check This check is optional, since there is an oil level warning light.



228NM235



1. vehicles without auxiliary cylinder 2. vehicles with auxiliary cylinder The system of vehicles fitted with auxiliary cylinder have two inter-connected tanks. The following operations are to be carried out on one tank only.



2 Proceed as follows:



228NM236



3



228NM237



D park the vehicle with the engine off and wheels straight; D clean the area around the plug, then unscrew the plug and check that the reservoir oil level is between the two notches (Fig. 3) on the dipstick; D if necessary top-up the level and close the plug.



1
295



HD9 Euro3



1



Changing the hydraulic oil --- Vehicles without auxiliary cylinder Proceed as follows: Dumping D raise the vehicle until the front wheels are off the ground; D prepare a suitable container, unscrew delivery (Fig. 1, see arrow) pipes from the power steering casing and remove the oil reservoir cap; D with engine off, turn the steering wheel from lock to lock until the oil stops flowing out; D reconnect the hoses.



285A015018R



Filling D fill completely reservoir with oil; D with engine off, turn the steering wheel from lock to lock topping up reservoir with oil, at the same time, until oil level is stabilised; D start the engine to fill the system with oil: since the level drops rapidly, continue pouring oil into the tank while PREVENTING AIR BEING DRAWN INTO THE SYSTEM; D proceed until the level is steady.



1
296



HD9 Euro3



1



Bleeding off air D with the engine running at idle, turn the steering wheel from lock to lock until the residual air bubbles are eliminated; During this operation the oil level should be constantly checked. If the above indications are followed strictly, oil should not exceed the upper notch on the dipstick by more than 0.5 cm when the engine is stopped, nor suddenly emulsify. This phenomenon would denote a remarkable presence of air in the circuit due to incorrect operations during the filling phase.



285A015018R



D for vehicles fitted with emergency steering pump run a road test of approx. 10 km , then top up the level.



1
297



HD9 Euro3



1



228NM238



Changing the hydraulic oil for --- Vehicles with auxiliary cylinder Proceed as follows: Dumping D raise the vehicle until the front wheels are off the ground; D prepare a suitable container, remove drain plug (Fig. 1, see arrow) from the power steering casing and remove the oil reservoir cap; D with engine off, turn the steering wheel from lock to lock until the oil stops flowing out; D close the plug. Filling D fill completely reservoir with oil; D with engine off, turn the steering wheel from lock to lock topping up reservoir with oil, at the same time, until oil level is stabilised; D start the engine to fill the system with oil: since the level drops rapidly, continue pouring oil into the tank while PREVENTING AIR BEING DRAWN INTO THE SYSTEM; D proceed until the level is steady.



1
298



HD9 Euro3



1



Bleeding off air D with the engine running at idle, turn the steering wheel from lock to lock until the residual air bubbles are eliminated; During this operation the oil level should be constantly checked. If the above indications are followed strictly, oil should not exceed the upper notch on the dipstick by more than 0.5 cm when the engine is stopped, nor suddenly emulsify. This phenomenon would denote a remarkable presence of air in the circuit due to incorrect operations during the filling phase.



228NM238



D run a road test of approx. 10 km, then top up the level.



1
299



HD9 Euro3



1



Replacing oil filter Proceed as follows:



4



2 3



5 1



178NM60



D loosen the retaining screws (Fig. 1, ref. 2); D remove the cover (Fig. 1, ref. 3), gasket (Fig. 1, ref. 4) and the spring (Fig. 1, ref. 5); D replace the filter cartridge (Fig. 1, ref. 1); D check the cover seal. If damaged, replace it; D replace the cover.



1
300



HD9 Euro3



1



178NM47



2



272NM005X



Stub axle greasing Fig. 1: Axle Fig. 2: Drive axle Proceed as follows: D clean the joint concerned; D inject grease into the axle stub grease nipples (Fig. 1 - Fig. 2, see arrow). Inject grease until it seeps from the grease nipples to ensure efficient lubrication. A hand pump must be used for greasing, and never a high pressure grease gun.



1
301



HD9 Euro3



1



Steering linkage grease application Fig. 1: 3-axle vehicles with auxiliary cylinder



342BNM017L



Fig. 2: 4-axle vehicles Proceed as follows: D clean the joint concerned; D inject grease into the joint pressure nipples (see arrow). Inject grease until it seeps from the grease nipples to ensure efficient lubrication. A hand pump must be used for greasing, and never a high pressure grease gun.



2



228NMR11



1
302



HD9 Euro3



Front wheel toe-in check This operation must be carried out by adequately trained personnel. For further information contact your Dealer. Before starting the check, make sure: D the vehicle is on a level surface and empty D the tyres are inflated to the correct pressure. Proceed as follows: D set the wheels so that they are pointing forwards; D check that the distances A and B measured along the centreline of the rims at the same height from the ground, correspond to the specified values. Fore-carriage 1st axle 2nd axle



Measurement B = A --- (1 / 3 mm) B=A



If this is not the case, adjust as follows: D loosen the bolts fastening the heads (ref. 1) to the coupling bar (ref. 2); D rotate the bar itself right and left by enough to obtain the required measurement; D tighten the head clamp bolts; D move the vehicle straight forwards or backwards by at least one turn of wheels and check toe-in again. The entire steering mechanism must be checked if adjustments require more than 5 mm from the indicated measurements. For further information contact your Dealer.



1
303



HD9 Euro3



A



B



C



D



Front wheel toe-in check A: 4x2 and 6x4 vehicles B: 4x4 and 6x6 vehicles C: 8x4 vehicles D: 8x6 vehicles E: 8x8 vehicles



E



1



2



1



2



1
304



HD9 Euro3



1



COMPRESSED AIR SYSTEM Tank visual inspection Visually inspect tank external condition. Under no circumstances should any form of heat treatment or welding be carried out on the outside of the tank. If the reservoir is dented, have it replaced. The conditions for use of the compressed air tank (pressure and temperature) are given on the label applied to the tank itself (Fig. 1). Application should conform to these indications. During operation the tank must not be subject to stresses in addition to those deriving from the normal conditions of use and by its weight. The tank is only designed for use with compressed air systems.



178NM66



The tank is maintenance-free. The following precautions should however be taken: D any painting should be preceded by a preparatory coat; D surface treating of the bolts and screws with passivation; D clean with products which do not contain alcohol.



1
305



HD9 Euro3



1



178NM67



2



178NM68X1



Air dryer functionality check Proceed as follows: D check that the air drier functions correctly by operating the drain valve (Fig. 1, see arrow), in this case the air should come out of the tank with no traces of condensation. As soon as a small amount of moisture is noticed, carry out a number of inspections at shorter intervals to check whether this fact is only due to temporary overloading of the drier or (Fig. 2, ref. 1) whether its efficiency is permanently impaired. In the second case it will be necessary to renew the cartridge as the dampness absorption capacity of the granulate is greatly reduced due to the action of oils, dirt, etc. If a mixture of oil and water comes out of the tanks during this check, this means that the compressor is not working correctly as it is discharging oil. In this case in addition to replacing the cartridge, the compressor must also be overhauled.



1
306



HD9 Euro3



1



178NM68X1



Air dryer filter change Proceed as follows: D with the engine off unscrew the cartridge (Fig. 1, ref. 2) with the correct spanner if necessary, then thoroughly clean the support seat; D hand-tighten the cartridge until the washer comes into contact with the support, then tighten it by ¾ of a turn; Do not overtighten the cartridge to avoid damaging the washer. Always follow the manufacturer’s recommendations. D run the engine for a few minutes to check for the absence of air leaks.



1
307



HD9 Euro3



1



BRAKING SYSTEM Shoe-drum play check This check must be made separately on both the shoes of each wheel. Front wheels (Fig. 1) Rear wheels (Fig. 2)



228NMR17



2



228NMR18



Proceed as follows: D remove the caps (see arrow) through the inspection slots; D measure the play between the shoes and drums; this must be between 0.8 and 1.5 mm; D if not, remove and overhaul the automatic play take-up device; D check the condition of the brake linings; D measure brake lining thickness: if less than 8 mm, replace the linings. After completing the hecks, replace the plugs in the corresponding holes. Check pedal distributors Check that there are no leaks from the drain holes of the two distributors. A leak in the rest position indicates that the air inlet valve is worn while the exhaust valve is worn if the leak occurs during braking.



1
308



HD9 Euro3



1



TYRES AND WHEELS Checking wheels and tyres Proceed as follows: D check the inflation pressure of the tyres (Fig. 1) is within the specified values; otherwise adjust to correct pressure; Check pressure and inflate the tyres when cold.



178NM70



D check the condition of the rims and the wear on the tyres; D check that bolts are fastened at the specified torque (see TECHNICAL SPECIFICATIONS section); D check tyres for evident cuts; check whether the tyres touch the vehicle. If anomalous wear is found on the front tyres, check the front wheel toe-in. Never exceed the maximum load per axle if the vehicle is fully loaded. Inflating tyres Proceed as follows: D remove the protective cap and connect the inflation device fitting to the valve (Fig. 1, see arrow); D take to specified pressure; D disconnect the fitting and close the protective cap.



1
309



HD9 Euro3



1



272NM009MY



CAB TIPPING SYSTEM Oil level check / fluid change To check level, check through the filler cap (Fig. 1, see arrow) that the oil level with cab tilted is 1 - 1.5 cm from the cap. Top-up if necessary. To change the fluid, proceed as follows: D clean the area around the cap and remove it; D using a syringe and flexible pipe, draw-out the fluid in the reservoir; D fill with the required quantity of fluid then close the cap.



1
310



HD9 Euro3



1



357ANM001L



Greasing Proceed as follows: D tip the cab; D grease the mechanism of both cab stop hooks (Fig. 1, ref. 1); D grease the telescopic manual transmission control rod (Fig. 1, ref. 2).



1
311



HD9 Euro3



1



TOWING SYSTEMS Greasing the fifth wheel Fig. 1: fixed fifth wheel Fig. 2: pivoting fifth wheel



307FNM002L



2



307FNM003L



Proceed as follows: D release the semi-trailer from the tractor; D clean the surface of the fifth wheel plate and the semi-trailer hitching plate; D apply plenty of grease the fifth wheel plate, the locking mechanism for the fifth wheel, the coupling pin and semi-trailer attachment plate; D the rubber buffers require no maintenance; D clean the concerned fitting; D inject grease in the pressure fittings of the fifth wheel (see arrow). Inject lubricant until it pours out of the lubricated points to ensure efficient lubrication. Use a manual grease dispenser only. Never use a high pressure grease dispenser. The grease nipple of the fifth wheel plate (ref. 1) is to be used for lubrication between services without needing to uncouple the semi-trailer.



1
312



HD9 Euro3



1



307HNM002L



Tow hook greasing --- Type I Proceed as follows: D release the trailer from the tractor; D clean the internal surface of the bell head (Fig. 1); D grease the hooking pin; D clean the coupling involved; D inject grease in the hook pressure fittings (Fig. 1, see arrow). To ensure efficient lubrication, continue to inject lubricant until it flows out from the lubricated points. To grease, use a hand pump only, never use a high pressure greasing device. This operation should be carried out with the lever raised.



2



Tow hook greasing --- Type II Proceed as follows: D release the trailer from the vehicle and leave the hook in open position; D carefully clean the hook with a jet of compressed air; D lubricate the zone in contact with the trailer towing eye; D clean the coupling involved; D inject grease in the hook pressure fittings (Fig. 2, see arrow). To ensure efficient lubrication, continue to inject lubricant until it flows out from the lubricated points. To grease, use a hand pump only, never use a high pressure greasing device.



1
313



HD9 Euro3



1



342BNM018L



AIR CONDITIONER Air-conditioner system maintenance Proceed as follows: D open the radiator grill; D remove the cover (Fig. 1, see arrow) and replace dust filter; D inspect and clean the condenser with compressed air (max 5 bar).



1
314



HD9 Euro3



1



System charge check Check system charge once a year or when reduced cooling effect is noticed (Fig. 1). 1. system checking and charging equipment 2. high pressure circuit valve 3. low pressure circuit valve Checking and charging must be carried out by specialist personnel using specific equipment. R134a (tetrafluoroethane) coolant is used. This coolant is classified as an environmentally-friendly product by law. Do not use this fluid in systems working with the previous fluid R12 (Freon 12). For reasons of incompatibility between compressor oil and fluid, do not use R12 in systems designed to use R134a.



342BNM019L



Do not discharge R134a into the atmosphere. Although the product has a zero ozone depletion potential it has a global warming potential. Always use type-approved coolant recovery and recharging devices. Do not mix different coolants in the same device.



1
315



HD9 Euro3



11



357ANM108L



SUPPLEMENTARY HEATER Replacing the supplementary heater fuel filter Proceed as follows: D arrange a container of appropriate capacity and clean the filter area; D unscrew the cup (Fig. 1, see arrow) using the wrench if necessary, and remove it from its seat; D replace the filter cartridge; Do not fill the new filter with fuel to prevent introducing impurities. D fasten the cup; D run the heater for a few minutes and check for leakage of fuel.



1
316



HD9 Euro3



1



357ANM109L



2 Temperature



Product



Water



---35 ˚C ---20 ˚C ---10 ˚C 0 ˚C summer



1 1 1 1 1



0 1 2 6 10 178NM80



3



BODYWORK Replacing front windscreen wiper blade (Fig. 1) Proceed as follows: D lift the arm and blade; D push the blade backwards, disengaging it from the stop and removing it; D fit the correct adapter on the new blade and approach the blade to the clip to fasten it in the adapter; D pull the blade fastening the adapter clip. Observe the specifications provided by the supplier. Windscreen washer reservoir You are advised to use a specific antifreeze product mixed with water as shown in the table (Fig. 2). Proceed as follows: D open the radiator grill; D unscrew the plug (Fig. 3, see arrow) and fill until completely full; D replace the cap and close the grill. Use the proportion of detergent recommended by the manufacturer.



342BNM004L



HD9 Euro3



1
317



Bodywork maintenance Periodically wash the vehicle with neutral detergent and water to remove any corrosive agents (salt, sand, etc.). Dry accurately with compressed air to fully eliminate any stagnating water. Do not use products containing aromatic solvents, methanol or hydrocarbons for cleaning paintwork. Do not wash inside the cab with a jet of water or steam. Cleaning plastic parts Plastic parts should be cleaned using the same procedure as for normal washing. For any remaining traces of dirt use specific products, carefully following the manufacturer’s recommendations. Do not use products containing aromatic solvents, methanol or hydrocarbons for ceaning paintwork. Fabric panels cleaning Upholstery may be cleaned with dry foam and general solvents. Exercise caution when using these products as they are flammable and give off fumes. Ventilate the cabin until they are completely dry. Never use chloride solvents (trichloroethylene, hypochlorite, etc.). Cleaning seat belts Seat belts may be washed by hand with hot water and neutral soap, then rinsed and left to dry in the shade. Never use strong detergents, bleach or dyes. Avoid any chemical substance that may weaken the fibres.



1
318



HD9 Euro3



1



228NMR21



2



LIGHTING SYSTEM Headlight/front sidelight bulb replacement Proceed as follows: D unhook the guard grill by rotating it toward the outside (Fig. 1, see arrow); D unscrew the screws (Fig. 2, see arrow) on the inside of the fenders and rotate the complete headlight group toward the outside; D remove the corresponding cover (Fig. 3): 1. headlight 2. side light 3. high beams D disconnect the electrical connector; D release the bulb retaining spring and remove the halogen bulb or D remove the sidelight bulb; Never touch a halogen bulb with fingers, to avoid damage.



228NMR22



3



228NMR23



D check that bulb is correctly fitted. D for replacement, follow the removal instructions in reverse order.



1
319



HD9 Euro3



1



178NM103



2



238NM51



3



228NMR24



Headlight alignment After dismantling the headlights or following crash damage, the headlights have to be realigned. It is advisable to use specific equipment for this operation. However, a sufficiently correct alignment can be achieved proceeding as follows: D park the unladen vehicle, with tyres at correct pressure, on flat ground nearly up against a light coloured wall; D mark two crosses on the wall, corresponding to the two headlights (Fig. 1); D back the vehicle up 10 m and shine the headlights (Fig. 1) on the wall. The distance between the crosses and reference points P-P must be equal to the percentage of the distance between the vehicle and the wall indicated on the specific plate (Fig. 2); D if necessary, use the adjuster screws (Fig. 3): 1. vertical adjustment 2. horizontal adjustment For vehicles fitted with adjustable headlights, turn the adjuster knob to position 0.



1
320



HD9 Euro3



1



228NMR25



2



228NMR26



Front direction indicator light bulb replacement Proceed as follows: D working from the inside of the fenders, disconnect the connector (Fig. 1, see arrow); D rotate and extract the fitting with bulb; D press and turn the bulb anti-clockwise; D check that bulb is correctly fitted; D for replacement, follow the removal instructions in reverse order. Side direction indicator bulb replacement Proceed as follows: D remove the cover fastening screws (Fig. 2, see arrow) and remove it; D press and turn the bulb anti-clockwise; D check that bulb is correctly fitted; D for replacement, follow the removal instructions in reverse order.



1
321



HD9 Euro3



1



2



228NMR27



228NMR28



Rear light bulb replacement Proceed as follows: D remove the cover fastening screws (Fig. 1) and remove it; D press and turn the bulb to replace (Fig. 2) anti-clockwise: 1. position (double) 2. stop 3. direction indicator 4. clearance 5. rear fog lamp 6. reversing light D check that the replaced bulb is correctly fitted. D for replacement, follow the removal instructions in reverse order.



1
322



1



HD9 Euro3



1



Front clearance light bulb replacement Proceed as follows: D remove the fastening screws and remove the complete light (Fig. 1, ref. 1); D for replacement, follow the removal instructions in reverse order. Rotary warning light bulb replacement Proceed as follows: D remove the screws and the cover (Fig. 2, ref. 1); D replace the bulb; D for replacement, follow the removal instructions in reverse order.



228NMR29



2



Ceiling light bulb replacement Proceed as follows: D insert a screwdriver between the light fitting and cabin interior lining (Fig. 3, ref. 1); lever off the fitting and replace the bulb. D for replacement, follow the removal instructions in reverse order.



228NMR30



Replacing cab step light Proceed as follows: D press and turn the bulb anti-clockwise (Fig. 3, ref. 2). D For replacement, follow the removal instructions in reverse order.



3



228NMR31



1
323



HD9 Euro3 List of bulbs Use



Type



Watt



Lights: --- main beam and dipped beam light --- position Front direction indicator Side direction indicator



Double filament halogen Round Round Round



75/70 4 21 21



Round double filament Round Round Round Round Round Round Round Round/cylindrical All glass All glass



5/21 21 21 21 10 5 21 21 5/5 1.2 1.2



Rear lights: --- position/brake (stop) --- turn --- reverse --- rear foglight Number plate light Overall light Rotating light Rear light Cabin ceiling light Instrument panel/warning lights Warning lights



1
324



HD9 Euro3



1



ELECTRICAL SYSTEM Precautions Make absolutely sure that the electrical power is disconnected before working directly or indirectly on electrical system parts by operating the battery disconnect switch (Fig. 1). A: power off B: power on



272CNU093



The vehicle electrical system should work even if the fitted battery is flat. In order to avoid incorrect interventions which may irreversibly damage the electronic control units installed on board the vehicle the following recommendations should be followed: D when work on the chassis requires arc welding the connector should be removed from the control units: when welding is to be carried out near the control units, remove the units; D after a service operation requiring battery disconnection, make sure that the terminals are well connected; D never use a battery charger to start the engine; D disconnect the batteries to recharge them; D do not disconnect or connect the connectors to the electronic control unit when the engine is running or control units are powered; D do not disconnect the batteries when the engine is running; D remove the electronic control units in the event of operations at temperatures exceeding 80˚C (oven painting, etc.).



1
325



HD9 Euro3



1



Battery teries)



maintenance



(unsealed



batSealed batteries (maintenance free) do not require topping up with water in normal working conditions and mild climate. The electrolyte should be checked approximately once a year in tropical climates.



274CNU102



2



174NM43



3 Temperature ˚F ˚C 40 20 0 -20



Electrolyte density (100% of charge) g/dm3 1.265 1.285 1.300 1.365 178NM84



Proceed as follows: D open the access cover (Fig. 1): D carefully clean the batteries, the cables and the case, removing rust and dirt which can cause voltage drops; D check through the caps that the distance between the electrolyte (Fig. 2) and the upper edge of the plate of each element is as specified: level-plate distance 10-12 mm (0.4-0.5 in) D if required, top up with distilled water when the batteries are cold and rested, through the specific filler holes; D check the battery charge with a densimeter (Fig. 3).



1
326



HD9 Euro3



1



274CNU102



Always take the following precautions when working: D devices that require current draw from accumulators (Fig. 1) must only be used for the time strictly necessary for the checks to perform on the vehicle. D carry out function checks requiring current draw from accumulators with the engine running, if possible and in compliance with safety standards. D do not use the installed batteries to power tools when fitting-out. D always disconnect the batteries when carrying out any kind of welding operation.



1
327



HD9 Euro3



1



Recharge with external devices Recharge should usually be performed with batteries disassembled from vehicle.If this is not possible, the batteries can also be recharged using an external source (battery charger) connected directly to the battery terminals. The vehicle is equipped with a 24 volt electrical system with negative and earth.



174NM44



Proceed as follows: D lay the cables on the ground ensuring that the terminals do not touch metal parts or each other. Connect the red cable (Fig. 1, ref. a) to the POSITIVE terminal of the flat battery; D connect the black cable (Fig. 1, ref. b) to the NEGATIVE terminal of the flat battery; D set the recharge time and current. Start recharging. Respect the instructions provided by the battery charger supplier. Respect the sequence of the operation. Do not reverse the polarity when making the connection.



1
328



HD9 Euro3



1



Changing the battery Follow all safety precautions when handling the battery.



274CNU102



D cut---out electric power supply acting on the battery master switch; D remove the battery compartment cover (Fig. 1): D disconnect the battery as follows: --- disconnect the negative terminal; --- disconnect the positive terminal. D remove the flat batteries; D thoroughly clean the battery compartment, removing oxides and grime; D install the new batteries; D connect the battery leads as follows: --- connect the positive terminal; --- connect the negative terminal. D smear pure Vaseline on the terminals; D replace the battery compartment cover. D activate electric power supply. Always follow the battery manufacturer’s instructions. Observe the sequence of operations. When connecting, never invert polarity.



1
329



HD9 Euro3



1



Interconnection control unit (fuses and relays) Fuses that protect electrical system equipment and relays are arranged in a special compartment (Fig.1, see arrow) inside the cab. If a fuse valve blows more than once, look for the cause in the electrical system.



342BNM020L



2



The control unit has two types of fuses: D type A (AMP unival) (Fig.2, ref. 1) D type A0 (AMP minival) (Fig.2, ref. 2) To remove fuses type A0, use the special pliers provided (Fig.3, see arrow).



342BNM021L



3



342BNM022L



Fuse replacement Proceed as follows: D disconnect the batteries from the battery master switch; D remove the compartment lid; D remove the blown fuse from its housing; D fit a new fuse WITH THE SAME AMPERES as the blown fuse; D refit the compartment lid;



1
330



HD9 Euro3



FUSE / RELAYS HOLDER PLATE



342BNM023L



1
331



HD9 Euro3 FUSES Fuse holder (70005) FUNCTION



POSITION



CAPACITY (A)



1



DTCO --- Cluster



3



2



DTCO --- Cluster



5



3



IBC2



5



4



Left low beam, right main beam headlights and cab IBC2



10



5



Right low beam, left main beam headlights and symbol panel IBC2



10



6



Right side position lights and rear fog light IBC2



10



7



Left position side lights --- braking lights IBC2



10



8



Turn indicators IBC2



10



9



Windshield wiper IBC2



10



10



Fog light --- work headlight --- day lighting



10



11



Reverse gear



10



12



Pivotable headlights --- horn --- air horns



15



13



Alternator --- Vehicle service equipment



5



14



Solenoid valves VGT --- Synchro protection --- differential locks --- solenoid valves PTO



10



15



Heated fuel pre-filter



15



16



Brakes air drier --- fuel filter water detector sensor



5



17



Ignition key --- PTO solenoid valve



3



18



Climate control --- Heater



20



19



Cigar lighter --- 24V/12V voltage reducer --- MC net



20



20



Electric window risers



20



1
332



HD9 Euro3



Fuse holder (70601) FUNCTION



POSITION



CAPACITY (A)



1



Trailers ABS



30



2



ABS control unit



15



3



ABS control unit



5



4



OBD socket --- refrigerator . 30-pole diagnostics socket



10



5



Centralised closure



10



6



Centralised closure --- heated mirrors



10



Fuse holder (70602) FUNCTION



POSITION



CAPACITY (A)



1



ECM control unit



15



2



ECM control unit



3



Heated seats



7,5



4



Heated mirrors



10



5



+ 30 outfitters



15



6



+ 30 outfitters



10



5



1
333



HD9 Euro3 Fuse holder (70401) FUNCTION



POSITION



CAPACITY (A)



1



AsTronic/Allison control unit



10/15



2



AsTronic/Allison control unit



10/15



3



---



---



4



+ 30 trailer



20



Fuse holder (70402) FUNCTION



POSITION



CAPACITY (A)



1



Preparation



15



2



Intarder



10



3



Intarder



10



4



Heated diesel water separator



20



Fuse holder (70403) not used



1
334



HD9 Euro3



RELAYS DESCRIPTION



REF.



CODE COMPONENT



001



Relay for climate control



25332



002



Resistor holder for PTO parameter setting



61125



003



Synchro protection engagement relay



25611



004



Power steering failure warning light control relay



25868



005



Horn relay



25805



006



Lights on relay



25806



007



Flywheel PTO engagement enable relay



25701



008



PTO1 engagement relay



25704



009



PTO2 engagement relay



25897



010



PTO3 engagement relay



011



PTO1 parameter setting recall relay



(outfitters)



012



PTO2 parameter setting recall relay



(outfitters)



013



PTO3 parameter setting recall relay



(outfitters)



014



SET adjustment relay +( outfitters)



(outfitters)



015



SET adjustment relay --- ( outfitters)



(outfitters)



016



PTO engaged confirmation relay



(outfitters)



017



Idle gear confirmation relay



(outfitters)



018



External cruise activation relay



(outfitters)



019



Reverse light relay for vehicle with automatic or automated transmission



25898



25030



1
335



HD9 Euro3 RELAYS REF.



DESCRIPTION



A



Diodes holder EV PTO outfitter wiring



CODE COMPONENT (outfitters)



B



Vehicle doors open locking relay



C



---



25500 ---



D



---



---



E



---



F



Terminal 15a/50A relay



G



Window washer level delay relay



25907



H



40A engeine start relay



25200



I



Fuel pre-filter heating relay



L



Terminal 15b/50A relay



--25213A



25825 25213B



1
336



HD9 Euro3



Additional relays board



1



356ANM001L



REF.



DESCRIPTION



CODE COMPONENT



1---A



Emergency stop relay



1---B



ECM deactivation relay



25205



2---A



Set + relay



2---B



Set --- relay



25914 B



3---A



Off relay



25914 C



3---B



Resume relay



25914 D



25903 25914 A



1
337



HD9 Euro3 Supplementary flying fuse



A. Fuse holder (20A)



272NM009X



There is a flying fuse holder near to the batteries, which contains a 20A fuse.



1
338



HD9 Euro3



Page left intentionally blank



1
339



HD9 Euro3



Table and diagrams



1
340



HD9 Euro3



Page left intentionally blank



HD9 Euro3



1
341



INTRODUCTION Scheduled maintenance intervals refer to normal operating conditions. They may vary according to the type of use, road and environmental conditions. If in doubt or faults not possible to correct with normal maintenance, contact the Dealer.



1
342



HD9 Euro3



LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM 2-axle vehicles



342BTB007L



1
343



HD9 Euro3 Key (see diagram on previous page) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17



semi-trailer fifth wheel/tow hook greaser cardan joint greaser not used leaf spring articulation greaser stub axle greaser not used not used VGT actuator grease application procedure engine oil vapour filter engine oil engine oil filters VGT filter clutch control system oil fuel filters main/secondary air cleaner engine coolant not used



18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35



oil/power take off oil filter transmission oil transmission oil filter transfer oil (only 4x4 version) front axle final reductions oil (only 4x4 version) front axle oil (only 4x4 version) not used not used not used rear axle and final reductions oil power steeling oil power steeling filter not used air conditioning fluid air cleaner of air conditioning compressed air drier filter not used cabin tilting oil Service frequency is expressed in: [h] vehicle working hours [m] months



1
344



HD9 Euro3



LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM 3-axle vehicles



342BTB006L



1
345



HD9 Euro3 Key (see diagram on previous page) 1 2 3 4 5 6 7. 8 9 10. 11 12 13 14. 15 16 17 18



semi-trailer fifth wheel/tow hook greaser cardan joint greaser rear carriage articulation greaser leaf spring articulation greaser stub axle greaser not used not used VGT actuator grease application procedure engine oil vapour filter engine oil engine oil filters VGT filter clutch control system oil fuel filters main/secondary air cleaner engine coolant not used oil/power take off oil filter



19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36



transmission oil transmission oil filter transfer oil (only 6x6 version) front axle final reductions oil (only 6x6 version) front axle oil (only 6x6 version) not used not used intermediate axle and transfer case oil rear axle and transfer case oil power steeling oil power steeling filter no used air conditioning fluid air cleaner of air conditioning compressed air drier filter not used cabin tilting oil supplementary fan system oil/oil filter Service frequency is expressed in: [h] vehicle working hours [m] months



1
346



HD9 Euro3



LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM 4-axle vehicles



342BTD005L



1
347



HD9 Euro3 Key (see diagram on previous page) 1 2 3 4 5 6 7. 8 9 10. 11 12 13 14. 15 16 17



semi-trailer fifth wheel/tow hook greaser cardan joint greaser rear carriage articulation greaser leaf spring articulation greaser stub axle greaser steering linkages greaser (only 4-axle vehicles) not used VGT actuator grease application procedure engine oil vapour filter engine oil engine oil filters VGT filter clutch control system oil fuel filters main/secondary air cleaner engine coolant not used



18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35



oil/power take off oil filter transmission oil transmission oil filter transfer oil (only 8x6 and 8x8 version) front axle final reductions oil (only 8x6 and 8x8 version) front axle oil (only 8x6 and 8x8 version) second axle final reductions oil (8x8 only) second axle oil (8x8 only) intermediate axle and transfer case oil rear axle and final reductions oil power steeling oil power steeling filter not used air conditioning fluid air cleaner of air conditioning compressed air drier filter not used cabin tilting oil Service frequency is expressed in: [h] vehicle working hours [m] months



1
348



HD9 Euro3



LOCATION OF COMPONENTS Engine F3B



342BTB001L



HD9 Euro3 LOCATION OF COMPONENTS Engine F3B Key (see diagram on previous page) 8 9 10 11 12 14 15 16



VGT actuator grease application procedure engine oil vapour recirculation filter engine oil engine oil filter VGT system filter fuel filter main/secondary air filter engine coolant fluid



1
349



1
350



HD9 Euro3



LOCATION OF COMPONENTS Engine F2B



342BTB002L



HD9 Euro3 LOCATION OF COMPONENTS Engine F2B Key (see diagram on previous page) 8 9 10 11 12 14 15 16



VGT actuator grease application procedure engine oil vapour recirculation filter engine oil engine oil filter VGT system filter fuel filter main/secondary air filter engine coolant fluid



1
351



1
352



HD9 Euro3



LOCATION OF COMPONENTS Manual transmission



357ATB001L



HD9 Euro3 LOCATION OF COMPONENTS Manual transmission Key (see diagram on previous page) 13 clutch control system oil 19 manual transmission 20 manual transmission oil filter (intarder equipped vehicles only)



1
353



1
354



HD9 Euro3



LOCATION OF COMPONENTS Automated/automatic transmission



357ATB201L



HD9 Euro3 LOCATION OF COMPONENTS Automated/automatic transmission Key (see diagram on previous page) 19(A) 19(b) 20(A) 20(B)



automated transmission oil automatic transmission oil automated transmission oil filter automatic transmission oil filter



1
355



1
356



HD9 Euro3



LOCATION OF COMPONENTS Multipower/NMV 221 power take off



272CNM005



HD9 Euro3 LOCATION OF COMPONENTS Multipower/NMV 221 power take off Key (see diagram on previous page) 17(A) Multipower power take off oil 17(B) Multipower power take off oil filter 18 NMV 221 power take off oil filter



1
357



1
358



HD9 Euro3



LOCATION OF COMPONENTS Drive-line



272CNM007



HD9 Euro3 LOCATION OF COMPONENTS Drive-line Key (see diagram on previous page) 21 22 23 24 25 26 27



reducer-distributor oil final transfer case oil of 1st front axle 1st front axle oil final transfer case oil of 2nd front axle 2nd front axle oil intermediate axle and final transfer case oil rear axle and final transfer case oil



1
359



1
360



HD9 Euro3



LOCATION OF COMPONENTS Greasing transmission shafts



272CNM008



HD9 Euro3 LOCATION OF COMPONENTS Greasing transmission shafts Key (see diagram on previous page) 2



universal joint greaser



1
361



1
362



HD9 Euro3



LOCATION OF COMPONENTS Suspension geasing



272CNM009



HD9 Euro3 LOCATION OF COMPONENTS Suspension geasing Key (see diagram on previous page) 3 4



rear carriage articulation greaser leaf spring joint greaser



1
363



1
364



HD9 Euro3



LOCATION OF COMPONENTS Steering linkages, semi-trailer fifth wheel, tow hook greasing



272CNM010



HD9 Euro3 LOCATION OF COMPONENTS Steering linkages, semi-trailer fifth wheel, tow hook greasing Key (see diagram on previous page) 1(A) 1(B) 5 6



semi-trailer fifth wheel greaser trailer pintle greaser stub axle greaser steering linkages greaser



1
365



1
366



HD9 Euro3



LOCATION OF COMPONENTS Systems



342BTB004L



HD9 Euro3 LOCATION OF COMPONENTS Systems Key (see figure on previous page) 28 29 31 32 33 35



power steering oil power steering oil filter air conditioner system fluid air conditioner filter compressed air dryer filter cab tipper oil



1
367



1
368



HD9 Euro3



SERVICE SCHEDULE Checking, adjusting and cleaning operations OPERATION Check engine oil level Check engine coolant level Check service brake and parking brake Check external lights, dashboard warning lights and windscreen wiper Windscreen washer fluid level check Check trailer pintle /semi-trailer fifth wheel condition Bleed compressed air tank Check tyre pressure/conditions Fuel filter check/water drain (1) Check tightness of wheel fasteners (2) Turbocompressor intake/lubrication system seal check Check clutch control oil level Check gearbox oil level Check transfer oil level Check transfer case oil level Check axle oil level Pedal distributors check Tow hook/thrust washer functioning check Check compressed oil dryer function/if necessary bleed off condensation from tank(s)/visual inspection of tanks



day



400



hours 800



1600



year



X X X X X X X X X X X X X X X X X X X



Battery maintenance (unsealed batteries) X (1) or when respective warning light comes (2) after 20-40 km and again after 100 km when the vehicle is new or after changing the wheel. The table indicates the time interval between two consecutive operations.



1
369



HD9 Euro3 Checking, adjusting and cleaning operations (contd.) OPERATION



day



hours 400



800



Check cab tilting system oil



X



Check accessory belt



X



Check conditioner compressor belts



X



Bleed fuel tank condensation water



X



Check power steering system oil level (^^)



X



Intercooler external cleaning (1)



X



Front wheel toe-in check (˚)



X



Brake shoe-drum play check



X



1600



Check EDC engine control system with diagnosis equipment (˚)



X



Adjust tappet /injector-pump play (˚)



X



year



Clean conditioner condenser



X



Check antifreeze concentration



X



Check headlight alignment



X



(˚) (^^)



For further information contact your Dealer This check is optional, since there is an oil level warning light.



(1)



according to working environment



The table indicates the time interval between two consecutive operations.



1
370



HD9 Euro3



Lubrication and replacement operations --- Engine OPERATION Replace engine oil/filter with ACEA E2 or equivalent (*) (1)



100



400 X



Replace engine oil/filter with ACEA E5/E7 or equivalent (*)



hours 800 1600



X



Replace main air cleaner element (2) (*)



X



Replace air cleaner main element (3)



X X X



Replace accessory belt (˚)



X



Replace air conditioner compressor belts (˚)



X



Replace AdBlue filter (˚)



X



(˚)



for further information contact your Dealer



(*) (**)



yearly for shorter periods of use than foreseen every two years for periods of use less than envisaged interval



(1) (2) (3)



with a NEW vehicle, change engine oil the first time after 800 hours of operation or when respective warning light comes on or after every three main filter replacements



year



X



Replace fuel pre-filter/filter



Change engine coolant (**)



3200



X



Engine oil vapour recirculation filter replacement



Replace VGT circuit air filter



2400



The table indicates the time interval between two consecutive operations.



1
371



HD9 Euro3 Lubrication and replacement operations --- Vehicle OPERATION Grease lubrication points



100 X



400



hours 800 1600



2400



3200



Change clutch control oil



X



Change power hitch oil (*)



X



Transmission oil change (*) (***)



X



Manual transmission oil filter change with intarder/automatized (*) (***)



X



Transmission oil filter change (*)



X



Change transfer oil (*)



X



Change axle transfer case oil



X



Change power steering system oil (**)



X



Replace power steering system oil filter Replace compressed air dryer filter (*)



year



X X



Change oil in cab tilting system (**)



X



Recharge conditioner system fluid (˚)



X



Replace air conditioner filter



X



(˚)



for further information contact your Dealer



(*) (**) (***)



yearly for shorter periods of use than foreseen every two years for periods of use less than envisaged interval every two years or 240,000 km if reached before the foreseen time (automatized transmission only) The table indicates the time interval between two consecutive operations.



1
372 LUBRICANT AND HYDRAULIC FLUID TABLES



HD9 Euro3



1
373



HD9 Euro3



APPENDIX



1
374



HD9 Euro3



Page left intentionally blank



HD9 Euro3



1
375



WARNING This appendix contains the use standards of the AsTronic2 V35 version (recognisable by the pushbutton selector on the dashboard in lieu of the selection lever). Consult the use standards in this volume for all details not included in this APPENDIX.



1
376



HD9 Euro3



1



LEFT-HAND DRIVE VEHICLES Mirror selection and handling This adjustment is to be made with the vehicle stationary. Refer to the specific chapter for further information concerning operation of the display.



342BNU050L



2



357ANU056L



Acting on the selection control (Fig. 1, ref. 1) the “MIRRORS SELECTION AND HANDLING” screen page is automatically activated. The selected mirror is highlighted in red (Fig. 2). Acting on the mirrors adjustment control (Fig. 1, ref. 2) the selected mirror can be handled. If there is no electrical adjustment installed, the driver has to move the mirrors by hand.



1
377



HD9 Euro3



1



The following mirrors are handled by the system (Fig. 1): 1. Main driver mirror 2. Driver wide-angle mirror 3. Main passenger mirror 4. Passenger wide-angle mirror Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns



284CNU004L



2



Press the mirror heater button (Fig. 1, ref. 3) to rapidly demist the mirrors. Press the button to turn the mirror heating system on. Press the button again to turn the mirror heating system off.



342BNU051L



3 3



Automated transmission control Selection of the different operating modes is done through a pushbutton selector (Fig. 3).



1
378



HD9 Euro3



1



RIGHT-HAND DRIVE VEHICLES Mirror selection and handling This adjustment is to be made with the vehicle stationary. Refer to the specific chapter for further information concerning operation of the display.



342BNU050L



2



357ANU056L



Acting on the selection control (Fig. 1, ref. 1) the “MIRRORS SELECTION AND HANDLING” screen page is automatically activated. The selected mirror is highlighted in red (Fig. 2). Acting on the mirrors adjustment control (Fig. 1, ref. 2) the selected mirror can be handled. If there is no electrical adjustment installed, the driver has to move the mirrors by hand.



1
379



HD9 Euro3



1



The following mirrors are handled by the system (Fig. 1): 1. Main driver mirror 2. Driver wide-angle mirror 3. Main passenger mirror 4. Passenger wide-angle mirror Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns



284CNU004L



2



Press the mirror heater button (Fig. 1, ref. 3) to rapidly demist the mirrors. Press the button to turn the mirror heating system on. Press the button again to turn the mirror heating system off.



342BNU051L



3



Automated transmission control Selection of the different operating modes is done through a pushbutton selector (Fig. 3).



1
380



HD9 Euro3



ALL VEHICLES INSTRUMENTS



Instrument panel (Fig. 1)



1



342BNU026L



HD9 Euro3



1
381



Instrument panel (Fig. 1) 1. Engine oil low pressure warning light Red. Indicates that engine oil pressure is too low 2. Engine cooling liquid level low warning light Red. Indicates that engine cooling liquid level is too low 3. Engine oil pressure indicator. 4. Engine cooling liquid temperature indicator 5. Engine oil temperature high warning light Red. Indicates engine oil temperature is too high 6. Engine cooling liquid temperature high warning light Red. Indicates that the engine cooling liquid temperature is too high 7. Revs counter 8. Speedometer 9. LCD screen with hour and partial trip counter 10. Partial trip reset button 11. Fuel level indicator 12. Fuel reserve warning light Red. Indicates that fuel level in tank is in reserve 13. AdBlue additive level indicator 14. AdBlue additive reserve warning light Red. Indicates that AdBlue additive level in tank is in reserve 15. Instruments lighting adjustment button A. B. C. D.



Warning lights panel A Warning lights panel B Warning lights panel C Display



For further information regarding warning lights panel and display see further on.



1
382



HD9 Euro3



1



Functions of instrument panel keys Key 1 (Fig. 1, rif. 1): Colour display (Fig. 1, ref. 3) and LCD display (Fig. 3, ref.1) brightness adjustment. When the key is pressed a window (Fig. 2) is shown on the colour display that informs the user of the brightness level.



272GNU004



2



357ANU001L



3



342BNU027L



Key 2 (Fig. 1, rif. 2): Changing from total km to partial km (trip). Pressing key 2 for three seconds or less, partial km or total km are displayed. Partial trip reset. Partial trip reset. Press key 2 for more than 3 seconds to reset the partial trip shown on the LCD display (Fig. 3, ref. 1).



1
383



HD9 Euro3 Warning lights panel A details



1



1



342BNU028L



Retarder on warning light. Yellow. Indicates that hydraulic retarder is active. 2 Engine brake engaged warning light. Yellow. Indicates that the engine brake is engaged. 3 Rear traverse differential locked warning light. Yellow. Indicates that the rear differential clamp is engaged. 4 Transfer box longitudinal differential locked warning light. Yellow. Indicates that the transfer box differential clamp is engaged. 5 Tandem longitudinal differential locked warning light. Yellow. Indicates that the tandem longitudinal differential is engaged. 6 Front transverse differential locked warning light. Yellow. Indicates that the front differential clamp is engaged. 7 External lights on warning light. Green. Indicates that the side lights (and dip headlights) are on. 8 Main beam on warning light. Blue. Indicates that main beam headlights are on. 9 Parking brake engaged warning light. Red. Indicates that the parking brake is engaged. 10 Left direction indicator warning light. Green. Indicates that the left direction indicator has been activated. 11 Fog warning light on. Yellow. Indicates that the fog light is on. 12 Brakes air pressure low warning light. Red. Indicates that the vehicle brakes air pressure is insufficient.



1
384



HD9 Euro3



1



Warning lights panel B details 1 2 3 4



272GNU007



Seat belt not fastened warning light Red. Indicates that the driver’s seat belt is not fastened. Tachograph variation warning light Red. Indicates a malfunctioning of the tachograph. Immobilizer engaged warning light Yellow. Indicates that the immobilizer system is on. Not used.



1
385



HD9 Euro3



1



Warning lights panel C details 1 2 3 4. 5 6 7 8



342BNU029L



9 10 11 12



PTO 1 engaged warning light. Yellow. Indicates that PTO 1 is activated. PTO 2 engaged warning light. Yellow. Indicates that PTO 2 is activated. PTO on flywheel engaged warning light. Yellow. Indicates that PTO on flywheel is activated. Splitter reduced ratios engagement warning light. Green. Indicates that splitter reduced ratios are engaged. Transmission oil temperature high warning light. Red. Indicates that the transmission oil temperature is high. Power steering oil level low warning light. Red. Indicates that the power steering oil level is insufficient. Alternator warning light. Red. Indicates that the current delivered to the alternator is insufficient. Water in fuel pre-filter warning light. Yellow. Indicates the presence of water in the fuel pre-filter. Hazard lights on warning light. Red. Indicates that the hazard warning lights are on. Right direction indicator warning light. Green. Indicates that the right direction indicator has been activated. Cab unhooked warning light. Red. Indicates that the cab has not been secured correctly. Air filter clogged warning light. Yellow. Indicates that the engine air filter is clogged.



1
386



HD9 Euro3



1 A



B



C



D



357ANU002L



DISPLAY STRUCTURE The display is divided into four sections (A,B,C,D). Each section contains specific information. Section A D Batteries power supply voltage (default) D Tractor ABS failure D Power steering 1 circuit failure D Power steering 2 circuit failure D Trailer braking system pressure low D Trailer ABS failure D Doors open D Front/rear brakes wear D Second speed limit engagement D ASR deactivation D ABS off-road engagement D Programmed maintenance time-out D Cruise control engagement D Engine cooling liquid level low D Window washer liquid level low D Container tipped Section B D Logo and outside temperature (default) D Generic fault D Serious fault



1
387



HD9 Euro3



1 A



B



C



DISPLAY STRUCTURE Section C D Running condition indicator Section D D Date - Time - Station/track time (default) D Steering system failure D Scheduled maintenance due in 50 hours D PTO (n˚): rpm D Headlights geometry adjustment D Mirrors selection for handling D Menu D Front/rear axles braking system pressure D Engine/transmission oil temperature



D



357ANU002L



1
388



HD9 Euro3 This table indicates the symbols used on the display (Section A) Meaning



Symbol



Colour



Meaning



Symbol



Colour



Batteries power supply voltage



Grey



Second speed limit activation



Tractor ABS failure



Giallo



ASR off



Grey



Yellow



Power steering 1 - power steering 2 circuit failure



Red



ABS off-road activation



Grey



Trailer braking system pressure low



Red



Scheduled maintenance due



Red



Yellow



Cruise Control connection



Grey



Red



Window washer liquid level low



Red



Trailer ABS failure



Doors open



Front - rear brakes wear



Yellow



Engine warm ---up



Yellow



Container tipped



Yellow



1
389



HD9 Euro3 This table indicates the symbols used on the display (Section B) Meaning



Symbol



Colour



Meaning



Symbol



Colour



Logo and outside temperature



Grey



Generic fault



Yellow



Outside temperature lower than 3 ˚C (numbers in red)



Grey



Serious fault



Red



1
390



HD9 Euro3 Automated transmission display (Fig. 1) Indications on the instrument display (Fig. 2) 1 01 --- 16 =Indicates the forward gear engaged 00 = idle R1 = fast reverse gear R2 = slow reverse gear In addition, the display shows any information regarding faults: AL = no air supply AP = accelerator depressed at engine start CH = system troubleshooting: at ignition. CL = indicated clutch overloaded. CW = indicates clutch wear; clutch must be replaced as soon as possible. HT = excessive electronic control unit temperature.



2 2



3



Mode symbol



The following cases may occur for the modes below (Fig. 3) a. automatic mode b. manual mode The number of horizontal lines stands for the gears that can be shifted in the current condition: e.g: three lines = 3 speeds c. manoeuvre mode at low speed



1
391



HD9 Euro3



Page left intentionally blank



1
392



HD9 Euro3



1



Display operation Turn the switch to the MAR position: main systems and their state will appear on the display. Display controls On the steering wheel there are the keys for the selection and management of certain functions 1. MENU/OK Key 2. PAGE Key 3. ESCAPE Key 4. Key Y Key B 5.



272GNU013



Key + ( ) Key - ( )



1
393



HD9 Euro3 Display menu structure



3



S S



RADIO CD



5



3 2



3



3 1



S S S S S S S



2



2



2



2



S S S



RADIO VEHICLE DATA TRIP 1 TRIP 2 CHECK LANGUAGE PASSWORD DISPLAY BUZZER LIGHTS 272GNU200



The numbers in squares indicate the steering wheel control to be pressed. For further information regarding the steering wheel controls, see the previous page.



1
394



HD9 Euro3



1



KEY ON (CHECK) When the key is turned to MAR, the display shows the following data: D Time. D Date. The buzzer sounds twice.



272GNU014



The page (Fig. 1) is displayed for 3 seconds during which the vehicle electronic system runs the check. After the check “VEHICLE MOTION”.



2



1



If during the check or when running the vehicle, the electronic system detects a generic fault/failure, the yellow symbol is shown (Fig. 2, ref. 1) on the display



2



Continue with caution and take the vehicle as soon as possible to a Service Network workshop. If during the check or when running the vehicle, the electronic system detects a serious fault/failure, the red symbol is shown (Fig. 2, ref. 2) on the display. 357ANU007L



Park the vehicle safely at the roadside, and contact a Service Network workshop as soon as possible.



1
395



HD9 Euro3



1



357ANU002L



VEHICLE MOTION When the vehicle is running, the following data is shown on the display: D D D D D D



Battery voltage; External temperature; Transmission conditions; Date / PTO engaged and engine speed; Time; Radio station / CD track (if there is sound system with controls on steering wheel).



1
396



HD9 Euro3



1



357ANU004L



2



357ANU008L



3



357ANU009L



FRONT/REAR AXLES BRAKING SYSTEM PRESSURE When key 2 (PAGE) on the steering wheel is pressed, the following information is displayed: D Front and rear axles pressure ; D Correct front axles pressure (5.5 bar < P < 12 bar) (Fig. 1); D Insufficient front axles pressure (< 5.5 bar) (Fig. 2); D Correct rear axles pressure (5.5 bar < P < 12 bar) (Fig. 1); D Insufficient rear axles pressure (< 5.5 bar) (Fig. 3).



1
397



HD9 Euro3



1



357ANU004L



2



Under normal running conditions (pressure values > 5.5 bar) by pressing key 3 (ESCAPE) on the steering wheel, or not pressing any key on the steering wheel for 30 seconds the “VEHICLE MOTION” page returns. If one of the pressure gauges indicates an insufficient pressure value, the page remains displayed until the user presses key 3, (ESCAPE) or 2 (PAGE) on the steering wheel. The “brakes air pressure low “ warning light on the cluster switches on. If an insufficient pressure is displayed when running, stop the vehicle immediately and have the system checked. Do not continue to drive the vehicle. The vehicle is to be taken toa Service Network workshop as soon as possible.



357ANU008L



3



357ANU009L



1
398



HD9 Euro3



1



ENGINE OIL TEMPERATURE This page is shown only on vehicles with manual or automatic gearbox.



357ANU010L



2



357ANU011L



3



357ANU012L



Press key 2 (PAGE) on the steering wheel twice in succession, or Press key 2, (PAGE) on the steering wheel once after the “BRAKING SYSTEM PRESSURES” display, to view the following information: Engine oil temperature (Fig. 1): D Low engine oil temperature (< 30˚C) (Fig. 1); D Correct engine oil temperature (30˚C < T < 120˚C) (Fig. 2); D High engine oil temperature (> 120˚C) (Fig. 3).



1
399



HD9 Euro3



1



357ANU010L



2



357ANU011L



3



357ANU012L



Under normal running conditions (temperature value below the red zone) by pressing key 3 (ESCAPE) on the steering wheel, or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns. Press key 2, (PAGE) to return to “BRAKE SYSTEM PRESSURES”. If the indicator shows a high temperature value, the page remains until the user presses key 3 (ESCAPE) or 2, (PAGE) on the steering wheel. The “engine oil temperature high” warning light on the cluster switches on. If a high temperature value is displayed while running, stop the vehicle immediately and have the system checked. Do not continue to drive the vehicle. The vehicle is to be taken toa Service Network workshop as soon as possible.



1
400



HD9 Euro3



1



RADIO --- CD PLAYER The “RADIO - CD PLAYER” key is only used to switch on the radio or the CD player from steering wheel controls (only if the vehicle has sound system with controls on steering wheel). To change the radio settings, see “SOUND SYSTEM” in the DIALOGUE MENU (next page).



357ANU002L



2



357ANU005L



3



The sound system can be switched on by pressing the ON/OFF key on the front panel, or by pressing key 5 ( ) on the steering wheel. When key 5 ( ) is pressed on the steering wheel, the “RADIO - CD PLAYER” page is displayed (Fig. 2) Press key 4 (Y / B) on the steering wheel to select the RADIO/CD function (the window of the selected function lights up in yellow). Press key 1 on the steering wheel to confirm the selected function. The CD function is only accepted if a disk has already been inserted.



357ANU016L



By pressing key 3 (ESCAPE) on the steering wheel, or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns



1
401



HD9 Euro3



1



357ANU002L



2



357ANU005L



3



357ANU016L



Once the RADIO/CD function has been activated, the station / track can be changed from the “VEHICLE MOTION” page (Fig. 1), by pressing key 4 (Y / B) on the steering wheel and the volume adjusted with key 5 (+ / -) on the steering wheel. The volume level is shown on the display of the specific page (Fig. 3) To switch off the sound system press the OFF key on the front panel . For further information regarding the functioning of the sound system, see the relevant documents.



1
402



HD9 Euro3



1



357ANU017L



DIALOGUE MENU When key 1 (MENU/OK) on the steering wheel is pressed, the “DIALOGUE MENU” page is displayed. Press key 4 (Y / B) on steering wheel to select (Fig. 1) required function from those available: D SOUND SYSTEM D VEHICLE DATA D TRIP 1 D TRIP 2 D CHECK D LANGUAGE D PASSWORD D DISPLAY D BUZZER D LIGHTS The string of the selected function lights up in yellow. Press key 1 (MENU/OK) on the steering wheel to check or change the settings of the selected function.



1
403



HD9 Euro3



1



357ANU017L



2



357ANU020L



By pressing key 3, (ESCAPE), on the steering wheel , or not pressing any key on the steering wheel for 30 seconds the “VEHICLE MOTION” page returns. The complete list of the DIALOGUE MENU functions is only available when the vehicle is travelling at less than 10 km/h (Fig. 1). When vehicle speed exceeds 10 Km/h only the SOUND SYSTEM (Fig. 2) function can be accessed. If the DIALOGUE MENU function is accessed when the vehicle speed is less than 10 km/h, then this speed limit is passed, the cluster immediately and automatically returns to the “VEHICLE MOTION” page.



1
404



HD9 Euro3



1



357ANU020L



SOUND SYSTEM When key 1 (MENU/OK) is pressed on the steering wheel, the “DIALOGUE MENU” page is displayed. Press key 4 (Y / B) on the steering wheel to select the SOUND SYSTEM function (Fig. 1) (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to have access to the RADIO/CD menu (Fig. 2).



2



357ANU005L



Pressing key 3 (ESCAPE) on the steering wheel, or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns Press key 4 (Y / B) on the steering wheel to change the RADIO/CD function (the window of the selected function lights up in yellow). Press key 1 (MENU/OK) on the steering wheel to confirm the selected function.



1
405



HD9 Euro3



1



The CD function is only accepted if a disk has already been inserted. Otherwise the RADIO function remains active. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



357ANU020L



2



To switch off the sound system press the OFF key on the front panel. For further information regarding the functioning of the sound system, see the relevant documents.



357ANU005L



1
406



HD9 Euro3



Page left intentionally blank



1
407



HD9 Euro3



1



357ANU021L



2



357ANU022L



3



VEHICLE DATA When key 1 (MENU/OK) is pressed on the steering wheel the “DIALOGUE MENU” is displayed. Press key 4 (Y / B) on the steering wheel to select the VEHICLE DATA function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to have access to the VEHICLE DATA menu (Fig. 1, 2, 3). Press key 4 (Y / B) on the steering wheel to scroll all the vehicle data: D TOTAL DISTANCE  km D AVERAGE SPEED  km/lh D AVERAGE CONSUMPTION Al/100km D AVERAGE CONSUMPTION Bl/100km D TOTAL HOURS  h :  min D VEHICLE TIME IN IDLE  h :  min D VEHICLE RUNNING TIME  h :  min D TIME IN PTO 1  h :  min D TIME IN PTO 2  h :  min D TIME IN PTO 3  h :  min D NEXT MAINTENANCE  h :  min Press key 1 (MENU/OK) on the steering wheel to return to the “DIALOGUE MENU” page.



357ANU023L



By pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



1
408



HD9 Euro3



1



357ANU024L



2



357ANU025L



TRIP 1 Press key 1 (MENU/OK) on the steering wheel to view the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select TRIP 1 function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to access the TRIP 1 menu (Fig. 1). Press key 4 (Y / B) on the steering wheel to scroll all the vehicle data: D TOTAL DISTANCE  km D AVERAGE SPEED  km/h D AVERAGE CONSUMPTION Al/100km D AVERAGE CONSUMPTION Bl/100km D TOTAL HOURS  h :  min D VEHICLE TIME IN IDLE  h :  min D VEHICLE RUNNING TIME  h :  min D TIME IN PTO 1  h :  min D TIME IN PTO 2  h :  min D TIME IN PTO 3  h :  min



1
409



HD9 Euro3



1



357ANU024L



2



357ANU025L



To reset TRIP 1 data, press key 5 ( ): D when the reset symbol is shown by a solid dot () (Fig. 1) all the data can be deleted by pressing key 1 (MENU/OK) on the steering wheel. D when the reset symbol is shown by an empty dot (¥) (Fig. 2) pressing key 1 (MENU/OK) on the steering wheel the “DIALOGUE MENU” returns. By pressing key 3 ESCAPE on the steering wheel, or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns



1
410



HD9 Euro3



1



TRIP 2 The default password is “00000”. To change the password see PASSWORD in the “DIALOGUE MENU”.



357ANU026L



2



357ANU027L



Press key 1 (MENU/OK) on the steering wheel to display the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select TRIP 2 (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel, the PASSWORD entry is requested (Fig. 1). Press key 4 (Y / B) on the steering wheel to select the digit (highlighted in red on the keypad); to confirm the selected digit, press key 5 ( ) on the steering wheel. Use the icon () on the keypad to move back by one or more digits entered. PTo confirm the typed PASSWORD select icon (n) on the keypad If the PASSWORD entered is not correct, “WRONG PASSWORD “ (Fig. 2) is displayed, together with a single beep of the buzzer. ”WRONG PASSWORD” remains displayed for 3 seconds, after which the page returns to enter the PASSWORD (Fig. 1).



1
411



HD9 Euro3



1



357ANU024L



2



357ANU025L



Press key 4 (Y / B) on the steering wheel to scan all the vehicle data: D TOTAL DISTANCE  km D AVERAGE SPEED  km/h D AVERAGE CONSUMPTION Al/100km D AVERAGE CONSUMPTION Bl/100km D TOTAL HOURS  h :  min D VEHICLE TIME IN IDLE  h :  min D VEHICLE RUNNING TIME  h :  min D TIME IN PTO 1  h :  min D TIME IN PTO 2  h :  min D TIME IN PTO 3  h :  min To reset TRIP 2 data, press key 5 ( ): D when the reset symbol is shown by a solid dot () (Fig. 1), all the data can be deleted by pressing key 1 (MENU/OK) on the steering wheel. D when the reset symbol is shown by an empty dot (¥) (Fig. 2), pressing key 1 (MENU/OK) on the steering wheel the “DIALOGUE MENU” returns. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



1
412



HD9 Euro3



1



357ANU028L



2



CHECK Press key 1 (MENU/OK) on the steering wheel to view the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select the CHECK function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to access the CHECK page that displays the faults concerning the control units installed on the vehicle (Fig. 1, 2). Press key 4 (Y / B) on the steering wheel to scroll the control units and any faults. The information is set out in three columns: Faults no longer present when the “CHECK” page is viewed are grey, and remain less visible than faults that are still active.



357ANU029L



1
413



HD9 Euro3



1



ECU Indicates the control



DTC Displays the fault code of the failure



FMI Indication regarding the failure mode



Press key 1 (MENU/OK) on the steering wheel to return to the “DIALOGUE MENU” 357ANU028L 272GNU043



2



357ANU029L 272GNU044



Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



1
414



HD9 Euro3



1



357ANU023L



2



357ANU033L



LANGUAGE Press key 1 (MENU/OK) on the steering wheel to view the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select the LANGUAGE function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to access the “LANGUAGE” page to change the languages of the pages (Fig. 1, 2). Press key 4 (Y / B) on the steering wheel to select the required language (the window of the selected function lights up in yellow). The following languages can be selected: D ITALIAN D ENGLISH D GERMAN D FRENCH D SPANISH Press key 5 ( ) on the steering wheel to confirm the selected language (the window of the selected language lights up in green). Press key 1 (MENU/OK) on the steering wheel to return to “DIALOGUE MENU”. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



1
415



HD9 Euro3



1



PASSWORD This function is used exclusively to change the previously set password. If you have forgotten the password entered, it is necessary to go to service network workshop to reset the original value “00000”.



357ANU034L



2



357ANU035L



Press key 1 (MENU/OK) on the steering wheel to display the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select the PASSWORD function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to access the PASSWORD page to change the password (Fig. 1).



1
416



HD9 Euro3



1



357ANU034L



2



357ANU035L



When the PASSWORD page is accessed the text CURRENT PSW lights up. Press key 4 (Y / B) on the steering wheel to select the digit (highlighted in red on the keypad). to confirm the selected digit, press key 5 ( ) on the steering wheel. Use the icon () on the keypad to return back by one or more digits entered. To confirm the entered PASSWORD select the icon (n) on the keypad and press key 5 ( ) on the steering wheel. If the CURRENT PASSWORD (CURRENT PSW )entered is not correct, the message WRONG CURRENT PASSWORD (Fig. 2) is displayed, together with a single beep of the buzzer. The “WRONG PASSWORD” display remains for 3 seconds and at time-out the page to enter the “CURRENT PASSWORD “ (CURRENT PSW ) is displayed again.



1
417



HD9 Euro3



1



357ANU034L



2



357ANU036L



3



357ANU037L



If the CURRENT PASSWORD (CURRENT PSW) entered is correct, the text NEW PASSWORD (NEW PSW) lights up(Fig. 1). Press key 4 (Y / B) on the steering wheel to select the digit (highlighted in red on the keypad); to confirm the selected digit press key 5 ( ) on the steering wheel. Use the icon () on the keypad to return back by one or more digits entered. To confirm the typed PASSWORD select the icon (n) on the keypad and press key 5 ( ) on the steering wheel. When the NEW PASSWORD (NEW PSW) has been entered, the text CONFIRM NEW PASSWORD (CONF.PSW) lights up. Press key 4 (Y / B) on the steering wheel to select the digit (highlighted in red on the keypad); to confirm the selected digit, press key 5 ( ) on the steering wheel . Use the icon () on the keypad to return back by one or more digits entered. To confirm the typed PASSWORD select icon (n) on the keypad and press key 5 ( ) on the steering wheel.



1
418



HD9 Euro3



1



If the CONFIRM NEW PASSWORD (CONF PSW) entered is not correct the text “INCONSISTENT PASSWORD” (Fig. 2) will be displayed, together with a single beep of the buzzer. ”INCONSISTENT PASSWORD” remains displayed for 3 seconds, and at time-out the page to enter the CONFIRM NEW PASSWORD (CONF. PSW) is displayed again.



357ANU034L



2



If the CONFIRM NEW PASSWORD (CONF PSW) entered is correct “PASSWORD CHANGED” (Fig. 3) is displayed together with a single beep of the buzzer. ”PASSWORD CHANGED” is displayed for 3 seconds and at time-out the “DIALOGUE MENU” returns.



357ANU036L



3



357ANU037L



1
419



HD9 Euro3



Page left intentionally blank



1
420



HD9 Euro3



1



357ANU038L



2



357ANU039L



DISPLAY Press key 1 (MENU/OK) on the steering wheel to view the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select the DISPLAY function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to access the “DISPLAY” page to change the colour and pattern of the display background (Fig. 1, 2). The following backgrounds can be selected: D BACKGROUND 1 (blue) D BACKGROUND 2 (grey) D BACKGROUND 3 (red) D BACKGROUND 4 (yellow) D BACKGROUND 5 (green) Press key 4 (Y / B) on the steering wheel to select the background (the window of the selected function lights up in yellow and the display background changes, giving a preview). To confirm the background selected, press 5 ( ) on the steering wheel. Press key 1 (MENU/OK) on the steering wheel to return to the “DIALOGUE MENU”. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



1
421



HD9 Euro3



1



357ANU040L



BUZZER Press key 1 (MENU/OK) on the steering wheel to view the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select the BUZZER function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to access the “BUZZER” page to change the volume of the warning beep (Fig. 1). Press key 5 (+ / -) on the steering wheel to adjust the volume (at each impulse of the key 5 (+ / -) a preview is given of the buzzer sound level) Press key 1 (MENU/OK) on the steering wheel to confirm the chosen sound level and return to the “DIALOGUE MENU”. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



1
422



HD9 Euro3



1



LIGHTS Turn the light switch to position 2 to monitor the lights.



357ANU041L



2



357ANU042L



Press key 1 (MENU/OK) on the steering wheel to view the “DIALOGUE MENU”. Press key 4 (Y / B) on the steering wheel to select the LIGHTS function (the window of the selected function lights up in yellow) Press key 1 (MENU/OK) on the steering wheel to access the LIGHTS page and monitor the functioning of the vehicle lights (Fig. 1). The following lights are monitored by the system: D Front right zone: turn, side, clearance lights D Front left zone: turn, side, clearance lights D Right central zone: turn lights D Left central zone: turn lights D Right rear zone: turn, side, clearance, stop lights D Left rear zone : turn, side, clearance, stop, licence plate lights



1
423



HD9 Euro3



1



Broken lights are highlighted by a red symbol. Press key 1 (MENU/OK) on the steering wheel to return to “DIALOGUE MENU”. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



357ANU041L



2



357ANU042L



The monitoring procedure applies to the parking lights, the direction indicators, the clearance lights and the brake lights only. It is advisable to perform the monitoring procedure at the end of each working day.



1
424



HD9 Euro3



1



FUNCTIONS VIEWED ON THE DISPLAY Headlights geometry adjustment The headlights geometry adjustment is only to be carried out with the vehicle stationary and ignition key set on MAR.



272GNU062



2



Using the command (Fig. 1, ref. 1) the slant of the headlights geometry can be changed according to the vehicle load, bearing in mind that when the vehicle is heavily loaded the slant of the beam has to be lowered accordingly, to avoid disturbing other drivers. Acting on the headlights geometry adjustment command automatically activates the “HEADLIGHTS GEOMETRY ADJUSTMENT” page (Fig. 2, 3).



357ANU043L



3



357ANU044L



1
425



HD9 Euro3



1



272GNU062



2



The slant of the light beam can be adjusted in 10 positions (0 - 9). If the vehicle is completely without load, select position 9 (Fig. 2). If the vehicle has a full load, select position 0 (Fig. 3). For intermediate loads adjust the slant of the light beam selecting from positions 8 to 1. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns. For more precise adjustment, contact the Service Network.



357ANU043L



3



357ANU044L



1
426



HD9 Euro3



1



Scheduled maintenance 50 hours before the scheduled maintenance time expires, the message “SCHEDULED MAINTENANCE DUE IN 50 HOURS” (Fig. 1) is displayed together with a single beep of the buzzer. The page remains displayed until the user presses key 3 (ESCAPE) on the steering wheel.



357ANU045L



2



357ANU046L



At the scheduled maintenance time-out, the warning icon is displayed in section “A” of the display (Fig. 2) together with single beep of the buzzer. The icon remains for three minutes, and reappears at each vehicle ignition.



1
427



HD9 Euro3



1



The scheduled maintenance intervals are the following: The scheduled maintenance intervals are the following: 0h - 400h - 800h - 1600h - 2400h - 3200h - 4000h... and related multiples This indication is only indicative. The vehicle must be services as shown on the Service Schedule in the corresponding chapter.



357ANU045L



2



357ANU046L



The Service Network workshop resets the counter that resumes the calculation up to the next pre-set interval.



1
428



HD9 Euro3



1



Steering system failure This function is active only for vehicles with steering emergency circuit. If while driving a power steering circuit failure is displayed, it is not possible to continue. Take the vehicle to a Dealership workshop as soon as possible



357ANU047L



2



Vehicles with auxiliary cylinder In the case of a failure on the main power steering circuit the warning icon is shown in section “A” of the display and the message “STEERING SYSTEM FAILURE” (Fig. 1) together with the sounding of the buzzer. This function is only active with ENGINE RUNNING.



357ANU048L



In the case of a failure on the auxiliary power steering circuit the warning icon is shown in section “A” of the display and the message “STEERING SYSTEM FAILURE” (Fig. 2) together with the sounding of the buzzer. This function is only active with VEHICLE SPEED >10KM/H. The page remains displayed until the user presses key 3 ESCAPE on the steering wheel. The sounding of the warning buzzer remains active. At the next vehicle start-up the warning icon is displayed in section “A” of the display together with activation of the buzzer.



1
429



HD9 Euro3



1



Vehicles without auxiliary cylinder In the case of a failure on power steering circuit the warning icon is shown in section “A” of the display and the message “STEERING SYSTEM FAILURE” (Fig. 1) together with the sounding of the buzzer. This function is only active with VEHICLE SPEED >10KM/H.



357ANU048L



The page remains displayed until the user presses key 3 ESCAPE on the steering wheel. The sounding of the warning buzzer remains active. At the next vehicle start-up the warning icon is displayed in section “A” of the display together with continuous sounding of the buzzer.



1
430



HD9 Euro3



1



ABS system fault The “ABS SYSTEM FAULT” message (Fig. 1) appears in the event of ABS ECU message timeout. The message will remain displayed until key 3 (ESCAPE) is pressed on the steering wheel.



357ANU049L



2



357ANU050L



The warning icon in section “A” of the display will then remain on (Fig. 2).



1
431



HD9 Euro3



1



2



357ANU052L



Immobiliser fault Proceed as follows at key-on if problems to the electronic key occur and the correct code cannot be sent to the immobiliser. D Wait for the warning light check up procedure to be completed; D Wait for the “IMMOBILIZER CODE” message to appear (Fig. 1); D Proceed with the releasing operation. Cruise Control Failure If the CAN message is not available or the message is not consistent with the speed, the warning icon is shown in section “A” of the display (Fig. 2). This indication is displayed: D when the Cruise Control lever is activated; D at start-up after the display of the batteries voltage icon.



1
432



HD9 Euro3



1



357ANU051L



PTO Engagement When a PTO is engaged, information concerning the number of the PTO and the rpm (PTO X: XXXX rpm) is shown instead of DATE on the “VEHICLE MOTION” page (Fig. 1). Back camera The back camera is automatically activated when reverse gear is selected. The image coming from the back camera is shown full-screen on the display. Selecting a forward gear the back camera is automatically deactivated and the “VEHICLE MOTION” page returns on the display. To return to “VEHICLE MOTION” with reverse gear still engaged, press key 3 (ESCAPE) on the steering wheel.



1
433



HD9 Euro3



1



CONTROL OPERATION Position and headlight controls (Fig. 1) The control has three positions: D position 0: off; D position 1: first click: position lights on; D position 2: second click: headlights on.



272NU043X



1



2



0



2 272NU044X



Headlight control (Fig. 2) The control has three positions. D position 0: normal headlights; D position 1 (light push forward): high beams; D position 2 (pull lever back): Beam flasher.



1
434



HD9 Euro3



1



1



0



2



272NU045X



2



1 2 272NU046X



Direction indicator control (Fig. 1) The control has three positions: D position 0 off; D position 1 (up) right direction indicators; D position 2 (down) left direction indicators. Horn (Fig. 2) The horn can be sounded by pressing the indicated points (Fig. 2, ref. 1, 2).



1
435



HD9 Euro3



3



1



2



1 0



272NU047X



2



272NU048X



3



272NU049X



Windscreen washer/wiper control The control (Fig. 1) has four positions: D position 0 = disengaged; D position 1 = intermittent; D position 2 = slow; D position 3 = fast. Pushing the end of the ring (Fig. 2, see arrow), the windscreen wiper makes one sweep. The windscreen washer is the button (Fig. 3, see arrow) on the control stick. Pressing the windscreen washer button also activates slow windscreen wiper operation. Releasing the washer button, the wiper makes three more cleaning strokes before stopping.



1
436



HD9 Euro3



1



Ignition switch (Fig. 1) The ignition switch has three positions: D position 0 (STOP): all off, key may be removed; D position 1 (MAR): ready to start, electrical power on, key locked in; D position 2 (AVV): starting engine. 272NU056X



22



272NU060X



Engine braking control The device is controlled by turning the end part of the lever (Fig. 2) and which has three positions (from 0 to 2), corresponding to one only braking level.



1
437



HD9 Euro3



1



Cruise control The vehicle is fitted with an engine speed / vehicle speed control. Memory control (Fig. 1, ref. 1). RESUME/OFF: engaging the (RESUME) pushbutton calls up the stored configuration. Engaging the pushbutton (OFF) again deactivates the function. The button switches between engage/exclusion of the function at each activation.



2 Speed setting control



HD9ST0005L



ON button (+): pressing the button (Fig. 2, ref. 1) increases the rpm / vehicle speed value. ON button (-): pressing the button (Fig. 2, ref. 2) decreases the rpm / vehicle speed value.



1
438



HD9 Euro3



1



1



272NU055X



2



Hazard light control Press the control (Fig. 1, ref. 1) to turn the hazard lights on. Press again to switch the hazard lights off. Exhaust brake pre-selection The control (Fig. 2) has three positions: D position 0: the exhaust brake is applied when the command is actuated; D position 1: the exhaust brake is applied when the accelerator pedal is released; D position 2: exhaust brake applied each time the brake pedal is pressed; All Cruise Control operations are deactivated when the exhaust brake is applied.



285ANU039L



1
439



HD9 Euro3



1



285ANU021L



2



285ANU022L



Courtesy light switch Press the button (Fig. 1) to turn the courtesy light on. Press the button again to turn the courtesy light off. Electro-pneumatic horn pre-selection Press the control (Fig. 2) to operate the electro-pneumatic horn by means of the horn control on the left steering stalk. Press the control again to operate the electric horn by means of the horn control on the left steering stalk.



1
440



HD9 Euro3



1



342ANU001L



2



Swivelling light control Press the button (Fig. 1) to turn the swivelling light on. The warning light (Fig. 1, ref. 1) indicates that the swivelling light is on. Press the button again to switch the swivelling light off. Work light Press the button (Fig. 2) to switch the work light on. The warning light (Fig. 2, ref. 1) indicates that the work light is on. Press the button again to switch the work light off. Rear fog light The rear fog light will only come on when the dipped beam headlights are switched on (light and headlight control in second position).



342ANU002L



3



342ANU003L



Press the button (Fig. 3) to switch the rear fog light on. The warning light (Fig. 3, ref. 1) indicates that the rear fog light is on. Press the button again to switch the rear fog light off.



1
441



HD9 Euro3



1



342ANU004L



2



306ANU002L



Fog light control Press the button (Fig. 1) to turn the fog lights on. The warning light (Fig. 1, ref. 1) indicates that the fog lights are on. Press the button again to switch the fog lights off. Electric battery isolator control Press the pushbutton (Fig. 2) to switch on the main power supply. This switch replaces the manual switch located near the battery case. After a certain time from activation or after the engine has been switched off, the batteries disconnect automatically.



1
442



HD9 Euro3



1



342ANU005L



ASR off command Press the button (Fig. 1) to turn the ASR system off. Press the button again to switch the ASR system off. Vehicle traction can be improved by pressing the ASR button in particular terrain conditions (deep snow, mud, etc.). The corresponding warning light will come on.



1
443



HD9 Euro3



1



342ANU006L



ABS Off Road function control Press the button (Fig. 1) to activate the ABS Off Road function. Press the button to restore the brakes anti --- lock device (ABS). Under certain road surface conditions (deep snow, mud, etc.) vehicle braking can be improved activating the ABS exclusion key. When this button is pressed the ABS system is: D cut out up to 15 km/h; D made less sensitive between 15 km/h and 40 km/h; D restored over 40 km/h. The driver is warned of activation by the related warning light . The ABS system is automatically restored at each engine re-start . Pressing this button with a normal road surface the wheels may lock in the case of braking.



1
444



HD9 Euro3



Page left intentionally blank



1
445



HD9 Euro3



1



342BNU001L



USE OF THE VEHICLE Precautions for the initial period of use When the vehicle is new a brief running-in period of at least 150/200 hours is required: Observe the following precautions during this time: D do not demand maximum engine power; D after starting, warm the engine slowly; avoid driving at high revs too soon; D frequently check the oil level; D check the tightening of the wheel bolts. General checks Before starting to use the vehicle, check: D tyre conditions; D correct functioning of all lights, headlights and windshield wiper; D fuel level in tank; D any faults or low levels indicated on the instrument board; D check service brake and parking brake efficiency. Visually inspect the vehicle, checking working conditions and for damage/problems which may cause damage to the vehicle or injury to operators.



1
446



HD9 Euro3



1



272CNU043



Immobilizer To increase protection against attempted theft, the vehicle is fitted with an electronic engine disable system. The ignition keys (Fig. 1) have an electronic device that transmits a coded signal to the immobilizer control unit.



1
447



HD9 Euro3



1



272CNU043



2



272CNU044



Code Card A Code Card is supplied with the keys (Fig. 1), bearing the following information: a the electronic code to use for starting (Fig. 2, ref. 1); b the mechanical code of the keys themselves (Fig. 2, ref. 2). To enable the electronic code to use in case of emergency start, contact the Service Network. We recommend keeping the electronic code on the Code Card at all times in case it is required for an emergency start. The Code Card is an indispensable and unique element supplied with each vehicle. Keep it in a safe place. We recommend recording the code, not leaving it in the vehicle. Do not lose it! If the vehicle is sold, the new owner must be given all the keys and the Code Card.



1
448



HD9 Euro3



1



Emergency start This function allows the vehicle to be started without recognisable key or immobilizer system fault. Starting is possible after entering the Electronic Code (on the Code Card) by means an appropriate procedure to be carried out using the accelerator pedal (Fig. 2, ref.1).



272BNU079



Proceed as follows: D Turn the key to MAR (Fig. 1, ref. 1) D After 2 seconds the immobilizer warning light (Fig. 3) starts to flash quickly. D Keep the accelerator pedal fully down for 5-12 seconds. D The immobilizer warning light starts to flash slowly as soon as the accelerator pedal is released. D When the number of flashes corresponds to the first digit of the Electronic code, press the accelerator pedal fully down then release again (while pressed down, the immobilizer warning light remains off). D Continue with the reading and related pressure on the accelerator pedal for the remaining four numbers of the Electronic code D At the end of the sequence, if the code entered is correct and there are no failures in the system, the immobilizer warning light stops flashing D Start the vehicle.



2



272NU062X



3



272NU058X



1
449



HD9 Euro3



1



272BNU079



2



Contact the Service Network as soon as possible to check the system.



Each key has a mechanical code and an electronic code, different to all others, which must be memorised by the system control unit. When ordering spare keys, remember that the codes must be memorised on all keys, including those already in your possession. Contact the service network directly, taking all the keys and the Code Card with you. The codes of keys not presented for the process will be cancelled by the memory to ensure that any lost keys cannot start the engine.



272NU062X



3



272NU058X



1
450



HD9 Euro3



1



STARTING ENGINE Exhaust gases are poisonous. Check for adequate ventilation before starting the engine in a confined space. Always engage the handbrake before starting the engine.



272CNU093



2



306ANU002L



Checks before starting Check that the main switch (Fig. 1) is on. A: power off B: power on or Activate the electric battery isolator (Fig. 2).



1
451



HD9 Euro3



1



272BNU079



2



272GNU093



Make all the required daily checks (for more information see MAINTENANCE INSTRUCTIONS). Especially check: D engine oil level; D engine coolant level; D tyre condition; D tow-hook /semi-trailer fifth wheel condition. Power up the vehicle electrical system turning the ignition switch (Fig. 1) to MAR (Fig. 1, ref. 1) and check: D fuel level; D lights, warning light, horn and windscreen wiper function; D that after the check lasting 3 seconds no fault symbols are shown on the display (Fig. 2).



1
452



HD9 Euro3



1



272BNU100



2



272GNU014



3



HD9ST0016MR



Starting from the driver’s cab Proceed as follows: D check that the parking brake engaged; D turn the ignition switch to position MAR (Fig. 1, ref. 1); D Wait for the vehicle electronic system to make the check (Fig. 2) that lasts three seconds. D wait for the engine warm ---up indicator light (Fig. 3) to switch OFF. If the vehicle is not started within a few seconds, to start the engine bring the ignition key to STOP (Fig. 1, ref. 3) and repeat the procedure described.



1
453



HD9 Euro3



1



272BNU101



Turn the ignition switch (Fig. 1, ref. 1) to RUN, the immobilizer is disabled only if the protection system recognises the code transmitted by the key. If the code is recognised as valid, the protection system control unit sends its coded signal to the engine control unit permitting engine start (immobilizer system disabled). D turn the ignition switch (Fig. 1, ref. 2) to AVV and release it as soon as the engine fires. Do not press the accelerator when starting engine. If the engine does not start immediately, do not persist on the starter motor for more than 15 consecutive seconds. It is not recommended to leave the engine idling for long periods, whether cold or hot. After starting the engine, to warm up start the vehicle and proceed slowly for a certain time, keeping the engine at medium-low revs.



1
454



HD9 Euro3



1



Starting from engine bay The engine can be started with the cabin tipped in the following way: D Turn the ignition switch (Fig. 1, ref. 1) to MAR position; D tip the cabin and press the starter button (Fig. 2, see arrow). Engine starting is only possible if: D gearbox is in neutral; D parking brake is engaged.



272BNU079



2 Tow starting The engine cannot be started by towing.



178NU47



1
455



HD9 Euro3



1



HD9ST0018L



2



HD9ST0019L



AUTOMATED TRANSMISSION (ASTRONIC) Type II The ZF AsTronicselection system isacombination of an electro-pneumatic engagement transmission with an automated clutch. Selection of the different operating modes is done through a pushbutton selector (Fig. 2 ref. 1). 1. automatic/manual switch (button D) 2. idle switch (button N) 3. reverse switch (button R) The desired mode is engaged/disengaged each time the button is pressed. In addition, the steering column contains a lever (Fig. 2) that allows manual gear shifting. D Briefly pulling the lever (+1) upshifts gears by one speed. D Pulling and holding the lever (+2) upshifts two speeds. D Briefly pushing the lever (---1) downshifts gears by one speed. D Pulling and holding the lever (---2) downshifts two speeds.



1
456



HD9 Euro3



21



HD9ST0020L



2



HD9ST0021L



STARTING UP When the engine has been started the display shows the symbol N (Fig. 1). The system is in manual mode. Start-up is only enabled after sufficient air pressure has been reached. If the pressure is not sufficient the display shows the symbol AL. If, stopping the vehicle, due to low air pressure the clutch does not disengage, the engine stops. If gear shift takes place with air pressure too low, the gear may remain in idle, and no motion is transmitted. Moreover, there is no braking effect of the engine brake. If engine start-up is not possible because a gear has remained engaged and it is not possible to select idle position due to insufficient air pressure, it is necessary to autonomously supply air to the transmission from an external source.



1
457



HD9 Euro3



11



Start-up in automatic mode D start engine; D when the display shows the 00 symbol press button (D) (Fig. 1) to engage automatic mode. The system automatically sets optimal starting gear that is shown on the display (Fig. 2). For start ---up with inclines greater than 10%, especially at full loads, the manual mode MUST be engaged.



HD9ST0022L



2



HD9ST0023L



3



272NU005MY



D release the parking brake by simultaneously pressing the accelerator pedal (Fig. 3, ref. 1); D the clutch is automatically disengaged and the vehicle is started. Failing to action the accelerator pedal results in no dynamic coupling of the system, therefore the vehicle may move out of control.



1
458



HD9 Euro3



11



HD9ST0022L



2



HD9ST0025L



Start-up in manual mode D start engine; D when the display shows the 00 symbol press button (D) (Fig. 1) to engage automatic mode The system automatically sets the optimal starting gear.. D Press button D (Fig. 1) AGAIN. D The system reverts to manual mode and maintains the set gear that is shown on the display (Fig. 2). Pressing button D AGAIN reverts back to automatic mode.



1
459



HD9 Euro3



2



HD9ST0019L



D If necessary, modify the starting speed by using the control lever (Fig. 1); the new gear appears on the display. D release the parking brake by simultaneously pressing the accelerator pedal (Fig. 3, ref. 1); D the clutch is automatically disengaged and the vehicle is started. Gears 1 to 5 can be selecting for starting speed. If the symbols “AP” and “CH” flash on the display, take your foot off the brake pedal. Failing to action the accelerator pedal results in no dynamic coupling of the system, therefore the vehicle may move out of control. For start ---up with inclines greater than 10%, especially at full loads, you MUST: D to select the take-off gear, D do not change gear when driving uphill. If the accelerator pedal is not sufficiently pressed during these manoeuvres, the vehicle may move backwards. In this case the clutch gets engaged and disengaged at short intervals (strikes). This is applicable also while rolling forward with the reverse gear engaged moving downhill.



1
460



HD9 Euro3



1



272GNU095



DRIVING THE VEHICLE Under normal conditions the danger warning lights and danger display indications (RED) should be off. If one or more of the warning lights/indications should come on, stop the vehicle and find the cause. When driving check that: D the fueltank level(Fig. 1, ref. 2)isnotminimum; Never fully drain the fuel tank to prevent dirt and condensation on the bottom of the tank from reaching the injection system.



2 D the engine coolant temperature (Fig. 2, ref. 1) should remain about 90˚C.



357ANU115L



1
461



HD9 Euro3



1



357ANU116L



2



357ANU008L



D the engine oil pressure (Fig. 1, ref. 1) is appropriate (between 4 and 6 bars): the warning light is to switch off when the engine has started; D the brakesair pressure (Fig. 2)isappropriate (max 12 bar, min 5.5 bar); the display indicates brakes low air pressure when the pressure drops below 5.5 bar; Do not exceed maximum engine speed, especially downhill. Never travel with the transmission in Neutral. Avoid using the auxiliary brakes (engine brake, intarder) on long downhill stretches to prevent overheating the service brakes. Never use the parking brake (expect in an emergency) when travelling.



1
462



HD9 Euro3



11



Forward movement in automatic mode Running in automatic mode takes place: D when the vehicle has been started in automatic mode; D when button D (Fig. 1) is pressed and vehicle is in manual mode Upshifting and downshifting



HD9ST0022L



2



Gear changes take place automatically according to these parameters: D running situations; D full load; D accelerator pedal position; D vehicle speed; D engine speed. The display shows the automatic mode and gear when gear is engaged (Fig. 2).



HD9ST0023L



The gear engaged by the system can be adjusted by acting on the lever without exiting the automatic mode: D moving the lever in the (+) direction  upshifts one gear D holding the lever in the (+) direction  upshifts two gears. D moving the lever in the ( ---) direction  downshifts one gear D holding the lever in the ( ---) direction  downshifts two gears. The system accepts the gear engaged by the lever only if not in contrast with the saved operating and safety conditions.



1
463



HD9 Euro3



11



HD9ST0022L



Kick-down function Pressing the accelerator pedal beyond the hard limit stop point causes the control system to set POWER mode. Before shifting up, each gear is maintained up to the corresponding maximum engine speed, downshifting in case of sharp acceleration. The system remains in automatic mode during kick-down. Maintaining the selected gear In automatic mode, press the D pushbutton (Fig. 1) without engaging the lever to maintain selected gear (e.g.: to accelerate uphill). The system shifts to manual mode: no further gear shifts are possible except those made by means of the lever. To resume automatic gear shifting press the D pushbutton again (Fig. 1) without engaging the lever.



1
464



HD9 Euro3



11



HD9ST0022L



2



Forward running in manual mode Running in manual mode takes place: D when the vehicle has been started in manual mode; D when button D (Fig. 1) is pressed and vehicle is in automatic mode. Shifting to higher gears (Fig. 2) D moving the lever in the (+) direction upshifts one gear D holding the lever in the (+) direction upshifts two gears. During gear engagement, do not change accelerator pedal as engine speed is automatically adjusted. For the entire duration of the engaging manoeuvre, all other gear selections are ignored, that is the engaging operation must be concluded before being able to execute another gear change.



HD9ST0028L



33



HD9ST0029L



Shifting to lower gears (Fig. 3) D moving the lever in the (---) direction downshifts one gear D holding the lever in the (---) direction downshifts two gears. An engage command does not get executed if the prechosen ratio exceeds the nated r.p.m. of the engine (excess speed protection of the engine).



1
465



HD9 Euro3



1



Shift to neutral Proceed as follows: D Press button N (Fig. 1). The 00 symbol (Fig. 1) appears on the display. Manual mode is enabled. It is also possible to shift to neutral while driving. Shifting to neutral interrupts the dynamic coupling of the driveline. Engine braking in this case is not enabled.



HD9ST0030L



2



HD9ST0031L



It is possible to shift to neutral at any time and from any gear, even with the vehicle moving. Simply press the button (D). To avoid keeping the clutch disengage device engaged during stops lasting more than 1 ---2 minutes while engine is running (e.g: while in queue or rail crossing), it is best to revert to neutral by pressing the button (N). This avoids unnecessary use of the disengage system.



1
466



HD9 Euro3



1



HD9ST0032L



2



Reverse gear Reverse gear is only available in manual mode. The system is equipped with two reverse gears: R1 = slow reverse R2 = fast reverse Engaging reverse Proceed as follows: D stop the vehicle completely;



2



HD9ST0033L



3



HD9ST0034L



If the vehicle is still moving the reverse gear engagement does not take place. It is not important whether the gear is in idle position or a forward gear is engaged. D pressing the button (R): engages the low gear R1 (Fig. 2, ref.1); D moving the lever towards (+) (Fig. 3): engages the high gear R2 (Fig. 2, ref.2); D moving the lever towards (---) (Fig. 3): engages the low reverse gear again R1 (Fig. 2, ref.1).



1
467



HD9 Euro3



1



Reverse gear disengagement Proceed as follows: D Stop the vehicle completely. If the vehicle is still moving the reverse gear disengagement does not take place.



HD9ST0035L



2



D Press button N (Fig. 1) to select neutral mode D Press button D (Fig. 1) to select automatic mode OFF ROAD Function In particular off ---road conditions (snow, mud, etc.) driving and handling conditions of the vehicle can be improved by engaging the OFF ROAD feature. Gear and clutch control are modified. D Press the command to engage the feature. D Press the command again to disengage the feature.



1
468



HD9 Euro3



1



HD9ST0035L



2



HD9ST0036L



Manoeuvring To manoeuvre at low speeds (e.g. for hitching a trailer or semi---trailer) a manoeuvre condition is featured. The following are available for manoeuvring operations: D first gear forward; D low reverse. Perform the following: D fully stop the vehicle; D press and HOLD DOWN the button (D) (Fig. 1) for forward rolling manoeuvres; D press and HOLD DOWN the button (R) (Fig. 1) for reverse rolling manoeuvres. The display shows the manoeuvre conditions (Fig. 2). Do the following to exit the manoeuvre conditions: D press the button (D); or D press the button (R). In manoeuvring mode, the vehicle (the accelerator pedal) is more sensitive and the clutch action is not as normal. The engine torque is reduced.



During manoeuvres, the clutch is subject to greater stress. “CL” appears on the display if the clutch is overloaded. In this case, the driver must take action to reduce overload (engagement of 1st gear forward or R1)



1
469



HD9 Euro3



1



Protection functions Clutch protection If the clutch overheats (for example due to many consecutive starts at short intervals, or with low speed gear selected for too long) the CL symbol appears on the display and an alarm will sound. In this situation the driver must perform a manoeuvre that eliminates the overload (for example accelerating the vehicle to engage the clutch, stopping the vehicle or start-out selecting a low gear). If the accelerator is pressed the system will engage the clutch regardless of the overload signal, worsening the condition of the clutch itself (except in 1st and RL). This may cause the clutch to slip with engine over-revving and may even allow the vehicle to slip backwards if starting out on a hill. Engine over-rev protection The system does not permit engagement of gears not compatible with engine sped and load conditions.



1
470



HD9 Euro3



1



SPEED PROGRAMMER The speed programmer is a device that acts on the engine power supply management system, controlling rotation speed both with vehicle stationary and in motion, so that certain conditions are met.



HD9ST0037L HD9ST0037L



Engine idle speed adjustment / memorising The system allows adjustment of minimum speed in order to reduce/eliminate unpleasant cab vibrations. Conditions: Keep the brake pedal pressed throughout the operation. D engine at idle speed; D engine at temperature over 30 ˚C.



1
471



HD9 Euro3



1



HD9ST0037L



Proceed as follows: D press (RESUME) the Cruise Control button (Fig.1, ref.1) until engine speed reaches the set base value (approx. 550 rpm). D Adjust speed as required using ON + (Fig. 1, ref. 2) or ON --- (Fig. 1, ref. 3) (pivoting head key). Each touch of the ON key increases or decreases engine speed by circa 20 rpm. Engine idle speed must be between the following values: D minimum value: 550 rpm D maximum value: 750 rpm Adjust idle speed according to needs (noise, vibration, etc.).



HD9ST0037L



D Having achieved the set speed, press and hold (OFF) the Cruise Control button for approximately 5 seconds. D Release the brake pedal. This will memorise the new speed even after stopping the engine, and the new setting will be valid for all subsequent restarts. If the procedure is not carried out correctly and/or problems are encountered during it, the previously memorised speed is maintained.



1
472



HD9 Euro3 Vehicle speed (Cruise Control) adjustment / memorising The Cruise Control must not be used in heavy traffic conditions or on roads where constant speed adjustment is necessary. If the set speed is no longer achievable the device cuts-out automatically. If vehicle speed increases by more than 2 kph over the set value (e.g. on descending road) to slow the vehicle and maintain set speed, engine braking is automatically engaged. If vehicle speed increases more than 4 km/h also the retarder (if present) engages. Vehicles with automated transmission: if the vehicle speed exceeds 6 km/h, the transmission will shift down (automatic mode only). The automated transmission, in automatic mode, will shift down whenever necessary (increase coolant flow rate).



1
473



HD9 Euro3



1



HD9ST0037L HD9ST0037L



Conditions: D engine brake lever/retarder not engaged; D vehicle moving with gear engaged; D vehicle speed greater than 20 kph; D brake pedal not pressed; D clutch pedal not pressed. Control ON + ON --RESUME OFF



Vehicle speed regulation Increases speed Decreases speed Selects last set speed Cancels speed regulation



1
474



HD9 Euro3



1



Enable Proceed as follows: The function can be enabled only if the brake pedal has been pressed at least once after starting the vehicle.



HD9ST0037L HD9ST0037L



2



357ANU053L



D Bring the vehicle to the steady speed to maintain with the accelerator pedal; D Press the ON button (+) (Fig. 1, ref. 2) once: the speed value is automatically memorised; D Release the accelerator pedal.



1
475



HD9 Euro3



1



HD9ST0037L HD9ST0037L



Changing setting Proceed as follows: D after activating the function press ON (+) (Fig. 1, ref. 2) to increase vehicle speed; or D after activating the function press ON (---) (Fig. 1, ref. 3) to decrease vehicle speed. Tip Function Briefly press the pivoting ON button (+) (Fig. 1, ref. 2) or ON (---) (Fig. 1, ref. 3) to change speed in 1 kph steps. Ramp Function Holding the pivoting ON button (+) pressed (Fig. 1, ref. 2) or (---) (Fig. 1, ref. 3) increases speed continuously. The speed value is shown on the display. When using the Ramp Function, the value shifts to displaying the effective vehicle speed, and the set value will be the one reached at the moment the button is released. The display disappears after 10 seconds.



1
476



HD9 Euro3



1



Permanent disable Proceed as follows: D press (OFF) the Cruise Control pushbutton (Fig. 1, ref. 1); or D Operate the brake or engine brake pedal;



HD9ST0037L HD9ST0037L



2



357ANU002L



or D Press/turn the accelerator pedal (demanding a higher speed than set) for more than 60 seconds. The set speed disappears from section “A” of the display (Fig. 2). Following deactivation, it is possible to revert to the previous settings by pressing (RESUME) the push button again. If the set speed is no longer achievable the device cuts-out automatically. To prevent disabling the engine brake or intarder on downhill stretches, the Cruise Control remains active if the brake pedal is pressed at speed over 4 kph.



1
477



HD9 Euro3



357ANU054L



Temporary disable Proceed as follows: D Operate the clutch pedal (if present) the system shifts to stand-by. After disengaging the clutch the vehicle returns to the cruising speed set previously. D Press/turn the accelerator pedal for more than 60 seconds. As soon as the accelerator is released the function automatically resumes at the last set value. The speed set in section “A” of the display (Fig. 1, ref. 1) appears shaded.



1
478



HD9 Euro3



1



357ANU049L



2



357ANU055L



A.B.S. ANTI-LOCK BRAKING SYSTEM The A.B.S. system provides optimal braking and perfect vehicle control in all conditions. in particular: D it prevents wheel locking while braking in any road conditions; D it reduces stopping distance; D increases safety for the driver who can maintain vehicle stability and direction. Functioning check or any faults on the ABS system are indicated with the ignition key on “MAR”. 1. Tractor ABS (yellow) (Fig. 1); also the generic warning light switches on. This indicates a fault on the tractor ABS system. 2. Trailer ABS (yellow) (Fig. 2); also the generic warning light switches on. This indicates a fault on the trailer ABS system. When there is an A.B.S. circuit fault. the vehicle braking related to that circuit takes place in normal mode. In any case it is necessary to go as soon as possible to the nearest After Sales dealership .



1
479



HD9 Euro3



1



357ANU028L



2



DIAGNOSTICS Press key 1 (MENU/OK) on the steering wheel to display the “DIALOGUE MENU”. Press key 4 (Y/B) on the steering wheel to select the CHECK function (the window of the selected function lights up in yellow). Press key 1 (MENU/OK) on the steering wheel to access the CHECK page that displays the faults regarding the vehicle control units (Fig. 1, 2). Press key 4 (Y/B) on the steering wheel to scroll the control units and any faults. Press key 1 (MENU/OK) on the steering wheel to return to “DIALOGUE MENU”. Pressing key 3 (ESCAPE) on the steering wheel or not pressing any key on the steering wheel for 30 seconds, the “VEHICLE MOTION” page returns.



357ANU029L



1
480



HD9 Euro3



1



357ANU028L



2



357ANU029L



Press key 4 (Y/B) on the steering wheel to scroll the control units and any faults (Fig. 1, 2). The diagnostic systems are the following: 1. ECM (engine control unit) 2. ABS (brakes/traction control unit) 3. UDS (AdBlue additive dosing control unit) 4. VCM (vehicle control unit) 5. IBC (body computer control unit ) 6. ETC (automated transmission control unit) 7. EST (intarder control unit)



1
481



HD9 Euro3



1



The information is set out in three columns: Faults no longer present when the “CHECK” page is viewed are grey, and remain less visible than faults that are still active. ECU control unit faults are not displayed when the engine is running.



357ANU028L



2



ECU Indicates the control unit



357ANU029L



DTC Displays the relevant fault code



FMI Indicates the type of fault



1
482



HD9 Euro3



1



357ANU240L



DIAGNOSTICS --- CONNECTIONS FOR CONTROL SYSTEMS Use of jack 1 30---pole connector For connection with the specific IVECO diagnostics tool. There are the following diagnostics systems: D ECM (engine control unit); D ABS (brakes/traction control unit); D UDS (AdBlue additive dosing unit); D VCM (vehicle control unit); D IBC (body computer control unit); D ETC (automated transmission control unit); D EST (intarder control unit).



HD9 Euro3



1
483



FUSE / RELAYS HOLDER PLATE



342BNM023L



1
484



HD9 Euro3



FUSES Fuse holder (70005) FUNCTION



POSITION



CAPACITY (A)



1



DTCO – Cluster



3



2



DTCO – Cluster



5



3



IBC2



5



4



Left low beam, right main beam headlights and cab IBC2



10



5



Right low beam, left main beam headlights and symbol panel IBC2



10



6



Right side position lights and rear fog light IBC2



10



7



Left position side lights --- braking lights IBC2



10



8



Turn indicators IBC2



10



9



Windshield wiper IBC2



10



10



Fog light – work headlight – day lighting



10



11



Reverse gear



10



12



Pivotable headlights – horn – air horns



15



13



Alternator --- Vehicle service equipment



5



14



Solenoid valves VGT – Synchro protection – differential locks – solenoid valves PTO



10



15



Heated fuel pre-filter



15



16



Brakes air drier – fuel filter water detector sensor



5



17



Ignition key-brake pedal



3



18



Climate control --- Heater



20



19



Cigar lighter – 24V/12V voltage reducer –MC net



20



20



Electric window risers



20



1
485



HD9 Euro3 Fuse holder (70601) FUNCTION



POSITION



CAPACITY (A)



1



Trailers ABS



30



2



ABS control unit



15



3



ABS control unit



5



4



OBD socket – refrigerator . 30---pole diagnostics socket



10



5



SCR control unit



10



6



SCR control unit



3



Fuse holder (70602) FUNCTION



POSITION



CAPACITY (A)



1



ECM control unit



15



2



ECM control unit



5



3



VCM control unit



10



4



VCM control unit



5



5



+ 30 outfitters



15



6



+ 30 outfitters



10



Fuse holder (70401) FUNCTION



POSITION



CAPACITY (A)



1



Mirror heater



10



2



Centralised closure – motor-heated mirrors



10



3



Centralised closure



10



4



+ 30 trailer



20



1
486



HD9 Euro3



Fuse holder (70402) FUNCTION



POSITION



CAPACITY (A)



1



Heated seats



7,5



2



Intarder



10



3



Intarder



10



4



---



---



Fuse holder (70403) FUNCTION



POSITION



CAPACITY (A)



1



AsTronic/Allison control unit



10/15



2



AsTronic/Allison control unit



10/15



3



Preparation



15



4



Heated diesel water separator



20



1
487



HD9 Euro3 RELAYS DESCRIPTION



REF.



CODE COMPONENT



001



Relay for climate control



25332



002



Emergency engine stop relay



25205



003



Automatic transmission reverse light relay



25030



004



Second speed limit request relay



005



Horn relay



25805



006



Lights on relay



25806



007



Flywheel PTO engagement enable relay



25701



008



PTO diodes holder



61000



009



PTO1 engagement relay



25704



010



PTO2 engagement relay



25897



011



PTO3 engagement relay



012



Engine starter relay



(outfitters)



013



Engine stop relay



(outfitters)



014



SET adjustment relay +( outfitters)



(outfitters)



015



SET adjustment relay --- ( outfitters)



(outfitters)



016



PTO engaged confirmation relay



(outfitters)



017



Idle gear confirmation relay



(outfitters)



018



External cruise activation relay



(outfitters)



019



PTO engagement relay with vehicle stationary



(outfitters)



---



25898



1
488



HD9 Euro3



RELAYS DESCRIPTION



REF. A



---



B



Vehicle lock relay with doors open



C



---



D



---



E



Power steering 2 fault warning light relay



CODE COMPONENT --25500 ----25868



F



PTO solenoid valves diodes holder



G



Terminal 15a/50A relay



(outfitters) 25,213A



H



40A engeine start relay



25200



I



Fuel pre-filter heating relay



25825



L



Terminal 15b/50A relay



25213B