Supplemental Manuals_Peterbilt Model 210

Table of contents
Warnings and safety regulations
Warning symbols .................................................................................................. 14
Warnings and safety regulations ........................................................................ 16
Technical items of special importance ...............................................................21
Airbag safety instructions ................................................................................... 26
Alarm system
The system ............................................................................................................ 32
Use of the hand-held transmitter......................................................................... 32
Self-diagnosis ....................................................................................................... 33
Use when staying in the cab................................................................................ 34
Deactivation loadspace detection superstructure/trailer.................................. 35
The system LED .................................................................................................... 36
Loss of hand-held transmitter .............................................................................37
System does not respond to hand-held transmitter.......................................... 37
Battery, hand-held transmitters........................................................................... 38
Maintenance .......................................................................................................... 38
Disconnecting the vehicle battery....................................................................... 38
Cab, instruments and controls
Cab ......................................................................................................................... 40
Cab ................................................................................................................ 40
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Table of contents
Entering and leaving the vehicle ................................................................... 40
Doors............................................................................................................. 41
Electrically operated windows ....................................................................... 43
Mirrors ........................................................................................................... 44
Electrical mirror adjustment ........................................................................... 45
Windscreen wiper blades .............................................................................. 45
Bunks ............................................................................................................ 46
Roof console - oddments shelves ................................................................. 46
Tool boxes/storage compartments ................................................................ 47
Roof hatch ..................................................................................................... 48
Adjusting roof spoiler ..................................................................................... 48
Sun visors...................................................................................................... 50
Stepwell lighting ............................................................................................ 50
Interior lighting ............................................................................................... 51
Bunk lamp ..................................................................................................... 52
Instruments and controls .................................................................................... 53
Dashboard ..................................................................................................... 53
Instrument panel............................................................................................ 56
Warning indicators......................................................................................... 60
Control panel ................................................................................................. 66
Control panel of heating/ventilation system................................................... 70
Air conditioning switch ................................................................................... 71
Fan speed selector switch ............................................................................. 73
Temperature adjustment ............................................................................... 74
Air distribution selector switch ....................................................................... 76
Centre console .............................................................................................. 77
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Table of contents
Roof console.................................................................................................. 83
Left-hand steering column switch .................................................................. 85
Right-hand steering column switch................................................................ 87
Steering column switch, engine brake ........................................................... 88
Adjustable steering column............................................................................ 89
Auxiliary cab heater (air heating) ................................................................... 89
Seats
Important points ................................................................................................... 96
Seat settings .........................................................................................................97
Seat belts ............................................................................................................... 99
Master display
General ................................................................................................................ 104
Layout of master display ................................................................................... 105
Start-up phase..................................................................................................... 106
Menu selector switch .........................................................................................108
Menu overview .................................................................................................... 110
Faults ................................................................................................................... 112
Warning symbols ................................................................................................ 113
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Table of contents
Inspections and maintenance
Inspections.......................................................................................................... 120
Overview of daily checks ............................................................................. 120
Opening the front panel ............................................................................... 121
Engine oil level ............................................................................................ 121
Topping up coolant ...................................................................................... 122
Screen washer reservoir fluid level ............................................................. 124
Air filter indicator.......................................................................................... 125
Wheels and tires.......................................................................................... 126
Lighting and instruments ............................................................................. 126
Driver's seat and mirrors ............................................................................. 127
Trailer vehicle .............................................................................................. 127
Overview of weekly checks ......................................................................... 128
Clutch fluid level .......................................................................................... 128
Power steering fluid level ............................................................................ 129
Brake system air drier ................................................................................. 130
Draining the water separator ....................................................................... 131
Batteries ...................................................................................................... 132
Maintenance........................................................................................................ 134
General maintenance .................................................................................. 134
Lubricating fifth wheel/trailer coupling ......................................................... 135
Cab maintenance ........................................................................................ 136
Cleaning ...................................................................................................... 136
Preventative maintenance before the winter season .................................. 139
Diesel fuel.................................................................................................... 139
Cab heater................................................................................................... 140
Windscreen washer reservoir ...................................................................... 140
Maintenance after the winter season .......................................................... 141
Cooling system ............................................................................................ 141
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Table of contents
Coupling and uncoupling
Trailer coupling ................................................................................................... 144
Fifth wheel ........................................................................................................... 149
Connecting up the brake lines of a trailer ........................................................ 156
Connecting up the brake lines of a trailer with ABS or EBS .......................... 157
Connecting up the trailer vehicle lights (24V electrical system).................... 161
Driving
General ................................................................................................................ 164
Steering lock/contact/starter switch ................................................................. 165
Glow system........................................................................................................ 165
Starting procedure.............................................................................................. 166
Immobiliser fault ................................................................................................. 167
Engine speed control .........................................................................................168
Cruise control ..................................................................................................... 171
Vehicle speed limitation for special applications ............................................ 174
Driving style ........................................................................................................ 174
Differential lock................................................................................................... 175
Steering ............................................................................................................... 176
RAS-EC system................................................................................................... 176
ASR (Anti Slip Control)....................................................................................... 177
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Table of contents
ABS brakes ......................................................................................................... 178
Parking brake and service brake ...................................................................... 179
Engine brake ....................................................................................................... 180
Stopping .............................................................................................................. 181
Manual gearbox
ZF gearbox .......................................................................................................... 184
Eaton gearbox..................................................................................................... 186
Automatic gearbox
Allison 1000 & 2000 series................................................................................. 190
Allison MD3060 ................................................................................................... 192
Air suspension
General ................................................................................................................ 200
Remote control ................................................................................................... 201
Engaging air suspension................................................................................... 203
Setting memory keys (M-keys).......................................................................... 203
Stop button ......................................................................................................... 204
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Table of contents
Emergency repairs
Vehicle tool kit .................................................................................................... 206
Tilting the cab ..................................................................................................... 206
Replacing the poly-V belt ................................................................................... 209
Replacing the fuel fine filter............................................................................... 211
Bleeding the fuel system ................................................................................... 212
Draining the water separator ............................................................................. 213
Releasing the parking brake .............................................................................. 214
Wheel winch ........................................................................................................ 214
Jacking up the front axle ................................................................................... 215
Jacking up the rear axle ..................................................................................... 216
Changing the wheel ............................................................................................ 217
Tire inflating connection .................................................................................... 221
Towing ................................................................................................................. 222
Replacing bulbs .................................................................................................. 224
Fuses and relays................................................................................................. 230
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Table of contents
Technical data and identification
Technical data..................................................................................................... 236
Engine ......................................................................................................... 236
Electrical system ......................................................................................... 238
Wheels ........................................................................................................ 239
Tire pressure table ...................................................................................... 240
Lubricant-, engine coolant- and fuel specifications ..................................... 242
Engine oil..................................................................................................... 244
Coolants ...................................................................................................... 245
Diesel fuel.................................................................................................... 247
Steering gear ............................................................................................... 248
Cab tilting mechanism ................................................................................. 248
Clutch .......................................................................................................... 248
Identification ....................................................................................................... 249
Chassis number .......................................................................................... 249
Engine number ............................................................................................ 249
Engine identification plate ........................................................................... 250
Paint identification plate .............................................................................. 250
Vehicle identification plate ........................................................................... 251
ALR type plate ............................................................................................. 251
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Table of contents
Consumer Information
Federal Safety Standard Certification Label .................................................... 254
How To Order Parts ................................................................................. 254
NHTSA Consumer Information............................................................... 254
Canadian Consumer Information ........................................................... 255
State of California ..................................................................................... 255
California Proposition 65 Warning ............................................................... 256
Alphabetical index
Alphabetical index .............................................................................................. 258
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Table of contents
10
WHY THIS HANDBOOK IS SO IMPORTANT!
This handbook contains the information which you, the driver, will need for optimum
efficiency, safety and comfort when operating this vehicle.
Besides giving instructions about operation and use, it also pays attention to
maintenance and minor repairs which you may be able to carry out yourself.
Note:
This handbook is based on the chassis with its fittings as it originally left the factory.
Depending upon the required body and equipment, the bodybuilder may have made
fundamental changes to various parts or systems, such as the instrument panel, the
lighting or the electric wiring.
The vehicles covered by this handbook consist of various types and models.
Individual vehicles are furthermore constructed in accordance with the legal
regulations in the country concerned and in accordance with the expected operating
conditions. Certain descriptions or illustrations in this handbook may therefore not
correspond entirely to the situation on your own vehicle. However, this has
practically no influence on its operation or maintenance.
11
Important
Make sure this handbook is in the vehicle at all times.
Read it carefully before making your first journey, especially the "Warnings and
safety precautions", "Cab, instruments and controls", "Inspections and
maintenance" and "Driving" sections.
12
Warnings and Safety Regulations
13
Warnings and Safety Regulations
D000500
WARNING SYMBOLS
To ensure the highest level of safety in the operation of your vehicle, various
warnings are included in this handbook. Each warning is indicated by a special
warning symbol.
When text is accompanied by the adjacent warning symbol, this indicates that the
information in question is very important for the health and/or safety of those
concerned.
Disregarding this information may result in serious damage, injury or even death.
14
Warnings and Safety Regulations
D000501
When text is accompanied by the adjacent warning symbol, this indicates that the
information in question is very important for the operating safety of the vehicle.
Disregarding this information may result in the loss of directional stability, steering
problems or the vehicle otherwise getting out of control, causing serious damage,
injury and other life-threatening situations.
15
Warnings and Safety Regulations
}
WARNINGS AND SAFETY REGULATIONS
To prevent damage to the vehicle and in order not to jeopardise
your health and/or safety, or that of other people, the following
warning and safety regulations must be strictly observed.
First read the instructions and warnings on the labels and stickers on the various
components and comply with them!
They have been put there for your health and safety, so do not ignore them!
Modifications to the vehicle
Modifications to the vehicle or the vehicle configuration may require the
reprogramming of electronic units by an approved an authorized dealer.
Engine
Do not run the engine in an enclosed or unventilated area.
Make sure exhaust gases are properly extracted.
Components
Remain at a safe distance from rotating and/or moving components.
Cooling system filler cap
Do not remove the filler cap of the cooling system when the engine is at operating
temperature. Do not loosen the filler cap of the cooling system when the cab is
tilted.
16
Warnings and Safety Regulations
Warning triangle
Ensure that you are always in possession of a hazard warning triangle (obligatory in
certain countries), possibly in combination with other marking equipment.
In the event of a breakdown en route, wear reflective clothing when outside the
vehicle.
Fire extinguisher
Ensure that you are always in possession of a fire extinguisher (obligatory in certain
countries). It should be well secured under the seat, within the driver's reach and
easily accessible, also for rescue workers and others providing assistance. Have
the fire extinguisher checked for operational readiness each year. If it has been
used, have it refilled at the earliest opportunity.
In the event of fire:
In the event of a fire, certain plastic seals can produce gases which together with
water form a corrosive acid. Therefore do not touch any fire extinguisher fluid on the
vehicle without protective gloves.
Cab
Make sure there are no loose objects on the floor on the driver's side. Bottles, cans
etc. may get stuck under the brake pedal while driving, giving rise to extremely
dangerous situations.
While driving, do not use the clutch pedal as a footrest since this may cause
excessive wear of the clutch.
First aid kit
Ensure that you are always in possession of a first aid kit (obligatory in certain
countries). Replace first aid items as soon as possible after use to make the kit
complete again.
17
Warnings and Safety Regulations
Winter conditions
When winter driving conditions are expected (especially if the vehicle is operated in
mountainous areas), make sure that your vehicle is fitted with winter tires or that you
have snow chains with you. Also refer to "Maintenance operations before the winter
season" in "Inspections and maintenance".
Load
The load should always be properly secured so that it cannot move, not even during
an emergency stop. Remember that sidewalls, partitions, etc. are often not
designed to withstand high forces.
Loads must not project more than is permitted by local regulations.
Bear in mind that the stability of the vehicle may be impaired by the load and that
you may also need a larger turning circle.
Make sure when loading that the following values are not exceeded:
-
maximum permissible gross combination weight (GCW)
maximum permissible gross vehicle weight (GVW)
maximum permissible axle load
Oils and lubricants
Various kinds of oil and other lubricants used on the vehicle may constitute a health
hazard if they come into contact with the skin.
This also applies to engine coolant, windscreen washer fluid, refrigerant in air
conditioning systems, battery acid and diesel fuel.
So avoid direct contact as much as possible.
The engine and the surrounding area must be free of inflammable materials to avoid
the risk of fire.
Exercise caution when changing hot oil; it can cause serious bodily injury.
18
Warnings and Safety Regulations
Maintenance activities
When carrying out maintenance work under the cab, make sure the cab is fully tilted
and locked to prevent it from falling back accidentally.
If a cooler box/refrigerator has been fitted, it should be switched off and if necessary
unplugged before tilting (depending on the type).
The cooler box/refrigerator should remain switched off at least 30 minutes after the
cab has been tilted back.
Following a collision, only tilt the cab in an emergency situation.
The tilting mechanism may be damaged.
(The end stop may no longer be on the lifting cylinder.)
Always use stands to support the chassis when carrying out work under a vehicle
which is resting on a jack.
19
Warnings and Safety Regulations
Maintenance of air conditioning system
The air conditioning system contains coolant under high pressure. Removal of any
parts of the air conditioning system is not permitted. Work on the air conditioning
system may only be carried out by qualified personnel.
If the air conditioning fails to work, it must be repaired by a dealer as soon as
possible, to avoid further damage to the system.
Environment
Pollution constitutes a serious threat to the environment. To keep pollution to a
minimum, the following rules should be observed:
-
-
20
Do not dump used oil, fuel, lubricants, hydraulic fluid or coolants in drains,
sewers, in landfills or on the ground. This is illegal. These fluids should be
returned to the designated authority or appropriate chemical waste collection
company for recycling or destruction. All used fluids should be stored separately.
Make sure that the vehicle is serviced regularly according to the instructions and
recommendations. A properly serviced vehicle helps to optimise fuel economy
and reduce the level of harmful constituents in the exhaust gases.
Warnings and Safety Regulations
TECHNICAL ITEMS OF SPECIAL IMPORTANCE
To prevent damage to the vehicle, the following instructions must be strictly
observed.
Running-in
During the running-in period it is best not to subject the new vehicle to excessive
loads. This also applies when an overhauled engine, gearbox or differential has
been installed. Therefore, for the first 1,500 km (932 miles): drive carefully and
avoid accelerating sharply.
The following technical items of special importance apply to both the runningin period and to the period thereafter.
After a cold start continue to drive in a low gear and at a moderate engine speed
until the engine coolant temperature is out of the blue zone.
While driving, check the instrument panel regularly and take appropriate action if
you notice anything unusual, such as strange engine and transmission noises,
smoke, or poor performance.
Do not let the engine idle for longer than necessary.. This is harmful to the engine
and also causes unnecessary pollution of the environment.
Be aware that engine stalling while driving will lead to power steering failure.
Consequently, the vehicle will be more difficult to steer.
Before switching off the engine after a long trip or when the engine has been
subjected to high loading, let it idle for at least 5 minutes. It is important to let the
engine run for a while in order to prevent the coolant temperature becoming too high
and to allow the turbocharger to cool down.
The engine cooling system is thermostatically controlled.
21
Warnings and Safety Regulations
Removing the thermostat when the coolant temperature is (too) high serves no
useful purpose and is strongly advised against, since this will only cause the engine
temperature to rise to an even higher level.
The turbocharger is a precision component. You should therefore immediately
report any abnormal noise that seems to be coming from this component.
Air leakage
If the pressure in the air reservoirs drops rapidly with the engine switched off, this
indicates a leak. Since this affects the safety of the brake system, the leak must be
traced and repaired as quickly as possible.
System voltage
The vehicle is equipped with a 24-Volt electrical system.
When replacing or fitting electrical or electronic components, always verify that they
are suitable for this system voltage.
}
}
Batteries
Never disconnect the battery leads while the engine is running!
Always charge batteries in a properly ventilated area and avoid
sparking and naked flames due to the danger of explosion.
Always disconnect the battery earth lead before carrying out repairs or service on
the electrical system.
Never place tools on a battery. This may cause a short circuit and may even cause
the battery to explode.
22
Warnings and Safety Regulations
}
Charging
Thaw out frozen batteries before charging them. Remove all the
filler caps before charging.
Connect the positive lead (+) of the battery charger to the positive terminal (+) of the
battery first and then the negative lead (–) to the negative terminal (–).
After charging, switch off the battery charger and then disconnect the negative
terminal (–) and subsequently the positive terminal (+).
For normal charging, the battery leads may remain in place.
Fast charging should only be used in an emergency. For "fast charging" both
battery leads must be disconnected, otherwise the electronics may become
defective.
Battery capacity
Using electrical components, such as the cab heater or refrigerator when the engine
is not running, power will be drawn from the batteries.
Approximately half the battery capacity is required to start the engine.
If this is the case over a protracted period, particularly during low temperatures, the
result may be that the electrics have used so much power that there is not enough
to start the engine.
If the larger consumers, such as the cab heater, refrigerator, coffee percolator,
microwave oven or tail-lift are used, it is recommended that you obtain batteries of a
higher capacity in consultation with your dealer.
23
Warnings and Safety Regulations
Welding
For welding on the vehicle and/or superstructure, see the "Workshop manual" and
"Bodybuilders Guidelines".
Not following the welding instructions can cause damage to the electronic
components.
Starting with auxiliary batteries
The engine may be started with the aid of jump leads using the power from separate
auxiliary batteries (approx. 24 V) or from another vehicle with the engine running
(approx. 28 V). When this starting procedure is followed, the battery leads
must not be disconnected. Connect the jump leads first to the positive terminal (+)
and then to the negative terminal (–). To disconnect, first release the negative
terminal (–) and then the positive terminal (+).
In the event that the batteries are fully discharged and the engine is running, it is
important that the jump leads are not immediately disconnected. The engine must
be allowed to run for at least 2 to 3 minutes before the jump leads are disconnected
to prevent damage to the electrical system (peak voltage!).
Proceed as follows as soon as the engine starts running:
-
switch on as many power consumers as possible (for example: headlights, fog
lamps, heater fan, etc.);
remove the jump leads after the engine has run for 2 to 3 minutes;
switch off the consumers again.
Never start the engine using a fast charger!
24
Warnings and Safety Regulations
Mobile telephones and transmitters
If mobile telephones and transmitting equipment are used, the following points must
be taken into account:
-
Mobile telephones or transmitters must not be used in the vehicle without a
separate outside aerial!
}
-
The use of mobile telephones or transmitters without a separate
outside aerial may cause excessively high electromagnetic fields in
the cab interior (resonance effect). In this case, there may be
interference to the operation of the vehicle electronics.
Moreover, an outside aerial is necessary in order to achieve the maximum range
of the equipment.
Note:
It is important to observe the instructions for use of mobile telephones and
transmitters!
Original components
In order to meet the warranty conditions and guarantee the service life, safety and
reliability, the use of non original components, sensors and engine management
units/software is not permitted. The application of engine management software that
has not been approved will adversely affect critical systems in terms of the safety of
the vehicle, the braking system for instance.
25
Warnings and Safety Regulations
AIRBAG SAFETY INSTRUCTIONS
Vehicles equipped with an airbag and seat belt tensioner system can be identified
by a sticker with the airbag symbol on the windscreen and the word "AIRBAG" on
the airbag unit on the steering wheel. A vehicle equipped with an airbag also has an
automatic seat belt tensioner.
}
Equipment or objects using strong electromagnetic radiation in the
vicinity of the airbag or seat belt tensioner system may cause this
system to fail or, in extreme cases, may cause the system to be
activated. The use of such equipment or objects in the vicinity of
airbag/seat belt tensioner systems is therefore not recommended.
Work
- The safety precautions laid down must be observed when repairing, removing or
replacing the airbag or seat belt tensioner system or parts thereof. For this
reason, have this work carried out by an approved Service dealer or workshop
only.
- Do not make any modifications to the airbag and seat belt tensioner system or
parts thereof. This would cause an injury hazard and correct activation can then
no longer be guaranteed.
- Safety precautions regarding the airbag and seat belt tensioner system must be
observed when the vehicle is scrapped or dismantled.
- Retrofitting of accessories is only permitted if the accessories have been
approved for vehicles with an airbag and seat belt tensioner. Installation must
take place at the position indicated and according to the procedure specified by.
26
Warnings and Safety Regulations
-
-
When replacing the windscreen, observe a longer drying time for the
windscreen sealant. This longer drying time is usually stated on the windscreen
sealant packing/tube. If in doubt, contact an authorized dealer or the
windscreen sealant supplier.
If any welding is required, observe safety precautions for welding jobs.
Operation
- The airbag and seat belt tensioners are activated in the event of a (nearly) headon collision when a specific vehicle deceleration is exceeded. The airbag and
seat belt tensioners will not be activated when:
- the ignition is switched off.
- the vehicle is involved in a minor head-on collision.
- the vehicle is involved in a lateral collision.
- the vehicle is involved in a tail collision.
- the vehicle overturns.
- The system only provides optimal protection when the seat belt is correctly worn
and the seat, seat belt and steering wheel are well adjusted to the driver.
Do not keep any parts of the body (trunk, hand, head, foot)
unnecessarily close to the airbag cover.
}
}
}
The space between the driver and airbag must be free. Do not
place any animals, objects or persons between the driver and
the airbag.
Hold the steering wheel by the outer rim as much as possible to
allow unimpeded deployment of the airbag.
27
Warnings and Safety Regulations
Activation
- If the airbag is activated in a collision, a white powder/gas will be released. This
is in no way an indication of fire. The powder itself is not health-damaging.
- The airbag and seat belt tensioners can be activated only once. After activation
of the system the parts must be replaced by an authorized Service dealer to
provide the same protection.
- In the event of a minor collision not causing the airbag and seat belt tensioner
system to be activated, it is recommended to have the system checked as yet by
an authorized Service dealer.
}
}
28
The airbag fabric could cause slight injury because of the rapid
movement of the airbag during activation. People wearing
spectacles and persons smoking when driving run an increased
risk of facial injury in a collision involving deployment of the airbag.
Usually the injuries are by no means as serious as the injuries that
may occur in a collision without airbag and seat belt tensioners.
Avoid touching parts of the airbag shortly after deployment of the
airbag unit because they may be hot.
Warnings and Safety Regulations
Inspections
- The system is only functioning correctly if:
- after turning the ignition on, an airbag message appears on the master
display which disappears after approx. 5 to 10 seconds.
- The system is not functioning correctly if:
- after turning the ignition on, no airbag message appears on the master
display.
- the airbag message on the master display has still not disappeared after
approx. 10 seconds after turning on the ignition.
- the airbag message appears on the master display when driving.
- If the system signals a fault, it will be unable to activate the airbag and/or seat
belt tensioners and will therefore not provide extra protection in the event of a
collision. Have the fault remedied by an approved Service dealer as soon as
possible.
29
Warnings and Safety Regulations
Maintenance
- Clean the airbag cover only with a dry or damp cloth. If it is heavily fouled, ask
an authorized Service dealer for an approved cleaning agent.
Do not stick anything to the airbag cover. Do not treat the cover
with a cleaning agent, solvent, grease, paint, lacquer or other
substance.
}
}
-
Check that the cover of the airbag unit is not damaged. Do not
damage the tear seams or the cover of the airbag unit.
After a maximum of 15 years the main components of the airbag and seat belt
tensioner system must be replaced by an authorized Service dealer. This does
not apply to the electronic unit, which must be replaced after 10 years.
Sales
- If ownership of the vehicle is transferred, the previous owner must make the new
owner aware of the above instructions.
30
Alarm System
31
Alarm System
THE SYSTEM
The theft protection system consists of several forms of protection, which each
protect the vehicle in a different way:
-
The immobiliser (electronic drive-off lock) prevents the engine from being
started without the correct key.
Note:
If a vehicle does not have an alarm system but it does have an immobiliser,
there will always be a system LED. This LED will flash at a low frequency when
the ignition is switched off.
-
The acoustic and visual alarms ensure that, as soon as unauthorised persons
gain access to the vehicle, this can be seen and heard from outside.
USE OF THE HAND-HELD TRANSMITTER
The alarm system is activated by pressing the button (1) on the hand-held
transmitter. The warning lights will come on for 3 seconds.
1
2
Do not press the hand-held transmitter buttons unnecessarily hard. Check whether
the system is working with the warning lights.
The doors, cab tilting mechanism, interior and loadspace (if this has an alarm
system) are now protected.
In addition, the starting option is now locked.
The system LED will flash at a slow rate after approx. 50 seconds.
32
Alarm System
The system is now fully operational.
Ensure that there is nothing in the interior that can cause a false alarm, e.g. moving
objects in the cab.
Pressing the button (2) on the hand-held transmitter results in the system
deactivating itself. This is indicated visually by the warning lights lighting up 3 times.
SELF-DIAGNOSIS
The electronic anti-theft system has an extensive self-diagnostic function. Following
activation, all detection circuits (for the interior, grille, cab tilting mechanism and
doors) are automatically tested.
If a fault is found in one or more of these detection circuits, the affected circuit(s) is
(are) switched off. This is made noticeable by a short signal from the siren
immediately after activation of the alarm system.
If this signal is heard, first of all check whether the windows and/or doors are closed
properly.
Turn the alarm system off, close everything carefully and switch on the alarm
system again. If the short signal is heard once again, this means that the system is
(partially) defective. You should then have the system looked at by your authorized
Service dealer.
33
Alarm System
USE WHEN STAYING IN THE CAB
If people remain in the vehicle, the system may only be activated if the interior
protection is switched off. This avoids unnecessary sounding of the alarm.
The interior protection is deactivated as follows:
1. Deactivate the alarm system.
2. Press the "Switch off interior detection" switch. See "Cab, instruments and
controls". The system LED will come on for approx. 2 seconds.
3. Then activate the alarm system with button (1) on the hand-held transmitter. The
interior protection has now been switched off. It is then possible to stay in the
cab while retaining the other detection options.
If you want to leave the cabin from time to time, you must turn off the entire system
using button (2) on the hand-held transmitter.
Outside the vehicle, you can now make the choice between:
- not activating the alarm system, or
- Activating the alarm system.
On returning to the cabin, you must carry out the procedure once again, to
deactivate the interior protection.
Note:
If the interior protection is not activated, the alarm still works on the doors and the
cab lock. The start lock is also activated.
34
Alarm System
DEACTIVATION LOADSPACE DETECTION SUPERSTRUCTURE/TRAILER
If you need to access the loadspace of the superstructure/trailer while retaining the
remaining detection options, the system can only be activated if the loadspace
detection is switched off. This avoids unnecessary sounding of the alarm.
The loadspace detection is deactivated as follows:
1. Deactivate the alarm system.
2. Press the "Switch off loadspace detection superstructure/trailer" switch. See
"CAB, INSTRUMENTS AND CONTROLS". The system LED will come on for
approx. 2 seconds.
3. Then activate the alarm system with button (1) on the hand-held transmitter. The
loadspace detection has now been switched off. It is then possible to stay in the
loadspace while retaining the other detection options.
To protect the loadspace again, the alarm system should first be switched off and
then back on again.
35
Alarm System
THE SYSTEM LED
If the LED is off (A), the vehicle may be started.
If the LED flashes slowly (B), the alarm system has been activated.
If the LED flashes quickly (C), a self-test will be carried out or an error message is
given by means of a flashing code.
A
B
If the system raised an alarm, the cause can be determined via the system LED by
reading the flashing code (C).
This indication is displayed for 30 seconds after the system has been deactivated
with button (2) of the hand-held transmitter.
C
D000483
36
Flashing code Circuit
2
Ultrasonic, interior detection
3
Detection, driver's door
4
Cab detection approximation switch
5
Power supply after contact
6
Superstructure/trailer loadspace detection
8
Superstructure/trailer loadspace detection
9
Interrupted wire
10
Detection, co-driver's door
11
Radar sensor, interior detection
Alarm System
LOSS OF HAND-HELD TRANSMITTER
If you lose a hand-held transmitter, you must replace it as soon as possible.
When replacing it, the lost transmitter can be rendered unusable by erasing
the code from the central door locking memory.
Without hand-held transmitters, the alarm system can only be switched off by
turning on the ignition.
SYSTEM DOES NOT RESPOND TO HAND-HELD TRANSMITTER
If the system does not respond to the hand-held transmitter, the following tips may
provide a solution:
1. Check whether the battery of the hand-held transmitter is still working. This is
indicated by whether or not the LED on the hand-held transmitter lights up.
2. If there is a strong radio transmitter in the area, the range of the hand-held
transmitter can be considerably less. Operate the hand-held transmitter as close
as possible to the electronic unit. It is located at the front of the vehicle, on the
driver's side.
3. If the system does not respond to the transmitter at all, you can switch off the
alarm system by opening the vehicle with the ignition key and then starting it.
The alarm system cannot be activated with the ignition key.
37
Alarm System
BATTERY, HAND-HELD TRANSMITTERS
Recommendation: Ensure that two spare batteries (type CR 1620, 3V) are
available at all times. Depending on the use, the battery life is between 3 and 12
months.
MAINTENANCE
Have the alarm system checked at least once per year by your authorized Service
dealer. This guarantees optimum protection.
Watch the ultrasound sensors on both sides of the roof box. Make sure that they do
not come loose or are pointed in a different direction. Ensure that the sensors have
an "unrestricted view"; they must not be blocked by objects that might interfere with
their operation.
Prevent the sensors from coming into contact with moisture or dirt.
DISCONNECTING THE VEHICLE BATTERY
If the battery has to be disconnected without activating the signal horn, the alarm
system should first be switched off using button 2 on the hand-held transmitter.
38
Cab, Instruments and Controls
39
Cab, Instruments and Controls
CAB
The LF series has two cab versions:
D cab.
Day cab
S-cab.
Sleeper Cab
D0 00 632
ENTERING AND LEAVING THE VEHICLE
To get into and out of the cab, use the grab handles on the left and right-hand door
pillars and not the steering wheel. Also use all the steps and always face the cab
when getting in or out.
40
Cab, Instruments and Controls
}
DOORS
Do not drive the vehicle if the doors are not properly closed and
locked!
D0 00 604
Opening the door
Pull the handle to open the door from the inside.
D0 00 611
41
Cab, Instruments and Controls
Locking the door from the inside
Press the door handle downwards.
Standard version
Both doors can be locked and unlocked from the outside using the key.
Central door locking
Unlocking
To open the doors of a vehicle with central door locking, use the same procedure as
described above.
The door on the co-driver's side can be locked/unlocked using the switch on the
centre console.
Locking
- Both doors are locked when one of the doors is closed with the key.
- To lock the doors from the inside, press button (B).
- If an alarm system has been installed, it will be activated if the doors are locked
using the hand-held transmitter.
- Avoid locking yourself out!
42
Cab, Instruments and Controls
D0 00 585
ELECTRICALLY OPERATED WINDOWS
The switches only work when the ignition is switched on.
The driver's and co-driver's windows can be opened and closed with the switches in
the driver's door. The switch in the co-driver's door can only open and close the codriver's window.
43
Cab, Instruments and Controls
D0 00 586
MIRRORS
To adjust the mirrors, the cover must first be removed.
D0 00 577
The clamping bolts must then be slackened.
The mirror bracket can be folded back against the cab and will return to its original
position once the bracket is swung out again.
44
Cab, Instruments and Controls
On some models there is an extra wide angle mirror on the co-driver's side, in
addition to the kerb view mirror, which gives the driver a better view of the drawn
vehicle.
0
D0 00 612
ELECTRICAL MIRROR ADJUSTMENT
The electric mirrors can be adjusted by means of the switch in the driver's door.
Select the right or left mirror by turning the button either to the right or left position.
Move the switch forwards, backwards, left or right, to adjust the mirror.
WINDSCREEN WIPER BLADES
To prevent damage to the wiper blades during operation in winter conditions,
always check that the blades are not frozen to the windscreen. This can be
prevented by placing something between wiper blades and windscreen. Switch off
the windscreen wipers before turning off the ignition.
45
Cab, Instruments and Controls
Clean the wiper blades regularly with water and dry them with a soft cloth.
BUNKS
Depending on the cab type, there is a bunk behind the seats. This bunk can fold
down or can be stored with the belts provided on the sides of the cab. There are
three lockable storage compartments under the bunk.
D000565
ROOF CONSOLE - ODDMENTS SHELVES
In the roof console there are three pigeon holes, which are protected by a half-high
safety net. Do not place any heavy objects in these pigeon holes and ensure that
any objects are constrained and unable to move freely.
46
Cab, Instruments and Controls
D0 00 603
TOOL BOXES/STORAGE COMPARTMENTS
Under the bunk or behind and between the seats (depending on the cab type), there
are storage compartments that can be closed with a covering flap.
D0 00 582
47
Cab, Instruments and Controls
ROOF HATCH
Manual control
The manually operated roof hatch can be opened on both sides by countering the
resistance met.
Electrical operation (optional)
The electrically operated roof hatch is opened and closed using a switch on the roof
console.
ADJUSTING ROOF SPOILER
Note:
Correct adjustment of the roof spoiler is essential to minimise fuel consumption.
P
1/2
X
X
D001033
1. Place the vehicle on a level and horizontal surface. Make sure that in the case of
a tractor/semi-trailer combination the tractor is straight in front of the semi-trailer.
2. Determine the centreline of the vehicle and put a slat on the superstructure roof
protruding into the cab direction.
48
Cab, Instruments and Controls
1/2
X
X
D001032
3. Both slats should cross at half the distance (∂ X) between the roof spoiler edge
and the start of the superstructure.
The roof spoiler height can be adjusted using adjusting mechanism (B).
P
B
D001031
4. Put another slat (as a tangent) onto the outer roof spoiler edge (P) pointing into
the direction of the superstructure.
49
Cab, Instruments and Controls
SUN VISORS
As a protection against sun glare, the sun visors can be folded down. The sun visor
on the driver's side can also serve as a side window shade.
STEPWELL LIGHTING
In both doors, a lamp is fitted at the bottom to light the stepwell. This will light up as
soon as the door is opened.
50
Cab, Instruments and Controls
INTERIOR LIGHTING
A
B
C
The lights come on when a door is opened.
Lights switched off.
Lights on all the time.
The interior lighting operates independently of the position of the ignition key.
The cab lighting also includes a map reading lamp. It can be switched on by
operating the bottom on/off switch.
51
Cab, Instruments and Controls
D0 00 573
BUNK LAMP
If the vehicle is equipped with a sleeper cab, there is a bunk lamp over each seat,
each with its own on/off switch.
52
Cab, Instruments and Controls
DASHBOARD
53
Cab, Instruments and Controls
1
!
23
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
!
22 21 20 19 18 17
D0 00 708
54
Cab, Instruments and Controls
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Instrument panel
Dimmer, dashboard lighting
Differential lock
Vehicle speed limiter
Front/rear fog lights
Menu selection switch
Ashtray with 24V lighter
Hazard warning lights
Work lamp/loadspace lighting
Mirror/windscreen heating
Suppression switch, reversing alarm
Electrical master switch, transport of hazardous materials
Door lock, co-driver's side
Not in use
PTO operation
Switching off loadspace detection, superstructure/trailer
Air conditioning
12-V connection
Heater, fan speed selector switch in fresh air position or re-circulation
position
Heater, temperature control
Heater, air distribution selector switch
Headlamp height adjuster
Lighting switch
55
Cab, Instruments and Controls
INSTRUMENT PANEL
B
C
D
!
A
F G
!
I
H
J
K
E
D0 00 634
56
Cab, Instruments and Controls
A
B
C
D
E
F
G
H
I
J
K
Speedometer
Fuel gauge
Master display
Coolant temperature gauge
Rev counter
Reset button, trip odometer
Odometer and trip meter
Warning indicators
Air pressure gauge, circuit 1
Air pressure gauge, circuit 2
Outside temperature and clock
57
Cab, Instruments and Controls
A. SPEEDOMETER
Depending on the vehicle model, the speedometer has a single scale division in km/
h or a double scale division in km/h and mph.
B. FUEL GAUGE
The fuel gauge only operates when the contact is on.
Factor in the delay on the gauge when the contact is turned on.
C. MASTER DISPLAY
See "MASTER DISPLAY".
D. COOLANT TEMPERATURE GAUGE
The engine should not be operated under full load if the temperature is in the blue
field.
The engine is at operating temperature when the temperature gauge is vertical, or
slightly further.
If the coolant temperature suddenly rises and/or the pointer is in the red field, the
following points should be checked:
-
the coolant level (caution – danger of scalding; see "Topping up coolant" in
"INSPECTIONS AND MAINTENANCE");
the poly V-belt and water hoses;
the fan clutch.
E. REV COUNTER
Green area: economical
White: less economical
Blue area: only permitted when driving downhill and for optimal use of the engine
brake
Red area: not permitted
58
Cab, Instruments and Controls
F. TRIP METER RESET BUTTON
The trip meter is set to zero with the reset button.
G. ODOMETER AND TRIP METER
The total distance is displayed in "km" or "mls" in the top section of the display.
H. WARNING INDICATORS
See section concerned.
I. and J. AIR PRESSURE GAUGE, CIRCUITS 1 AND 2
Each gauge indicates the air pressure in the reservoirs of one of the service brake
circuits. If the pressure in one of the circuits drops below approx. 5 bar, an acoustic
signal is generated and the warning symbol "Air system pressure too low" will
illuminate in the master display. When the pressure is higher than 7 bar, the brakes
can be released with the parking brake lever. The acoustic signal and warning
symbol are only generated when the contact is on. The gauges also operate when
the contact is off.
The vehicle must not be driven when the acoustic signal sounds or when the
pressure in one of the circuits is lower than approx. 5 bar.
K. OUTSIDE TEMPERATURE AND CLOCK
The display is activated when the contact is on.
The clock is shown in the top section of the display.
The outside temperature is displayed in the bottom section in C or F.
59
Cab, Instruments and Controls
WARNING INDICATORS
5
1
1
2
B
A
4
3
2
E
H
1
6
1
2
3
4
5
6
4
3
D0 00 786
60
Cab, Instruments and Controls
A1
Tachograph fault
A2
Front fog light
A3
Rear fog light
A4
Parking brake
A5
Chassis not at normal driving level
A6
Work lamp/loadspace lighting
B1
Fuel level low
E1
Glow system
E2
Differential lock
E3
PTO
E4
ASR
H1
Left direction indicator, prime mover
H2
Left direction indicator, trailer
H3
Main beam
H4
Central "STOP" warning indicator
H5
Right direction indicator, trailer
H6
Right direction indicator, prime mover
61
Cab, Instruments and Controls
A1. Tachograph fault
See "Messages" in "Tachograph" operating manual.
A2. Front fog light
This warning indicator lights up if the front fog lights are switched on.
A3. Rear fog light
This warning indicator lights up if the rear fog lights are switched on.
A4. Parking brake
This warning indicator lights up if the parking brake is applied, or when the pressure
in the air system is too low to enable the parking brake to be released.
A5. Chassis not at normal driving level
This warning indicator stays on continuously if the chassis is not at normal driving
height or when traction control is in operation.
A6. Work lamp/loadspace lighting
The warning indicator lights up when the work lamp/loadspace lighting is switched
on.
62
Cab, Instruments and Controls
B1. Fuel level low
This warning indicator lights up when the reserve fuel level is reached. The fuel
reserve then is about 10% of the tank capacity. Refuel as soon as possible.
E1. Glow system operating
If the contact is on, the electronic unit automatically determines the necessary
preglowing and afterglowing times.
The necessary preglowing and afterglowing times depend on the temperature that
is measured by the electronic unit of the engine management system.
If the preglowing or afterglowing function is activated by the electronic unit, this
warning indicator lights up.
E2. Differential lock switched on
This warning indicator lights up when the differential lock is switched on.
E3. PTO engaged
This warning indicator lights up when the PTO is switched on.
E4. ASR
This warning indicator lights up if the ASR is active.
63
Cab, Instruments and Controls
H1. Left direction indicator, prime mover
This warning indicator flashes together with the direction indicators on the prime
mover.
H2. Left direction indicator, trailer
On a truck/trailer or truck/semi-trailer combination, this warning indicator starts
flashing as soon as the direction indicators are switched on.
H3. Main beam
This warning indicator lights up if the main beam is switched on or the headlight
flash is operated.
H4. Central "STOP" warning indicator
The central "STOP" warning light lights up when there is a serious fault in one of
the vehicle functions. The master display shows which vehicle function has
triggered the warning.
}
64
If the "STOP" warning indicator lights up and/or the buzzer is
audible while driving, the vehicle must be stopped as soon as
possible, parked in a safe place and the engine switched off.
Have an authorized Service dealer correct the problem as soon as
possible.
Cab, Instruments and Controls
H5. Right direction indicator, trailer
On a truck/trailer or truck/semi-trailer combination, this warning indicator starts
flashing as soon as the direction indicators are switched on.
H6. Right direction indicator, prime mover
This warning indicator flashes together with the direction indicators on the prime
mover.
65
Cab, Instruments and Controls
CONTROL PANEL
2
!!
23
3
4
5
6
!!
22
21
20 19 18 17
D0 00 705
66
Cab, Instruments and Controls
2
3
4
5
6
17
18
19
20
21
22
23
Dimmer, dashboard lighting
Differential lock
Not in use
Depending on the version:
- rear fog light
- front and rear fog lights
Master display menu selection switch
Air conditioning
12-V connection
Heater, fan speed selector switch in fresh air position or re-circulation
position
Heater, temperature control
Heater, air distribution selector switch
Headlamp height adjuster
Lighting switch
67
Cab, Instruments and Controls
2. DIMMER, DASHBOARD LIGHTING
When the lighting is switched on, the dashboard lighting will also illuminate. The
setting wheel enables dimming of the lighting.
3. SWITCH FOR CROSS-AXLE DIFFERENTIAL LOCK
The cross-axle differential lock can be activated with this switch.
Note:
This switch has a lock.
The differential lock should be engaged:
- with the vehicle stationary or moving very slowly;
- with the clutch pedal depressed.
Note:
For vehicles with automatic gearbox, the vehicle must be stationary and the
gearbox in Neutral (N).
See also "DRIVING".
68
Cab, Instruments and Controls
5. FOG LAMPS, FRONT/REAR
The switch can be a two or three-position switch. When there are just the rear fog
lights, it will be a two-position switch. In case of rear fog lights and front fog lights, it
will be a three-position switch. In position 2 only the front fog lights are on. In
position 3 both the rear fog lights and the front fog lights are on. The switch springs
back from position 3 into position 2. If both are switched on, the relevant warning
indicators will light up on the display.
6. MASTER DISPLAY MENU SELECTION SWITCH
See "MASTER DISPLAY".
17. AIR CONDITIONING
See "CONTROL PANEL OF HEATING/VENTILATION SYSTEM"
18. 12V CONNECTION
A 12-V consumer can be hooked up to this connection, for example an inspection
lamp. Do not connect any high loads (max. 180 W).
19, 20, 21. HEATER CONTROLS
See "CONTROL PANEL OF HEATING/VENTILATION SYSTEM"
22. HEADLAMP HEIGHT ADJUSTER
With this switch, the headlamp beams can be aimed higher or lower as required by
the driver.
Note:
Do not dazzle oncoming traffic.
69
Cab, Instruments and Controls
23. LIGHTING SWITCH
The vehicle lighting switch is a rotary switch with three positions:
position "0": lighting switched off
position "1": parking and marker lights on
position "2": headlamps, parking and marker lights on
CONTROL PANEL OF HEATING/VENTILATION SYSTEM
21
20
19
17
D0 00 672
17
19
20
21
70
Air conditioning
Fan speed selector switch in fresh air or re-circulation position
Temperature adjustment
Air distribution
Cab, Instruments and Controls
17. AIR CONDITIONING
See "AIR CONDITIONING SWITCH"
19. FAN SPEED
See "FAN SPEED SELECTOR SWITCH"
20. TEMPERATURE CONTROL
See "TEMPERATURE CONTROL"
21. AIR DISTRIBUTION
SEE "AIR DISTRIBUTION SELECTOR SWITCH"
D0 00 566
AIR CONDITIONING SWITCH
The cab air can be heated, cooled or dehumidified using the air conditioning unit.
The air conditioning unit only functions if:
- the engine is running
71
Cab, Instruments and Controls
-
the fan is running.
Use of the air conditioning
1. When the air conditioning is in use, the windows must remain closed.
2. To reduce the temperature quickly, first use maximum air speed. Later, the air
speed can be reduced.
3. Avoid direct cold or draught on your body. Do not aim the air vents directly at
your body.
4. Make sure that the temperature difference between the inside and outside of the
cab does not exceed 5 C when you leave the cab. You are therefore advised to
switch off the air conditioning towards the end of your journey.
5. Air conditioning consumes extra power and increases the fuel consumption.
6. On extreme angles (slopes, ruts and difficult terrain) switch off the air
conditioning, to protect the compressor pump against unlubricated operation.
7. Regularly (once a month) switch on the air conditioning briefly, even if cooling is
not required (e.g. in winter). This will prevent serious damage being caused to
the system (including compressor blockage).
Cooling
1. Switch the air conditioning on.
2. Switch the recirculation to position 1, 2 or 3.
3. Turn the temperature control switch to the desired position. For maximum
cooling set the knob to the far left position in the blue area.
4. Open the side and centre vents.
While heating, it is possible to use the air conditioning to remove moisture from the
air in the cab. This has the advantage that demisting of the window glass will be
quicker.
Dehumidification
1. Switch the air conditioning on.
2. Switch off the recirculation.
3. Open the vents on the centre console and at the side windows and set them as
desired.
72
Cab, Instruments and Controls
4. Control the temperature as desired.
5. Adjust the volume of air using the fan speed selector switch.
Note:
The air conditioning system is switched off when the engine coolant temperature
becomes too high. This will protect the engine.
}
The air conditioning system contains coolant under high pressure.
Removal of any parts of the air conditioning system is not
permitted. Work on the air conditioning system may only be carried
out by qualified personnel.
Note:
If the air conditioning system fails to work properly, it must be repaired by qualified
personnel as soon as possible, to avoid further damage to the system.
D0 00 644
FAN SPEED SELECTOR SWITCH
FRESH AIR POSITION OR RE-CIRCULATION POSITION
73
Cab, Instruments and Controls
The fan has two speeds: one applies to re-circulation the other to fresh air. The recirculation position is suited to quickly de-mist or cool the cab with the air
conditioning, quickly heat the cab, de-frost the windows with the heater and keep
out undesirable odours.
Note:
You are advised to switch on the re-circulation without air conditioning for short
periods only to prevent the air quality inside the cab degrading and moisture
increasing.
Fan speeds with fresh outside air ventilation valve open
Fan speeds with re-circulation valve closed, hardly any supply of
fresh outside air
D0 00 614
TEMPERATURE ADJUSTMENT
The supply of heat can be smoothly set from 0% (blue) to 100% (red).
74
Cab, Instruments and Controls
To achieve faster heating when the temperature outside is low, switch on the recirculation. In damp weather conditions it is recommended to reopen the recirculation flap after heating to prevent the windows from misting.
75
Cab, Instruments and Controls
AIR DISTRIBUTION SELECTOR SWITCH
D0 00 643
Dashboard
Dashboard vents and footwell
Footwell vent
Footwell and windscreen vents
Windscreen
76
Cab, Instruments and Controls
CENTRE CONSOLE
77
Cab, Instruments and Controls
7
8
9 10
11 12 13
14 15 16
D000706-2
78
Cab, Instruments and Controls
7
Ashtray with 24V lighter
8
Hazard warning lights
9
Work lamp/loadspace lighting
10
Mirror/windscreen heating
11
Suppression switch, reversing alarm
12
Electrical master switch, transport of hazardous materials
13
Door locking, co-driver's side.
14
Auxiliary heater indicator
15
PTO operation
16
Deactivating the superstructure/drawn vehicle loadspace detection
79
Cab, Instruments and Controls
7. ASHTRAY
In the centre console is an ashtray with lighter for the driver and co-driver.
The lighter plug can also be used as a 24V power supply for a 24V inspection lamp,
for example. Do not connect any consumer above 180 Watt.
To remove the ashtray, there are two springs on the top of the tray which should be
pressed in, after which the tray can be removed.
8. HAZARD WARNING LIGHTS
When this switch is pressed, all the direction indicator lights flash simultaneously.
The hazard warning lights are switched off by depressing the switch again. The
warning light in the switch indicates that the hazard warning is switched on.
9. WORK LAMP/LOADSPACE LIGHTING
This switch operates the lighting at the rear of the cab or in the loadspace.
10. MIRROR/WINDSCREEN HEATING
With the switch for mirror/windscreen heating in the centre console, the exterior
mirrors (excluding the kerb mirror) and the windscreen heating, if fitted, can be
heated.
When you press the switch again, the mirror heating is switched off while the
windscreen heating remains active for about 12 minutes.
If you press the switch again within 12 minutes, the windscreen heating is switched
off and the mirror heating is switched on again. Operate the switch once more to
switch everything off.
80
Cab, Instruments and Controls
11. SUPPRESSION SWITCH, REVERSING ALARM
With this switch, the reversing alarm can be switched off when reversing. The
following time you engage reverse, the alarm will sound again.
12. ELECTRICAL MASTER SWITCH, TRANSPORT OF HAZARDOUS
MATERIALS
Depending on the (country) version, this switch - in combination with the master
switch outside the cab (usually in the area of the battery pack) - can deactivate the
vehicle's electrical system (with the exception of the tachograph).
{
Take care not to deactivate the vehicle's electrical system with this
switch during NORMAL DRIVING!
Note:
The master switch can be switched on and off with this switch.
The engine must be switched off when the main switch is operated. Avoid
inappropriate use.
The master switch outside the cab can always be operated manually to deactivate
the vehicle's electrical system. Read the instructions on or near the master switch.
Always deactivate the vehicle's electrical system when the vehicle is parked.
13. DOOR LOCKING AT CO-DRIVER'S SIDE
See "DOORS".
81
Cab, Instruments and Controls
14. AUXILIARY HEATER INDICATOR
See "AUXILIARY CAB HEATER (AIR HEATING)"
15. PTO OPERATION
With this switch, the Power Take Off can be engaged, if necessary in combination
with the variable speed engine control. Engage the PTO only when the programmed
engaging conditions are met.
16. SWITCHING OFF LOADSPACE DETECTION SUPERSTRUCTURE/TRAILER
See "ALARM SYSTEM".
82
Cab, Instruments and Controls
ROOF CONSOLE
1
2
3
4
D0 00 589
1
2
3
4
Electric roof hatch
Rotating beacon
Switch "switch off cab interior detection"
Alarm system LED
83
Cab, Instruments and Controls
1. ELECTRIC ROOF HATCH
This switch opens and closes the optional roof hatch (partially).
2. ROTATING BEACON
If fitted, the rotary beacons on the roof of the cab can be operated with this switch.
3. SWITCH "SWITCHING OFF THE CAB INTERIOR DETECTION"
For operation of this switch, see "ALARM SYSTEM".
4. ALARM SYSTEM LED
This is where, on a vehicle with built-in vehicle alarm, there is a system LED that
shows whether the alarm system is active; see "ALARM SYSTEM".
84
Cab, Instruments and Controls
LEFT-HAND STEERING COLUMN SWITCH
C
A
B
D
D0 00 600
A
B
C
D
Horn
Main beam
Direction indicator, right
Direction indicator, left
A. HORN
The horn is operated with button A.
B. MAIN BEAM
Position B: The main beam is activated when the lights are on. The main beam
indicator on the instrument panel will also light up. To switch off the main beam, the
switch must be turned back through the "click" position towards the steering wheel.
If the lights are off, or if the switch has not been pushed through the "click" position,
it can be used to give signals.
C. DIRECTION INDICATOR, RIGHT
Position C: Right turn signal: on the instrument panel, the right direction indicator
will flash and there will also be an audible signal. To briefly operate the direction
85
Cab, Instruments and Controls
indicators (changing lanes, etc.), the switch can be pushed slightly against the
spring pressure. It will spring back when released.
D. DIRECTION INDICATOR, LEFT
Position D: Left turn signal: on the instrument panel, the left direction indicator will
flash and there will also be an audible signal. To briefly operate the direction
indicators (changing lanes, etc.), the switch can be pushed slightly against the
spring pressure. It will spring back when released.
86
Cab, Instruments and Controls
RIGHT-HAND STEERING COLUMN SWITCH
C
B
D
ON
OFF
RES
O
SET
1
2
3
A
D0 00 601
The right-hand steering column switch has the following functions:
1
2
3
4
5
6
7
Position 1: Intermittent wipe.
Position 2: Wipe speed (low).
Position 3: Wipe speed (high).
Position A: Wipe/wash.
Switch B: On/off switch, engine speed control and cruise control.
Switch C: Set, Resume, increase/decrease the pre-set value of the vehicle
controls.
Switch D: Extra Resume function of the engine speed control and cruise
control.
For operation of the engine speed control and cruise control, see "DRIVING".
87
Cab, Instruments and Controls
A
D0 00 720
STEERING COLUMN SWITCH, ENGINE BRAKE
The engine brake control is activated by placing the stalk in position A.
To apply the engine brake, see "DRIVING".
D0 00 616
88
Cab, Instruments and Controls
ADJUSTABLE STEERING COLUMN
The position of the steering column is adjustable. For adjustment, pull the handle
towards you and simultaneously move the steering column to the desired position.
The steering column is locked by releasing the handle. A pneumatically adjustable
steering column is available as an option. This is operated by a foot/heel switch to
the left underneath the driver's seat.
}
}
The steering column may only be adjusted while the vehicle is
stationary.
AUXILIARY CAB HEATER (AIR HEATING)
The auxiliary heater must be switched off when filling the tanks with
fuel. Switch off the auxiliary heater when leaving the cab for a
longer period of time. Do not switch on the auxiliary heater if the
vehicle is in an enclosed space. Make sure that the preprogrammed switch-on time does not coincide with a period in
which the vehicle is in an enclosed space.
The auxiliary heater warms the air in the cab and works independently of the vehicle
heating system and contact. The temperature in the cab is thermostatically
controlled. This thermostat also controls the speed of the built-in fan. The auxiliary
heater has a memory into which three different switch-on times can be
programmed. Pre-programming the switch-on time up to seven days in advance is
possible.
89
Cab, Instruments and Controls
Webasto
A B C D E F G
D0 00 572
The operating panel of the auxiliary cab heater is in the rear wall of the cab.
A
Display
B
Time setting
C Program selection
D On/off
E
Decrease setting
F
Increase setting
G. Adjustable thermostat
Activation with vehicle contact off
1. Briefly press button (D). The display (A) and the buttons will light up. The burner
symbol and the standard set burning time are shown in display A. The heating is
activated; the auxiliary heater indicator in the centre console will light up.
2. The set burning time can be shortened with button (E) to a minimum of 1 minute
and increased with button (F) up to a maximum of 120 minutes.
3. The desired temperature can be set using rotary switch (G). The setting range
lies between 10 C and 30 C.
Switching off
1. Press button (D). The display and button illumination will be switched off.
90
Cab, Instruments and Controls
2. The heater fan remains in operation for approximately 3 minutes to cool the
heater.
Adjusting the standard set burner time
1. The heater must not be running.
2. Press and hold button (E) until the set operating time flashes.
3. Release button (E).
4. Set the desired standard operating time using the buttons (E) and (F) (from 10 120 minutes). When the set operating time disappears, it has been stored.
Activation with vehicle contact on
1. Briefly press button (D). The display (A) will show the burner symbol with the
time and day. The heating is activated; the auxiliary heater indicator in the centre
console will light up.
2. The desired temperature can be set using rotary switch (G). The setting range
lies between 10 C and 30 C.
3. The heating remains in operation as long as the vehicle contact is on.
4. After turning off the vehicle contact, the heating remains operational for 15
minutes. This time can be reduced with button (E) to a minimum of 1 minute and
increased with button (F) to a maximum of 120 minutes.
5. The heater fan remains in operation for approximately 3 minutes to cool the
heater.
Deactivation with vehicle contact on
1. Press button (D). The display and button illumination will be switched off.
2. The heater fan remains in operation for approximately 3 minutes to cool the
heater.
Setting the time/date
1. Press and hold button (B) until the display starts flashing (after approx. 3 sec.).
2. Set the time with the buttons (E) and (F). Once the time has stopped flashing, it
has been stored.
3. The day will start flashing.
91
Cab, Instruments and Controls
4. Set the day with the buttons (E) and (F). Once the day has stopped flashing, it
has been stored.
5. Press button (B). The setting procedure is complete.
Note:
If the day does not need to be set, press button (B) twice after setting the time.
Programming the switch-on time
It is possible to program three switch-on times in the coming 24-hour period or one
switch-on time in the coming 7 days.
Selecting the memory position
1. Press button (C) once for the first memory position. Digit 1 and the default time
setting (12.00) will appear in the display.
2. Press button (C) twice for the second memory position. Digit 2 and the default
time setting (12.00) will appear in the display.
3. Press button (C) three times for the third memory position. Digit 3 and the
default time setting (12.00) will appear in the display.
4. Press button (C) until the memory display disappears.
Programming the switch-on time for the coming 24 hours
1. Select a memory store.
2. Briefly press button (E) or (F). The time will start flashing.
3. Set the desired switch-on time with the buttons (E) and (F). Setting is only
possible when the time is flashing. The switch-on time has been stored in the
memory when the time is no longer flashing.
4. Press button (C) to select another place in the memory, or wait until the display
shows the current time. This completes the programming.
5. The activated memory store is visible in the display. The burner symbol is also
flashing as a sign that the switch on-time has been programmed.
92
Cab, Instruments and Controls
Programming the switch-on time for the coming 7 days
1. Select a memory store.
2. Briefly press button (E) or (F). The time will start flashing.
3. Set the desired switch-on time with the buttons (E) and (F). Setting is only
possible when the time is flashing. The switch-on time has been stored in the
memory when the time is no longer flashing.
4. After approx. 5 seconds, the day begins to flash. Set the desired day with the
buttons (E) and (F). Programming is completed when the display shows the
current time.
5. The activated memory store is visible in the display. The burner symbol is also
flashing as a sign that the switch on-time has been programmed.
Deleting the programmed switch-on time
1. Select the memory store with button (C).
2. Press and hold button (C) until the time has been deleted.
Faults
If there is a fault, the burner symbol will flash and a fault code will be shown. In
some cases a fault can be reset by switching the heating off with button (D) and
then quickly on again. If the fault is not reset, turn the auxiliary heater off and have
the heating inspected by your authorized Service dealer.
Note:
To prevent faults during cold weather, turn the auxiliary heater on for 10 to 15
minutes once a month during the summer. If necessary, install a separate fuel tank
for the auxiliary heater.
Note:
On vehicles certified for transportation of hazardous materials, you can only switch
on and off the auxiliary heater manually. It is not possible to program the switch-on
time.
93
Cab, Instruments and Controls
94
Seats
95
Seats
{
IMPORTANT POINTS
-
96
The driver's seat must only be adjusted when the vehicle is
stationary. All adjustments may only be carried out when the seat is
occupied. The seat belt must audibly click shut.
You must read this section thoroughly and acquaint yourself with the seat
controls.
The vehicle air pressure must be a minimum of 7 bar.
Never operate several controls at once.
The armrest should be folded away before entering/leaving the vehicle.
The co-driver's seat is not suitable for a child's seat.
The seat fixings and component parts must be checked for wear from time to
time.
The seat may only be repaired and fitted by trained personnel.
Seats
SEAT SETTINGS
Note:
In case of an air-spring seat, ensure that the seat does not rub against the rear cab
wall when it has been set.
Co-driver's seat
Operation:
5
1
2
3
4
D0 00 693
1
2
3
4
5
Backrest angle adjustment
Seat height adjustment
Seat squab adjustment
Seat fore/aft adjustment
Armrest adjustment (rotary knob at front, at bottom of armrest).
97
Seats
Driver's seat
Operation:
10
9
1
2
3 4 5 6 7 8
D0 00 694
1
2
3
4
5
98
Seat squab adjustment
Seat fore/aft adjustment
Shock absorber setting: The suspension characteristics of the seat
(in terms of comfort) can be optimised by means of the infinitely adjustable
shock absorber (from "hard" to "soft") for each driving situation.
- Position switch up: minimum damping ("soft" comfort)
- Position switch down: maximum damping ("hard" comfort)
Note:
The shock absorber must always be set tight enough to withstand
conditions on a poor road surface.
Seat squab angle adjustment
Seat height adjustment
Seats
6
7
8
9
10
Entry/exit aid
- Knob down (seat in driving position): seat drops to its lowest position
(= entry/exit aid)
- Knob up (with lowered seat): seat returns to the last set height
Backrest lumbar setting low (+/-)
Backrest lumbar setting high (+/-)
Seat heating
Backrest angle adjustment
D000534
}
SEAT BELTS
The seats are equipped with seat belts; use them. (Mandatory in
some countries.) More persons using a single seat belt is not
permitted.
99
Seats
}
}
}
Seat belts only work properly when correctly tensioned. For this
reason, never use a clip or other device to reduce the seat belt
tension.
Always keep seat belts clean and dry. Clean the belts with an allpurpose cleaner, not with caustic substances.
If the seat belts have been subjected to high loading during a
collision, the complete assembly must be renewed, even if there is
no visible evidence of damage. Have repairs to the seat belts
carried out by qualified personnel only. Never modify seat belts
yourself.
Wearing seat belts
- The belt must be tight against the body and not be distorted.
- With a three-point type belt, the shoulder section must be across centre of the
shoulder, not against the neck. The pelvis section should be as low as possible
across the pelvis, not across the abdomen.
- Do not put any hard, sharp or fragile objects such as pens, glasses or phones
between your body and the seat belt.
100
Seats
Checking the seat belts
- Give a short pull on the seat-belt to test the locking mechanism.
- Repeat this check regularly, for example when putting on the seat belt, in order
to check the mechanism.
During this test, the belt must lock. This means that it must not be possible to
pull the seat belt out of the retracting unit after locking.
The locking mechanism should be immediately replaced and/or repaired if it is
defective.
-
Inspect the belts regularly for wear. Have the complete assembly replaced at
once if the belt is worn or damaged.
101
Seats
102
Master Display
103
Master Display
GENERAL
In the master display a menu can be displayed to show the driver all the information
regarding the function and operation of the various systems in as useful a way
possible.
The master display is a part of the Central Warning System. In addition, the system
contains a menu selection switch, a buzzer and a central "STOP" warning lamp
under the master display.
The master display consists of three different fields; an indication bar, an
information screen (yellow or red) and an information screen (yellow).
104
Master Display
LAYOUT OF MASTER DISPLAY
1
2 3
4
5
A
8
B
C
6
7
8
D000563
A
B
C
1
2
3
4
5
6
7
8
Indication bar
Information screen (yellow/red)
Information screen (yellow)
Number of active red warnings
Number of active yellow warnings
Alarm function engaged
Gear engaged(1)
Set speed(1)
Warning symbols/text
Warning symbols/text
Scrolling function active
(1) Application of functions 4 and 5 depends on the version of the vehicle.
105
Master Display
START-UP PHASE
If the ignition has been switched on and the engine is not yet running, the start-up
screen is shown in the master display.
The following warning symbols, if present, are then displayed:
-
Oil pressure (red)
Alternator voltage (red)
Steering circuit 1 output (red)
ABS of prime mover (yellow)
ABS of drawn vehicle (yellow)
Airbag (yellow)
Note:
When starting a vehicle equipped with an Allison MD3060 automatic gearbox, the
transmission fault warning symbol appears in the main display; this symbol
disappears once the engine is started.
During the start-up phase, the "STOP" warning lamp and the acoustic signal are
inactive.
Approximately 3 seconds after switching on the ignition, the yellow warning symbols
will disappear. During these 3 seconds, no other warnings can be displayed.
The red warning symbols should disappear from the screen approximately
2.5 seconds after the engine has been started.
If the oil pressure, charging voltage or steering circuit 1 output is still too low after
these 2.5 seconds, the warning screen will become active, in which the relevant red
warning symbol appears with the accompanying text. The "STOP" warning lamp
and acoustic signal will also be activated.
If there is a less serious fault, the respective yellow symbol with the accompanying
text will appear on the screen and an acoustic signal will be heard for a certain time.
106
Master Display
If the indication bar mentions several red and/or yellow warnings, the other
warnings can be called up by turning the menu selector switch one step further each
time. This takes place in order of priority. This means that the most important
warning will be displayed first.
A red warning cannot be removed from the screen when the engine is running.
The red warning symbol can be turned off when the engine is not running. This is so
that it is possible to use other menu options (if you return to the main screen, the
warnings will re-appear).
Yellow warnings can be switched off at any time.
The message detailing the number of warnings present remains active at all times.
A continuous acoustic signal accompanies a red warning.
A pulsating acoustic signal accompanies a yellow warning and sounds four times.
107
Master Display
MENU SELECTOR SWITCH
By pressing the menu selector switch, the main menu will be selected and the
selector bar will become visible.
Turning the menu selector switch will switch between screens in the main menu.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing the menu selector switch, the function/information chosen will be
selected, after which sub-menu 1 will appear, if present. If there is no sub-menu 1,
the menu function will be turned off.
D000711
By turning the menu selector switch you will browse through sub-menu 1.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing in the menu selector switch, the function/information chosen will be
selected, after which sub-menu 2 will appear, if present. If there is no sub-menu 2,
the menu function will be switched off.
D000555
108
Master Display
By turning the menu selector switch, sub-menu 2 can be accessed.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing the menu selector switch, the menu function will be switched off.
D000556
109
Master Display
MENU OVERVIEW
Main menu
Sub-menu 1
Sub-menu 2
Vehicle information
Fuel consumption
-
Current
Average
Average trip
Service inspection
-
Date
Distance
PTO counter
-
PTO 1 counter
PTO 2 counter
PTO consumption
Turbocharger pressure
Oil level
Chassis number
Back
Faults
All faults
Back
110
Master Display
Main menu
Sub-menu 1
Sub-menu 2
Trip info
Trip info
-
Distance
Time
Average speed
Average consumption
Fuel consumption
-
Setting alarm: hours
Setting alarm: minutes
Alarm time
Trip reset
Close
Settings
Language 1 or 2
Alarm on/off
Setting alarm
Time, local/home
Set local time
Clock AM/PM/24H
Display miles/km
Close
Close
111
Master Display
FAULTS
Serious fault
A red warning symbol is activated when there is a serious fault.
When a red warning symbol is activated, the "STOP" warning lamp and an acoustic
signal are activated at the same time.
}
If the "STOP" warning lamp lights up and/or the buzzer is audible
while driving, the vehicle must immediately be stopped with extra
caution, parked in a safe place and the engine switched off. Have an
authorized Service dealer correct the problem as soon as possible.
Less serious fault
A yellow warning symbol is activated if there is a less serious fault.
When yellow warnings appear you may continue driving but action must be taken at
the first opportunity to remedy the fault. Have an authorized Service dealer correct
the problem as soon as possible.
}
112
As the vehicle may behave differently from normal, the vehicle must
be driven with extra caution.
Master Display
WARNING SYMBOLS
Red warnings
Oil pressure low
Switch the engine off straight away.
Check the engine oil level See also "Daily inspections" in "INSPECTIONS AND
MAINTENANCE".
Cab lock open
See "Cab tilting" in "EMERGENCY REPAIRS".
Air pressure low
This warning symbol is active when the pressure in one of the service brake circuits
is lower than 5 bar.
Coolant temperature high
This warning symbol will come on when the coolant temperature exceeds the
maxi-mum permissible value. Check the following points:
the coolant level (caution – danger of scalding; see "Topping up coolant" in
"INSPEC-TIONS AND MAINTENANCE");
the poly V-belt and water hoses; the fan clutch.
113
Master Display
Alternator voltage high
If the charging voltage of the alternator rises above 30 V, this symbol will light up.
The battery voltage is then too high and the battery may start to boil. In that case,
switch on as many electrical consumers as possible.
If the symbol is still not extinguished, under no circumstance continue
driving!
Engine fault
Serious fault in the electronic unit.
Transmission fault
If the vehicle is equipped with an automatic gearbox, see "Faults" in "AUTOMATIC
GEARBOX".
Trailing axle fault
Fault in the steering system of the steered trailing axle (RAS-EC)
114
Master Display
Yellow warnings
Alternator fault
Alternator charge voltage not correct
Transmission fault
If the vehicle is equipped with an automatic gearbox, see "Faults" in "AUTOMATIC
GEARBOX".
ABS
Truck ABS fault
This symbol is activated when:
there is a fault in the ABS of the prime mover;
Trailer ABS fault
ABS
Alarm system fault
Engine fault
Depending on the fault, the engine can switch over to emergency control.
115
Master Display
Air suspension fault
Defect or fault on the electronic chassis height control (ECAS). Depending on the
type of fault the vehicle may not be driven further. See also "AIR SUSPENSION".
Central vehicle control unit fault
Fault in the (VIC) electronic unit that collects information and controls vehicle
functions.
PTO fault
Engine speed control does not meet the conditions. See "Engine speed control" in
"DRIVING".
Oil pressure low
Check the engine oil level See also "Daily inspections" in "INSPECTIONS AND
MAINTENANCE".
Water separator fuel filter
Check the fuel prefilter/water separator. See "Weekly inspections" in
"INSPEC-TIONS AND MAINTENANCE".
Truck brake lining
This symbol will light up if the brake lining on one or more wheels is worn.
116
Master Display
Trailing axle fault
Fault in the steering system of the steered trailing axle (RAS-EC).
Airbag warning
No warning
Key to abbreviations
ABS
Anti-lock Braking System
ECAS
Electronically Controlled Air Suspension
PTO
Power Take Off
VIC
Vehicle Intelligence Centre
RAS-EC
Rear Axle Steering - Electronically Controlled
117
Master Display
118
Inspections and Maintenance
119
Inspections and Maintenance
OVERVIEW OF DAILY CHECKS
Overview of the driver's daily checks:
- engine oil level
- coolant level
- fluid level in screen washer reservoir
- air filter indicator
- tires and rims
- lighting and instruments
- driver's seat and mirrors
- trailer
Visual check before starting the trip:
- check that no situation can occur (such as loose objects, improperly attached
load etc.) that may put other road users at risk.
Note:
Cleaning rags, flammable materials, accumulated dirt etc. in the vicinity of the
exhaust system must be removed as these create a fire hazard.
120
Inspections and Maintenance
OPENING THE FRONT PANEL
Open the front panel by gripping it at the bottom and lifting it up. The front panel will
tilt upwards and is held in place by two gas struts.
2
1
D0 00 721
ENGINE OIL LEVEL
1.
2.
3.
4.
5.
Ensure that the vehicle is standing on a flat and level surface.
Open the front panel.
Pull the dipstick (2) out of the holder.
Wipe the dipstick clean with a lint-free cloth.
Re-place the dipstick in its holder. Withdraw the dipstick again and check the oil
level.
Note:
It takes approx. 20 minutes for all the oil to run into the sump when the engine is
"warm". If the dipstick is checked immediately after switching the engine off or
121
Inspections and Maintenance
immediately after oil has been added, the level shown on the dipstick will be too
low.
6. Fill oil through the filler opening (1) until the oil level reaches the maximum mark.
Only use engine oil that meets specifications. See "TECHNICAL DATA".
Note:
For the difference between the minimum and maximum engine oil level, see
"TECHNICAL DATA".
}
TOPPING UP COOLANT
}
}
122
When the coolant is hot, there is an overpressure in the cooling
system. If circumstances dictate that it is necessary to top up the
coolant when the engine is warm, unscrew the filler cap carefully
one turn to relieve the overpressure. Take adequate precautions
against burning by, for example, placing a cloth over the cap.
Coolant is a toxic fluid. Contact with the skin should therefore be
avoided. Also see "Lubricant, engine coolant and fuel
specifications" in "TECHNICAL DATA"
To prevent damage to the engine block, topping up with cold
coolant when the engine is hot must be done slowly and with the
engine running.
Do not loosen the filler cap of the cooling system when the cab is
tilted.
Inspections and Maintenance
1
2
o
-25 C
o
-11 F
D0 00 593
1.
2.
3.
4.
5.
6.
Turn the rotary knob for the heating temperature control to "maximum hot".
Open the front panel.
Remove the black filler cap from the cooling system reservoir.
Run the engine for several minutes.
Stop the engine and check the coolant level.
If necessary, top up to the bottom of the filler opening.
Always use coolants which meet specifications. See "TECHNICAL DATA".
123
Inspections and Maintenance
D0 00 608
SCREEN WASHER RESERVOIR FLUID LEVEL
1. Open the front panel.
2. Check the fluid level in the screen washer reservoir.
3. Top up, if necessary, via the filler opening.
Note:
When topping up, it is recommended to add a windscreen cleaner to the water in the
screen washer reservoir.
During the winter period, add screenwash antifreeze.
124
Inspections and Maintenance
D0 00 596
AIR FILTER INDICATOR
The air filter indicator is right above the air filter housing at the cab's rear or behind
the grille at the front of the cab.
If the indicator is in the red area (showing the text "service"), the air filter is seriously
fouled and must be replaced. Consult an authorized Service dealer.
Clogged air filters lead to increased fuel consumption and loss of power.
125
Inspections and Maintenance
WHEELS AND TIRES
-
Remove any stones, etc. from the tread and from between the tires (if twin
wheels are fitted).
Check for evidence of wear and damage and for nails or other foreign objects
caught in the tires.
Check the attachment of the wheels.
Check the tire pressures (do not forget the spare wheel). The tire pressures
should be checked and corrected while the tires are cold. See chapter on
"Technical data" or the back page of this book for the correct tire pressures.
Note:
If a worn tire is underinflated by 2 bar, the ABS control will be inoperative under
extreme conditions! Also see "Changing the wheel" in the "EMERGENCY
REPAIRS" section of this manual.
LIGHTING AND INSTRUMENTS
-
126
Check the vehicle lighting, brake lights and instruments for correct operation.
Also check the operation of the horn, windscreen wipers and washers.
Inspections and Maintenance
DRIVER'S SEAT AND MIRRORS
Set the seat and mirrors to the correct positions.
Mirrors with field of vision projected on the ground
A
E
B
C
D
D001062
A
B
C
D
E
Side window
Dead angle mirror
Wide view mirror
Main mirror
Pavement mirror
TRAILER VEHICLE
-
Check the trailer coupling or fifth wheel for correct attachment and correct
operation.
Check the connections for lighting and brakes.
Check the operation of the lighting, brake lights and direction indicators.
127
Inspections and Maintenance
OVERVIEW OF WEEKLY CHECKS
Overview of the driver's weekly checks:
- clutch fluid level
- Power steering fluid level
- Brake system air drier
- Draining the fuel system water separator
- Batteries
MAXI
MINI
P MAX 4 BAR
D0 00 595
CLUTCH FLUID LEVEL
1. Open the front panel.
2. Check the fluid level in the reservoir. The fluid level must be between the two
markings.
3. If necessary, top up brake fluid via the filler opening, brake fluid specification:
see "TECHNICAL DATA".
128
Inspections and Maintenance
Note:
Brake fluid is highly corrosive. Take appropriate measures to protect yourself
and remove any spilt fluid immediately with plenty of water.
4. If the level is below the minimum mark, this is a sign of leakage. Contact an
authorized Service dealer as soon as possible.
D0 00 581
POWER STEERING FLUID LEVEL
1. Tilt the cab.
2. Clean the dipstick and its immediate surroundings to prevent any dirt from
entering the reservoir.
3. Check the fluid level in the reservoir using the dipstick.
4. The fluid level must be between the two marks.
5. Top up oil, if necessary, via the filler opening. Oil type: see "TECHNICAL
DATA".
6. If the level is below the minimum mark, this is a sign of leakage. Contact an
authorized Service dealer as soon as possible.
129
Inspections and Maintenance
D0 00 592
BRAKE SYSTEM AIR DRIER
The air drier can be checked for correct operation by inspecting the air reservoirs for
condensed water.
1. Check the air reservoirs for condensed water by pulling on the rings of the drain
valves.
2. If repeatedly more than the normal amount of water is drained off, the air drier
element will have to be replaced. Consult your Service dealer.
130
Inspections and Maintenance
B
A
D0 00 620
}
DRAINING THE WATER SEPARATOR
When draining the water separator, an amount of fuel will escape.
Collect the fuel and avoid the risk of fire.
Water in the fuel system may lead to significant damage.
1. Place a container beneath the water separator.
2. Remove the connector.
3. Unscrew the ring-shaped drain cock (B) on the bottom of the water separator in
anti-clockwise direction.
4. Drain the filter until pure diesel fuel comes out of the drain cock (A).
5. Turn the drain cock (B) if it abuts, another 1/8 - 1/4 turn.
6. Check the drain cock (B) for leakage.
7. To prevent pollution, the drained water/diesel fuel mixture should be passed to
the relevant authorities for reprocessing.
131
Inspections and Maintenance
D0 00 627
}
BATTERIES
-
132
Avoid sparks and open flames in the vicinity of batteries.
Battery acid is an aggressive fluid.
In the event of contact with the skin: rinse the skin profusely with
plenty of water.
Consult a doctor in the event of persistent redness or pain.
Remove polluted clothing and rinse in water.
In the event of contact with the eyes: rinse with plenty of water for
at least 15 minutes and consult a doctor.
If swallowed: do NOT induce vomiting. Rinse the mouth, drink two
glasses of water and consult a doctor.
In the event of inhalation: get fresh air, rest and consult a doctor.
Check the electrolyte level; this should be approx. 10 mm above the plates or up
to the level indicator, if present. If necessary, top up the batteries with distilled
water.
Inspections and Maintenance
-
Check that the battery poles and terminals are clean and greased. If necessary,
coat the posts with an acid-free petroleum jelly.
133
Inspections and Maintenance
GENERAL MAINTENANCE
The durability, safety, trade-in value and reliability of your vehicle largely depend on
the care you give it. This includes regular service in accordance with the
maintenance schedules specified.
The driving style of the person at the wheel and the care given to the vehicle will
have a direct influence on the condition of the vehicle. The driver can often provide
the dealer with information which is very important for correct maintenance.
Prior to the service intervals and the related activities, contact your authorized
Service dealer.
134
Inspections and Maintenance
LUBRICATING FIFTH WHEEL/TRAILER COUPLING
The fifth wheel or trailer coupling must be lubricated every 5,000 km (3,170 miles).
D000689
Lubricating the fifth wheel
D000690
Lubricating the trailer coupling
135
Inspections and Maintenance
CAB MAINTENANCE
In order to keep this quality as high as possible, during vehicle use, regular
maintenance should be carried out on the cab surfaces.
To prevent the formation of rust in box sections and other cavities, the cab is
protected with corrosion-inhibiting products (ML) in production.
Due to the setting of the structure, minor bare spots may develop in this
additional protective coating. For this reason, the manufacturer considers it
necessary to have further treatment carried out within a specific period
(consult the warranty manual) after the vehicle has been taken into service.
If this does not happen, the warranty will become invalid.
The relevant warranty conditions are listed in the warranty manual.
CLEANING
Cleaning the vehicle
Before the vehicle is cleaned, check for leaks in the engine, axles, gearbox, etc.
This is no longer possible after cleaning the vehicle and carrying out maintenance
work.
When a high-pressure cleaner is used, take special note of the following points:
-
136
Make sure that the doors, windows and roof hatch are properly closed.
Never spray directly on seals. There is a danger of them being forced open so
that water can penetrate or grease packed behind them is flushed away. This
may happen, for example, with the universal joint on the steering box. As a
result, the spider may seize so that the steering will jam.
Inspections and Maintenance
-
-
-
Do not spray directly onto steering ball joints.
The power steering fluid reservoir is fitted with a vent. Water may enter the
reservoir via this vent, which will cause damage to the steering gear.
When cleaning the radiator/intercooler, take care not to damage the fins.
Do not direct the high-pressure cleaner/steam cleaner jet too long at the
air-conditioning system condenser. As a result of the high temperature, the
pressure in the system will rise too high, which may cause damage to the
system. Parts of the air-conditioning must not be cleaned with the aid of a
high-pressure/steam cleaner as this can cause damage to the seals.
Make sure that no water can enter the differential and gearbox via the vents.
Make sure that no water can enter via the reservoir bleed screws of the clutch,
brakes, trailing axle, etc.
The engine and engine compartments can be cleaned with a high-pressure/
steam cleaner. Avoid spraying directly onto electrical components such as the
fuel system pump units, electronic units the starter motor, alternator,
air-conditioning compressor, headlights, etc.
Carefully clean the engine encapsulation and its fittings. Remove any spilled oil
and diesel oil to avoid the risk of fire.
Do not aim the jet of water directly at electrical connections such as connectors,
cable plugs in the vehicle lighting system, etc. Also do not aim the jet at the gear
lever unit.
When cleaning the vehicle, make sure that no water can enter the air inlet
system via the air intake or its flexible seals.
When the vehicle has been cleaned, it must be lubricated again with a grease
gun or via the automatic lubrication system. This is important because it
prevents the penetration of moisture and dirt at the various pivot points.
137
Inspections and Maintenance
Cleaning the cab
Depending on the vehicle's operating conditions, the external paintwork of the cab is
subject to attack by corrosive substances, for example road salt, grit and polluted
air. For instance, road salt and air pollution.
The paintwork must therefore be cleaned regularly.
When cleaning the cab, make sure that:
- no caustic cleaners are used
- no hard brushes are used
- all seams, gaps and door shut-lines are thoroughly cleaned.
Waxing the cab
The paintwork of new vehicles is waxed to protect it against the elements.
After a time this wax coating will gradually wear away as a result of cleaning and
other external influences.
To give corrosive substances less chance of attacking the paint, it is advisable to
protect the paintwork with a new wax coating at least twice a year.
It is advisable to use wax for this.
Your authorized Service dealer can advise you about additional anti-rust treatment
and maintenance of the paintwork when the vehicle is in service.
138
Inspections and Maintenance
Cleaning the interior
The day cab can be fitted with fabric or plastic trimming.
The sleeper cab is only available with fabric trimming.
The plastic can be cleaned with a household cleaning agent and warm water.
The fabric trimming should be cleaned with a non-aggressive dry-cleaning agent, or
an equivalent product.
Note:
The appearance of your vehicle is your company's face to the world!
PREVENTATIVE MAINTENANCE BEFORE THE WINTER SEASON
Your authorized Service dealer can always give you good advice to prepare
your vehicle for winter.
DIESEL FUEL
If outside temperatures are persistently low, only fill up with winter diesel oil
produced by a reputable oil company.
During the winter months the oil companies often use additives, to prevent
blockages caused by the precipitation of paraffin crystals (wax deposits).
It is not permitted to use your own fuel additives.
139
Inspections and Maintenance
Note:
Additives which are used to prevent precipitation of paraffin crystals have a purely
preventative effect. They can not dissolve the paraffin crystals once they have
been precipitated.
Always carry a spare fuel fine filter in the vehicle so that you can replace it quickly if
it becomes blocked in any way (for example, by paraffin crystals).
Always preferably fill up in the evenings to prevent condensation (especially in
winter).
CAB HEATER
If necessary, install a separate fuel tank for the cab heater.
If the tank has been filled up with winter diesel oil because of a cold weather period
or a trip to a colder country, allow the cab heater to run on the new fuel for half an
hour to ensure that all the old fuel has been used up.
The above recommendations apply for both air and water heating and for all vehicle
types.
WINDSCREEN WASHER RESERVOIR
-
140
When topping-up, it is advisable to add a cleaner to the water in the windscreen
washer reservoir.
During the winter period, add screenwash antifreeze.
Inspections and Maintenance
MAINTENANCE AFTER THE WINTER SEASON
Your authorized Service dealer can always give you good advice to prepare
your vehicle for summer.
COOLING SYSTEM
The coolant may be left in the cooling system during the summer.
141
Inspections and Maintenance
142
Coupling and Uncoupling
143
Coupling and Uncoupling
TRAILER COUPLING
Trailer coupling with manual unlocking
Coupling
A
B
D000678
1. Pull the safety pawl (A) out of the coupling and rotate it 90 .
2. Pull the lever (B) up.
3. Note the drawbar position and reverse the vehicle until the drawbar engages;
coupling is effected automatically.
4. After coupling, always check whether the safety pawl (A) is properly locked.
144
Coupling and Uncoupling
A
D000424
5. Safety pawl (A) unlocked: coupling unsafe!
A
6. Safety pawl (A) closed: coupling safe.
7. If the safety pawl (A) is not locked, the coupling is not safe and you must couple
the trailer again.
8. When coupling, check the coupling head rubbers of the air pipes of both the
prime mover and the trailer vehicle for any damage.
9. Connect the brake pipes and the cables for the lighting and ABS/EBS.
145
Coupling and Uncoupling
Uncoupling
1. Put wheel chocks in front and behind the trailer's rigid axle wheels.
2. Be absolutely certain that the trailer is braked.
3. Detach the brake pipes and cables for lighting and ABS/EBS.
4. Pull the safety pawl from the coupling and turn it 90 . The trailer vehicle coupling
can only be opened in the centre position or the two outer positions of the
coupling jaw. (If the coupling jaw is crooked, the coupling pin cannot be
unlocked!)
5. Pull the lever up and drive the vehicle away.
146
Coupling and Uncoupling
Trailer coupling with automatic unlocking
Coupling
A
B
D001050
1. Pull the lever (B) up; the locking indicator pin (A) will shoot out.
2. Note the drawbar position and reverse the vehicle until the drawbar engages;
coupling is effected automatically.
3. After coupling, always check that locking is effected properly.
A
D001051
4. Locking indicator pin (A) in unlocked position: coupling unsafe!
147
Coupling and Uncoupling
A
D001052
5. Locking indicator pin (A) fully level with the front: coupling safe.
6. If the locking indicator pin (A) is not entirely level with the front, the coupling is
not safe and you must couple the trailer again.
7. When coupling, check the coupling head rubbers of the air pipes of both the
prime mover and the trailer vehicle for any damage.
8. Connect the brake pipes and the cables for the lighting and ABS/EBS.
Uncoupling
1. Put wheel chocks in front and behind the trailer's rigid axle wheels.
2. Be absolutely certain that the trailer is braked.
3. Detach the brake pipes and cables for lighting and ABS/EBS.
4. The trailer vehicle coupling can only be opened in the centre position or the two
outer positions of the coupling jaw. (If the coupling jaw is crooked, the coupling
pin cannot be unlocked!)
5. Pull the lever up and drive the vehicle away.
148
Coupling and Uncoupling
FIFTH WHEEL
The following directions for use apply in general to the fifth wheels on your vehicle.
Coupling
1. Pull out the fifth wheel handle. The jaw is now opened and ready for coupling.
2. Drive the tractor close to the semi-trailer and make sure that the coupling pin is
in the middle of the V-shaped fifth wheel opening.
3. Check that the coupling pin and the V-shaped opening are at the same height. If
necessary, adjust the height of the semi-trailer or tractor.
4. Reverse the tractor slowly until the semi-trailer is on the fifth wheel and the jaw
is locked by the coupling pin. The handle then springs back into its original
position.
5. Check whether the fifth wheel is locked by slowly driving a little forward.
6. Lock the handle as shown below (if necessary with a safety catch or a padlock).
7. Check that the semi-trailer is coupled to the fifth wheel without any air gaps and
that the automatic locking has in fact taken place.
8. When coupling check the coupling head rubbers of the air pipes of both the
prime mover and the semi-trailer for possible damage.
9. Connect the brake pipes and the cables for the lighting and ABS/EBS.
10. Retract the semi-trailer undercarriage.
Uncoupling
1. Ensure that the semi-trailer is braked.
2. Place wheel chocks in front and behind the semi-trailer wheels.
3. Wind down the semi-trailer undercarriage using quick operation until the feet
touch the ground. Switch to slow operation and wind down a few turns further.
Do not lift the semi-trailer from the fifth wheel.
149
Coupling and Uncoupling
4. Detach the brake pipes and cables for lighting and ABS/EBS.
5. If fitted, detach the safety hook or padlock.
6. Unlock the fifth wheel by pulling out the handle. The hook is now opened and
ready for uncoupling.
7. Slowly drive the tractor from under the semi-trailer.
Note:
On vehicles with air suspension, the remote control electronic height control is used
for coupling/uncoupling the trailer. When coupling, the vehicle can be brought to the
correct coupling height, or the semi-trailer can be lifted before the supports are
wound down.
Important
After coupling or uncoupling a semi-trailer, always press the remote control key or
the appropriate key on the instrument panel for automatic resetting of the correct
driving height. This will set the correct driving height automatically.
Tractors may be fitted with a small towing hook at the rear end of the chassis. This
towing hook must only be used for light shunting work (max. 4300 kg).
150
Coupling and Uncoupling
JOST fifth wheel (version 1)
2
1
D001023
Unlocking
- Fold up the hook (2), as shown in the illustration.
- Pull the handle (1) forward and outward and hook the extended handle into the
fifth wheel.
2
1
D001022
151
Coupling and Uncoupling
Locking
- Locking is done automatically during coupling; check that the hook (2) is folded
down.
JOST fifth wheel (version 2)
A
1
D001021
Unlocking
- Pull the handle (1) forward and outward and hook the extended handle into the
recess (A).
152
Coupling and Uncoupling
2
1
2
'
Locking
- Locking is done automatically during coupling; check that mark (2) is within the
fifth wheel.
Georg Fischer fifth wheel (+GF+)
1
2
D001025
Unlocking
- Push the lever (2) down.
153
Coupling and Uncoupling
-
Pull the handle (1) backward and outward and hook the extended handle into
the fifth wheel.
1
2
D001024
Locking
- Locking is done automatically during coupling; check that the lever (2) is in its
original position.
VBG fifth wheel
1
D001027
154
Coupling and Uncoupling
Unlocking
- Remove the spring hook.
- Pull the handle (1) forward and outward and hook the extended handle into the
fifth wheel (see detail).
2
1
D001026
Locking
- Locking is done automatically during coupling; check that the handle (1) is in its
original position and fit the spring hook (2).
155
Coupling and Uncoupling
D000503
CONNECTING UP THE BRAKE LINES OF A TRAILER
The vehicle has automatic coupling heads which are used to connect up the air
pipes.
Connect the air pipes with these connectors. These coupling heads have safety
lugs which make it impossible to connect up the air pipes incorrectly. The coupling
heads on the trailer vehicle must of course have corresponding safety lugs.
Should a mistake nonetheless be made when connecting up the air lines the air
brakes on the trailer vehicle will consequently not be released.
}
However, an incorrectly connected trailer vehicle with empty air
reservoirs will not be braked automatically and this makes it
possible to drive away with an unbraked trailer. This can lead to
very dangerous situations!
When the red coupling head is properly connected, the brake system of the trailer
vehicle will slowly be filled and you will be able to hear this quite clearly. At the same
time there will be a marked drop in pressure in the air reservoirs of the tractor.
156
Coupling and Uncoupling
-
red = emergency line coupling head
yellow = service line coupling head
}
If the yellow and/or red air lines have not been connected, the trailer
vehicle will not be able to brake, which could lead to very
dangerous situations.
CONNECTING UP THE BRAKE LINES OF A TRAILER WITH ABS OR EBS
ABS: Anti-lock Braking System
EBS: Electronically controlled Braking System
A trailer with ABS is fitted with an anti-lock braking system.
A trailer with EBS is fitted with an electronically controlled braking system, which
incorporates ABS.
Both versions are connected by means of a special plug to the extra socket of the
ABS/EBS system on the prime mover.
If this plug is not connected, a yellow warning will appear on the master display.
157
Coupling and Uncoupling
ABS
EBS
ABS
EBS
ABS
EBS
ABS
EBS
D000491-2
158
Coupling and Uncoupling
}
Consequences of not connecting a trailer EBS to a prime mover
EBS via the ABS/EBS plug:
no load-dependent brake control;
no ABS (depending on trailer EBS system version);
no EBS control;
full brake action always maintained, regardless of load.
159
Coupling and Uncoupling
Overview of combination possibilities
Trailer without
ABS (properly
connected)
Prime mover without ABS
Prime mover with ABS
Prime mover with EBS
-
160
Trailer with ABS
(properly connected)
Load-dependent brake control
(mechanical)
active
No ABS control
Load-dependent
brake control
(mechanical) active
No ABS control
Load-dependent brake control
(mechanical)
active
No ABS control
Load-dependent brake control
(mechanical)
active
No ABS control
Trailer with EBS
(properly connected)
Trailer with EBS (5-pin
ABS wiring harness
connected instead of 7-pin
EBS wiring harness)
-
-
-
No load-dependent
brake control
No ABS control
-
No load-dependent brake
control
No ABS control
Note:
Forbidden by law
Note:
Forbidden by law
Load-dependent
brake control
(mechanical) active
ABS control active
-
-
Load-dependent
brake control
(mechanical) active
ABS control active
-
-
-
Load-dependent
brake control
(electrical) active
ABS control active
-
Load-dependent
brake control
(electrical) active
ABS control active
CAN communication
Load-dependent brake
control (electrical) active
ABS control active
Load-dependent brake
control (electrical) active
ABS control active
Coupling and Uncoupling
D000505
CONNECTING UP THE TRAILER VEHICLE LIGHTS
(24V ELECTRICAL SYSTEM)
A 7-pin socket is provided for connecting up the lighting of the trailer vehicle.
Furthermore, there is an additional 7-pin socket on the prime mover which can be
used for connecting up accessories which are fitted on the trailer vehicle. The two
sockets have different designs to rule out the possibility of making incorrect
connections. If the trailer vehicle has a 24V electrical system, it can be connected to
the electrical system of the tractor without any special measures having to be taken.
161
Coupling and Uncoupling
162
Driving
163
Driving
GENERAL
Before setting out on a journey, always check:
- the vehicle for possible water or oil leaks
- the engine oil level
- the fluid level in the screen washer reservoir
- the air filter indicator
- the coolant level
- the drawn vehicle coupling for correct attachment and correct operation
- the connection and operation of the drawn vehicle lighting and brakes
- the wheel attachment and tire pressures
- the tread depth of tires
- the tread of each tire for even distribution of wear pattern
- the correct setting of seat and mirrors
- the correct operation of lights and instruments
- the fuel level
After each journey check that:
- the doors of the vehicle are locked
- the load is still properly secured
164
Driving
{
STEERING LOCK/CONTACT/STARTER SWITCH
S
D
NEVER turn the ignition key to the rest position (0) or remove it
while the vehicle is in motion. This may cause the steering wheel
lock to engage.
Position 0: rest position
When the key is removed in this position the steering wheel can be locked.
If the steering wheel is turned slightly the steering wheel will lock.
0
A
D000970
Position A: accessories position
Steering wheel unlocked. The key cannot be removed. Accessories, such as a
radio, can be switched on.
Position D: ignition turned on
All power consumers can be switched on.
Position S: starting
When the key is released, it automatically returns to position D.
If the engine is running, the start lock is switched on.
GLOW SYSTEM
If the ignition is on, the electronic unit determines the necessary pre and after glow
time.
The necessary pre- and after glow time depends on the temperature that is
measured by the electronic unit of the engine management system.
If the pre- or after glow time is activated by the electronic unit, this warning lamp on
the instrument panel lights up.
165
Driving
}
STARTING PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
If you start the engine inside a building, open the doors fully to
ensure adequate ventilation. Exhaust gases contain carbon
monoxide, an invisible, odourless, but highly toxic gas. Inhalation
of these gases may cause unconsciousness and death.
Check that the parking brake is engaged.
Depress the clutch pedal and put the gear lever in neutral.
Switch the ignition to position D.
Check that the warning indicator of the parking brake lights up.
Check that the oil pressure warning symbol in the master display is lit.
Check the operation of the fuel gauge and the coolant temperature gauge.
Check that the glow system warning lamp is off.
Without pressing the accelerator pedal down, turn the ignition to position S. If the
engine does not start; the key must be released after 10 seconds. Then wait 10
seconds and try again.
Note:
The vehicle is equipped with start protection. If the gear lever is in neutral, the
starter motor will not function.
If the engine is running, the engine speed may not be increased before the oil
pressure warning symbol has extinguished.
Note:
Depending on the coolant temperature measured by the electronic unit, it is
possible that, in extremely cold conditions, the maximum engine speed is limited for
a specific period of time.
166
Driving
In case of an optional engine speed control, one of various engine speeds can be
selected with the right-hand steering column switch, if so desired.
Before driving away, check that the central "STOP" warning light is not illuminated.
IMMOBILISER FAULT
If the engine management system detects a problem with the immobiliser, the
"STOP" light on the instrument panel lights up continuously when the ignition is
switched on.
A warning is also activated on the instrument panel display.
Fuel will not be injected and consequently the engine will not start.
If you have a problem with the immobiliser, contact your authorized Service dealer
or International Truck Service (ITS).
C
B
D
ON
OFF
RES
O
SET
1
2
3
A
D0 00 601
167
Driving
ENGINE SPEED CONTROL
The minimum and maximum engine speeds that can be set are limited by a preprogrammed value in the electronic unit. This value may be below the idling speed.
In this case it will, however, not fall below idling speed.
The programmed engine speeds and conditions for activation/deactivation of the
engine speed control can be modified by an authorized Service dealer on request.
{
168
Check whether the stated conditions for deactivation of the engine
speed control apply to the vehicle.
Driving
Activating the engine speed control
1. Turn the ON/OFF switch (B) to the "ON" position.
2. Turn switch (C) briefly to the "RES -" or "SET +" position. The "RES -" and
"SET +" positions have two different programmed engine speeds.
If the rotating switch (C) is held in "RES -" or "SET +" position for over 1 second,
the engine speed control will be activated at the lowest programmable speed. If
this speed is below idling speed, the speed will not fall below the idling speed.
3. Adjust the engine speed using switch (C): "SET+" position to increase speed,
"RES-" position to decrease speed.
Note:
If the engine speed control is active, the engine brake is deactivated.
Note:
Depending on how the electronic unit is programmed, the accelerator pedal is active
or not. When speed is increased via the accelerator pedal, the speed will be
reduced to the set value once the accelerator pedal is released.
If the vehicle can be driven, the electronic unit will limit the maximum vehicle speed
to a programmed value. If the vehicle exceeds the programmed speed, the engine
speed control will be interrupted until the vehicle speed is once more below the
programmed maximum value.
Note:
The function of key (D), if activated, is equal to the "RES -" position of switch (C).
Deactivating the engine speed control
-
Turn the ON/OFF switch (B) to the "OFF" position.
169
Driving
Interruption of engine speed control
-
When the vehicle brake is operated.
When the parking brake is disengaged.
When the clutch is operated.
Turn the ON/OFF switch (B) to the "OFF" position
if the vehicle speed exceeds the programmed speed.
if the engine speed control is active via the superstructure.
if the external speed limiter on the superstructure is active.
when the ASR control is being activated.
{
Check whether the stated conditions for deactivation of the engine
speed control apply to the vehicle.
Re-activating the engine speed control after interruption
1. Re-activate the engine speed control by turning switch (C) briefly to the "SET +"
or "RES -" position.
Note:
The function of key (D), if activated, is equal to the "RES -" position of switch (C).
170
Driving
C
B
D
ON
OFF
RES
O
SET
1
2
3
A
D0 00 601
CRUISE CONTROL
The cruise control can be activated at a pre-programmed minimum vehicle speed.
This speed is 36 km/h (22 mph) as standard.
The programmed standard speed and the conditions for activation and deactivation
of the cruise control can be modified by an authorized Service dealer on request.
{
Check whether the stated conditions for activation and deactivation
of the cruise control apply to the vehicle.
Engaging the cruise control
1. Put the ON/OFF switch (B) to the "ON" position.
2. Turn the SET +/RES - switch (C) briefly to the "SET +" position. Cruise control
will be engaged and the vehicle will keep to the current speed.
3. The speed can be increased and decreased using the SET +/RES - switch (C):
"SET+" position to increase speed, "RES-" position to decrease speed.
171
Driving
Note:
The function of key (D) is equal to the "RES -" position of switch (C).
Note:
The accelerator pedal is still active. When, after accelerating, the accelerator pedal
is released, the vehicle speed will return to the last pre-set speed.
Deactivating the cruise control
-
Turn the ON/OFF switch (B) to the "OFF" position.
Interrupting the cruise control
-
Operation of the clutch pedal.
Operation of the service brake.
Operation of the parking brake.
Operation of the engine brake.
Turn the ON/OFF switch (B) to the "OFF" position
if the ABS/ASR system starts operating.
if the speed drops below 36 km/h (22 mph) or exceeds the maximum speed.
if the engine speed drops below the minimum or exceeds the maximum speed.
{
Check whether the stated conditions for activation and deactivation
of the cruise control apply to the vehicle.
Re-activating the cruise control after an interruption
1. Turn the SET +/RES - switch (C) briefly to the "RES -" position to return to the
vehicle speed set last.
2. Turn the SET +/RES - switch (C) briefly to the "SET +" position to fix the current
vehicle speed.
172
Driving
Note:
The function of key (D) is equal to the "RES -" position of switch (C).
173
Driving
VEHICLE SPEED LIMITATION FOR SPECIAL APPLICATIONS
Speed limitation for special applications consists of a switch which is fitted on the
vehicle superstructure. With this switch, the vehicle speed can be limited to a preprogrammed value. The programmed value can be modified by an authorized
Service dealer on request.
DRIVING STYLE
The following recommendations result in improved economy without adversely
affecting the vehicle speed (i.e. slowing down). In other words: an efficient driving
style.
Driving style in general
Some tips:
-
Anticipate traffic and other conditions; release the accelerator pedal in time (zero
fuel consumption) and do not press down on the accelerator when it is not
necessary.
With low engine loads, try to stay in the green low-rev range whenever possible.
At low engine loads in this rev range the engine has the lowest fuel consumption
per kW output.
At full load and at full throttle, the engine has the lowest consumption per kW in
the green area.
Note:
In the event of extreme acceleration to 30 to 40 km/h (19 to 25 mph) , and
depending on the vehicle and engine type, the engine management system will
intervene in the control of the engine to prevent excessive engine noise at high revs
and low speeds.
174
Driving
DIFFERENTIAL LOCK
The rear axle can optionally be equipped with a differential lock which can be
activated from the cab.
Directions for use
The differential lock may only be used when driving on soft ground or on a slippery
road surface, and never on firm ground.
The differential lock should be engaged:
-
with the vehicle stationary or moving very slowly
with the clutch pedal depressed.
{
{
The differential lock must never be engaged if one of the wheels is
spinning; always wait until the wheel has stopped spinning before
engaging the differential lock. Disengage the differential lock as
soon as you reach firm ground. If the warning indicator on the
instrument panel stays on, drive forwards and then reverse a short
distance in order to release the locking mechanism.
Failure to follow the above directions may cause damage to the
differential lock and/or the differential.
175
Driving
STEERING
The steering gear is hydraulically assisted. As excessive pressure may damage the
hydraulic pump, stop turning the steering wheel when the wheels are at full lock or
are blocked by an obstacle. The steering gear may be damaged, if this is ignored.
RAS-EC SYSTEM
The RAS-EC system is an electronically controlled, speed dependent steering
system for the trailing axle. This steering system reduces the turning circle and tire
wear to a minimum.
In contrast to the mechanically steered axle, the RAS-EC system has no steering
linkage, but speed dependent, electronic-hydraulic steering by means of a steering
cylinder.
Speed-dependent
At speeds of up to 15 km/h (9mph), the trailing axle co-steers with the front axle,
both in forward and reverse direction. Above 15 km/h (9mph) the steering effect is
gradually reduced until 38 km/h (23 mph) is reached. Above 38 km/h (23 mph) the
trailing axle is fixed exactly in the centre position. This means that at higher speeds
optimum direction stability is ensured.
Faults
If a less serious fault occurs, the trailing axle is fixed in the centre position. The
trailing axle will no longer co-steer.
If a serious fault occurs, the complete RAS-EC system will be switched off. The
trailing axle is no longer activated but is forced to co-steer.
Note:
In the event of a serious fault, reversing is impossible. Due to friction between tire
and road surface the trailing axle will steer maximum in an uncontrolled manner.
176
Driving
}
In the event of a serious fault, the driving properties of the vehicle
will be affected.
A serious fault is indicated by an acoustic signal and the "STOP"
warning indicator will light up. Stop as soon as possible, park the
vehicle in a safe place and turn off the engine.
Have an authorized Service dealer correct the problem as soon as
possible.
ASR (ANTI SLIP CONTROL)
The vehicle can optionally be fitted with ASR control. ASR is an electronic, air
pressure controlled anti-slip system designed to prevent the driven wheels from
slipping when accelerating. This ensures that the vehicle remains stable when
pulling away on critical road surfaces (especially accelerating when cornering).
Accelerating with ASR gives more traction in comparison to accelerating with
slipping wheels. ASR is an addition to the ABS system. ASR is only located on the
driven wheels. When there is a danger of slipping on one or both wheels, the
relevant wheel(s) will be braked via a magnet valve and/or the engine torque
decreased, using a specific control. This means that one or both wheels are
maintained within a narrow slipping range close to the maximum frictional
coefficient, through which an optimum traction is achieved. If the ASR system is
active, the ASR warning indicator will light up.
177
Driving
ABS BRAKES
The ABS system is an Anti-lock Braking System.
The ABS ensures good brake stability and good steering in a critical braking
situation.
By preventing the wheels from locking, the steering characteristics of the vehicle are
retained.
Bear in mind that when the prime mover is equipped with ABS but not the drawn
vehicle, or vice versa, the directional stability and steering characteristics will not be
as good as when both units are equipped with ABS.
}
}
}
178
The ABS does not release the driver from his obligation to adapt his
driving style to the traffic and road surface conditions.
The anti-lock protection cannot offset the results of driving too
close to the vehicle in front or taking a bend at too high a speed.
Do not adapt your driving style to the ABS system!
Above all, do not brake later and then harder.
This only causes unnecessary tire wear. It may also be hazardous
for other road users.
Note: occasionally, but not always, your braking distance will be
shorter with ABS.
If the yellow warning symbol "ABS truck fault" is activated, there is
a fault in the ABS system of the prime mover.
Driving
ABS warning symbol in master display
If the ABS warning symbol in the master display remains illuminated while driving,
the ABS system is partly or completely deactivated and the brake system will work
as if no ABS is present. The wheels may then lock upon braking.
D0 00 587
}
PARKING BRAKE AND SERVICE BRAKE
Always apply the parking brake when parking the vehicle. Do not
release the parking brake while the steering lock is still engaged.
The vehicle cannot be steered if the steering lock is still engaged.
The service brake is operated by the foot pedal. If the service brake fails to operate
owing to insufficient air pressure, the parking brake can be used as an emergency
brake. Moving the parking brake lever slowly backwards as far as the stop will
gradually brake the vehicle or combination in a controlled manner. The parking
brake is engaged by moving the parking lever back past the locking cam. On a
vehicle with a drawn vehicle connection, the parking brake has a test position. See
"Stopping". The parking brake is disengaged by lifting the locking ring up against the
spring pressure and letting the parking brake lever move forwards.
179
Driving
ENGINE BRAKE
The engine brake is primarily intended for prolonged braking, for example when
decelerating from high speed on a level road or when driving downhill. This reduces
service brake wear.
A
D0 00 720
By moving the operating lever on the steering column in direction A and releasing
the accelerator pedal, the engine brake control will be activated.
Note:
- The engine cannot be turned off with the engine brake.
- In order to save the service brakes and to prevent the engine brake valve from
becoming stuck, it is wise to regularly use the engine brake.
The braking effect decreases as the engine speed falls.
The most appropriate area of use for the engine brake is in the blue area of the rev
counter. The engine brake delivers the highest braking effect in this area.
When using the engine brake, adjust your gear selection so that the engine speed
remains in the most favourable range.
The engine brake is automatically switched off:
180
Driving
-
when the engine speed drops below 1000 rpm.
when the ABS/ASR system has established a tendency for the wheels to lock.
when the accelerator pedal is depressed.
when the vehicle speed control or engine speed control has been engaged.
{
C
If the ABS/ASR control is activated, the engine brake will be
switched off as long as the control is in operation. On vehicles
where the ABS/ASR control fails to function or on vehicles not
equipped with ABS/ASR, use of the engine brake may lead to the
risk of skidding on slippery surfaces.
B
A
D000645
STOPPING
Parking
-
Move the parking brake lever (from position A) backwards past the locking cam
(position B). The parking brake is now engaged.
181
Driving
-
-
When driving a vehicle combination, check whether the parking brake lever can
be moved even further backwards from position B against the pressure of the
spring. Press in the parking brake lever and pull it further back (to position C).
This is the test position, the drawn vehicle's brakes are not applied in this
position. Check that the vehicle combination remains in place.
Let the parking brake spring back to position B.
Place chocks in front of and behind the wheels.
Angle the front wheels so that the vehicle will not move into the traffic stream if it
is accidentally set in motion.
If the vehicle combination does not remain in place in the test position, find a flatter
place to park the vehicle. Always carry out this test if the vehicle is parked in
unfavourable circumstances (gradient, slippery road surface, etc.). In this way, the
combination will remain safely parked, even if air leakage should make the drawn
vehicle brakes ineffective.
Switch off the engine.
Put the gear lever in neutral when the vehicle is stationary.
Before switching off the engine after a long trip or when the engine has been
subjected to high loading, let it idle for at least 5 minutes. It is important to let the
engine run for a while in order to prevent the coolant temperature becoming too high
and to allow the turbocharger to cool down.
Switch the engine off by turning the ignition key to 0 position (rest position).
182
Manual Gearbox
183
Manual Gearbox
ZF GEARBOX
D0 00 609
ZF S5-42 gearbox
The ZF S5-42 gearbox has five fully synchronised forward gears and one
non-synchronised reverse gear.
D0 00 610
184
Manual Gearbox
ZF 6S-850 gearbox
The ZF 6S-850 has six fully synchronised forward gears and one non-synchronised
reverse gear.
Shifting gears
- To avoid excessive and unnecesssary clutch wear, always engage the first gear
when driving away. This applies to both laden and unladen vehicles.
- Always depress the clutch fully when shifting gears.
- Push the gear lever smoothly when shifting until the gear is engaged.
- Wait until the vehicle is at a standstill before engaging reverse. Failure to do so
may result in serious damage to the clutch, gearbox and engine.
Driving
- Select the highest possible gear while at the same time keeping the engine
speed in the green zone of the rev counter.
- When speeding up, keep the engine speed within the green area of the rev
counter as much as possible.
{
The reverse gear may only be selected 5 seconds after the vehicle
has come to a stop. When shifting down, you must always ensure
that the speed is not too high for the gear you are selecting.
185
Manual Gearbox
EATON GEARBOX
R 51 73
B
A
C 26 48
D0 00 584
Eaton 6309 gearbox
The Eaton 6309 gearbox has eight synchronised forward gears, one crawler gear
(position C) and one reverse gear. The gearbox has a low speed range (1st to 4th
gear) and a high speed range (5th to 8th gear).
Shifting gears
- To avoid excessive and unnecessary wear of the clutch, always engage the first
gear when driving away. This applies to both a laden and an unladen vehicle.
- Always depress the clutch fully when shifting gears.
- Push the gear lever smoothly when shifting until the gear is engaged.
- Shifting from the low to the high speed range is done with a range-change
switch on the front of the gear lever. With the switch down (position A), the low
range (1st to 4th gear) is engaged and with the switch up (position B), the high
range (5th to 8th gear) is engaged.
186
Manual Gearbox
-
Pre-selection is permitted. Actual shifting from the low to the high range or vice
versa takes place as the gear lever passes through neutral.
Wait until the vehicle is at a standstill before engaging reverse. Failure to do so
may result in serious damage to the clutch, gearbox and engine.
Note:
If shifting from the high to the low range takes place at too high a vehicle speed,
a safety device will prevent shifting to the low range.
{
The reverse gear may only be selected 5 seconds after the vehicle
has come to a stop. When shifting down, you must always ensure
that the speed is not too high for the gear you are selecting. There
is also a safety device for shifting up from the low speed group to
the high speed group. If you forget to turn the range-change switch
to the uppermost position (position B), it is possible to switch from
4th gear to 1st gear rather than 5th gear. This may cause serious
damage to the clutch, gearbox and engine.
Driving
- Select the highest possible gear while at the same time keeping the engine
speed in the green zone of the rev counter.
- When speeding up, keep the engine speed within the green area of the rev
counter as much as possible.
187
Manual Gearbox
188
Automatic Gearbox
189
Automatic Gearbox
ALLISON 1000 & 2000 SERIES
General
The automatic gearbox is fully electronically controlled. The automatic gearbox has
5 forward gears and 1 reverse gear.
The automatic gearbox is operated by a selector lever. The selector lever is located
next to the driver's seat.
D0 00 789
Shifting gears
The various gears are selected with the selector lever.
Neutral position
No gears are activated in the "N" position. The vehicle is not locked in this position
and can therefore roll.
Use the parking brake to lock the vehicle.
Automatic forward drive
If the "D" position is selected, the vehicle will immediately begin to move (if the
brake system is pressurised and the vehicle is not on the parking brake). It is
190
Automatic Gearbox
therefore advisable to depress the brake pedal before selecting position "D". In this
position the gearbox will automatically shift up and down in all forward gears. In the
"1", "2" and "3" positions the gearbox shifts up to the selected gear. These positions
are used to keep the engine within the proper speed range or to obtain the
maximum engine brake performance.
Reverse
If position "R" is chosen the vehicle will also be immediately set in motion. In this
case, too, first depress the brake pedal and then select "R" position.
Faults
If the transmission fault warning symbol lights up in the master display, a fault has
been detected in the gearbox.
Read the following recommendations first or consult an authorized dealer if
necessary.
Gearbox
The ECU will block the functions of the selector lever and ensure that the gearbox
will select a "safe gear". It is important to drive the vehicle to a safe place as soon as
possible and switch the ignition off. It will no longer be possible to shift the gearbox
to neutral. The ECU will prevent this.
After approximately 30 seconds, try starting the engine again and engaging a gear.
If the fault is one whereby the gearbox must in no circumstances be shifted, the
ECU will no longer shift the gearbox. Driving is therefore no longer possible!
191
Automatic Gearbox
ALLISON MD3060
D0 00 790
General
The automatic transmission is electronically controlled and has a diagnostics
system that saves possible errors in the memory of the ECU (Electronic Control
Unit). They can be read out later. The operation and display take place via the
selector keypad.
The selector keypad has a display located next to the driver's seat and replaces the
gear lever on manual gearboxes.
The selector has the following functions:
-
engaging and disengaging the gearbox
choosing a shift program
reading the oil level
reading and deleting fault codes
The selector has the following six keys:
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Automatic Gearbox
Neutral
Neutral position
Drive
Automatic forward drive
Reverse
Reverse
MODE
Shift program selection
Shifting up
√
Shifting down
D0 00 791
Shifting gears
Neutral position
No gear is engaged in the "N" position. The vehicle is not locked in this position and
can therefore roll.
Use the parking brake to lock the vehicle.
The letter "N" appears in the display.
193
Automatic Gearbox
Automatic forward drive
If position "D" is chosen, the vehicle will be immediately set in motion. (If the air
system is pressurised and if the parking brake is not on.) It is therefore advisable to
depress the brake pedal before selecting position "D". In this position the gearbox
automatically shifts up to the higher gear.
In the display, the figure of the highest gear to which the gearbox can be shifted
appears.
Reverse
If position "R" is chosen the vehicle will also be immediately set in motion. In this
case, too, first depress the brake pedal and then select "R" position.
The letter "R" appears in the display.
Shift program selection
By pressing the "MODE" key briefly once, another shift program can be selected
from stationary and driving position. Two selections are possible:
194
Automatic Gearbox
Normal program
This program is chosen automatically when the vehicle contact has been turned off.
The warning lamp at the "MODE" key is not on.
This program allows the gearbox to shift gears as and when necessary so that
driving at higher speeds is possible. This may be advisable on unpaved terrain.
Economy program
The warning lamp at the "MODE" key is on.
This program will, in general, shift gears at somewhat lower engine speeds. This
results in more economical fuel consumption.
√ Shifting down
After selecting the "D" key and when the vehicle is driving, this key can be used to
keep the gearbox in a lower gear. The selected gear is shown in the display. The
gearbox will not shift up further until the " " or "D" key is pressed. The number of
gears that can be used will appear in the display.
Shifting up
This key is used to allow the gearbox to shift to a higher gear. This is however only
possible after having previously selected to stay in a low gear.
195
Automatic Gearbox
Use of the engine brake
When the engine brake is operated in third or higher gear, the ECU will shift down to
second gear as soon as the engine speed permits to do so.
This is in order to allow the engine brake to deliver maximum braking force.
The selector display shows the second gear selected by the ECU.
Using the PTO
If the vehicle is fitted with a PTO, this can be switched on in both neutral and first
gear (depending on the version).
PTO operation is, however, not permitted in Drive when the vehicle is being held
stationary by the service brake or parking brake. In this case, shift to neutral in order
to prevent overheating. Depending on the version, the electronic unit will shift the
gearbox to neutral if a command is given to do so.
Faults
If the transmission fault warning symbol in the master display lights up, there is a
fault in the gearbox (shifting gears), or the temperature of the gearbox oil is too
high.
The accompanying fault code can be read in the selector display function.
Read the following recommendations first or consult an authorized dealer if
necessary.
196
Automatic Gearbox
Gearbox
The ECU will block the functions of the selector and the gearbox will select a "safe
gear" for the gearbox. It is important to drive the vehicle to a safe place as soon as
possible and turn the contact off. It will no longer be possible to shift the gearbox to
neutral. The ECU will prevent this.
After approximately 30 seconds, try starting the engine again and engaging a gear.
If the fault is one whereby the gearbox must in no circumstances be shifted, the
ECU will no longer shift the gearbox. Driving is therefore no longer possible!
If the fault is one whereby the gearbox may still be shifted, the warning in the main
display will disappear. The ECU will have recorded the fault as an inactive fault.
It is now possible to drive the vehicle again, though the fault will still need to be
remedied.
In this situation, however, it is no longer possible to shift gears.
Gearbox oil temperature
If the transmission fault warning symbol in the master display comes on during
driving, this could be an indication that the gearbox oil has reached its maximum
temperature.
In this situation, the ECU limits gearbox shifting to the first four gears.
It is important to drive to a safe place as soon as possible and let the engine idle in
neutral at an increased idling speed.
As a result, the cooling system of the engine will try to cool the gearbox oil.
If after approximately two minutes the warning in the master display has not
disappeared, the engine must be turned off and contact made with the nearest
authorized Service dealer.
197
Automatic Gearbox
198
Air suspension
199
Air suspension
GENERAL
The remote control unit is used to operate the vehicle height on vehicles equipped
with electronically controlled air suspension (ECAS).
The remote control unit is located against the console of the driver's seat and can
only be operated with the ignition switched on and when the vehicle speed is lower
than 9 km/h (5 mph).
The electronically controlled air suspension system (ECAS) is controlled by a
microprocessor. Chassis height parameters are stored in the memory. If the actual
chassis height is not in conformity with the set parameters, it will automatically be
adjusted. The remote control unit can be used to set the chassis to the most suitable
height for coupling/uncoupling a trailer or for loading/unloading the vehicle.
{
200
Driving a vehicle that is not at normal driving height, other than for
coupling and uncoupling a semi-trailer is not permitted. The driving
properties of the vehicle will be adversely affected and the legally
permitted driving height could be exceeded.
Air suspension
REMOTE CONTROL
Remote control A
A
M1
M2
STOP
D000427
201
Air suspension
vehicle rear end selected
automatic setting of normal driving height
M1
lifting of chassis to pre-set height
M2
as M1, but for a different, pre-set chassis height
lifting of selected chassis end(s) until key is released
lowering of selected chassis end(s) until key is released
Stop
202
all adjustments are stopped
Air suspension
ENGAGING AIR SUSPENSION
-
Press the "Vehicle rear" key; the relevant warning lamp on the remote control
will come on.
The choice can be cancelled by pressing the same key once again.
If the air suspension continues to regulate during loading/unloading, press the stop
button. The vehicle will stop readjusting.
SETTING MEMORY KEYS (M-KEYS)
-
Bring the chassis to the required height using the "lower chassis" or "lift chassis"
keys.
Then press the "stop" key and keep it depressed. Then press either of the
Mkeys briefly. The chassis height at that moment will then be programmed in the
ECAS unit.
If this M key is again pressed some time later, the vehicle will adjust itself to this
programmed chassis height.
A different chassis height can be programmed with the other M-key in the same
way.
203
Air suspension
STOP BUTTON
When the "Stop" button on the remote control unit is pressed, the system responds
as follows, irrespective of the vehicle speed:
-
When the chassis height is being changed, the electropneumatic valves are cut
out immediately. The current height will now become the desired height.
If the "stop" key is pressed while switching off the ignition, the delay setting is
activated. When this setting is activated, the height adjustment remains active
for 60 minutes when the ignition is switched off or until the air supply has
become insufficient.
Unless stated otherwise, the buttons only need to be pressed once briefly.
204
Emergency repairs
205
Emergency repairs
VEHICLE TOOL KIT
All vehicles are fitted with a tool bag in the cab and a jack in the storage
compartment to the left of the wheel winch.
}
It is essential that the jack is always carefully stowed after use in
the storage space to the left of the wheel winch. If this safety
precaution is not observed, this may cause injuries or material
damage.
TILTING THE CAB
}
}
}
}
General
206
Make sure that the filler caps of the cooling system, the hydraulic
clutch and the windscreen washer reservoir are tightened. Do not
loosen the filler caps when the cab is tilted.
Only tilt the cab when the engine has stopped.
Make sure there is sufficient clearance around the cab.
You can stop tilting the cab forward at any time by turning the valve
to position √.
Emergency repairs
}
}
}
If the vehicle has been involved in a collision, the cab must under
no circumstances be tilted without due precautions. The internal
mechanism of the lifting cylinder may have been damaged to such
an extent that the cylinder is no longer locked by the internal stop
washer. In that case there is a danger of the cab no longer being
held back and falling forward to the ground. Have your authorized
Service dealer check the tilting mechanism.
Make sure that there is no one in the cab. Also make sure there are
no loose objects inside the cab; this includes objects in the
refrigerator. Make sure there are no people immediately in front of
the cab.
Never work under the cab if the cab has not been tilted fully
forward.
Note:
If a cooler box/refrigerator has been fitted, it should be switched off and if necessary
unplugged before tilting (depending on the type). The cooler box/refrigerator should
remain switched off at least 30 minutes after the cab has been tilted back.
207
Emergency repairs
D0 00 623
The cab is tilted hydraulically using a hand pump. This pump is located at the
co-driver's side, behind the cab. The pump has a cock which can be moved to two
positions:
position
to tilt the cab forwards.
position √ to tilt the cab backwards; this is also the driving position.
Tilting forward
- Apply the parking brake.
- Put the gear lever in "neutral" position.
- Close the doors.
- Turn the lever fully to the right, against the spring pressure, until it is locked in
position ; use the jack rod.
- Operate the pump so that the cab tilts forward. The cab locking mechanism
automatically releases. As soon as the cab passes its natural point of balance,
the force of gravity will gradually tilt the cab further forward without additional
pumping.
Tilting back
- Turn the lever to position √.
208
Emergency repairs
-
Tilt the cab back by operating the pump with the jack rod. The last part of
tilting-back is effected by the cab's own weight. When the catch engages, the
cab is automatically locked.
Leave the lever in position √.
Push the gear lever in 1st gear to lock the gearbox control.
Put the gear lever in neutral.
Checking the cab locking
When the cab is back in its normal position, the cab lock warning lamp in the master
display should be extinguished.
REPLACING THE POLY-V BELT
Important
Always fit the same type of poly-V-belt as the one being replaced.
1. Disconnect the earth lead from the battery.
A
B
C
D000633
2. Place a ratchet (A) with a 3/8" socket in the arm of the automatic belt tensioner
(B).
209
Emergency repairs
3. Slacken the poly-V-belt (C) (see arrow in illustration), so that it can be removed
from the pulleys.
4. Carefully allow the automatic belt tensioner to spring back to the stop.
5. Push the poly-V-belt between the fan and the wind tunnel collar and remove the
poly-V-belt.
6. Check all pulleys over which the poly-V-belt runs for dirt, rust and damage.
7. Fit a new poly-V-belt between the fan and wind tunnel collar. Place the poly-Vbelt over as many pulleys as possible.
8. Tension the automatic belt tensioner and place the poly-V-belt over the
remaining pulleys. Carefully allow the automatic belt tensioner to spring back
against the new poly-V-belt.
9. Check that the poly-V-belt is in all pulley grooves.
10. Connect the earth lead to the battery.
D001177
210
Emergency repairs
}
REPLACING THE FUEL FINE FILTER
When removing the fuel fine filter, a quantity of fuel will escape.
Collect the fuel and avoid the risk of fire.
Dirt in the fuel system can lead to significant damage to the fuel
system.
Diesel fuel is toxic and can therefore have a damaging effect on
your health. Any direct or indirect physical contact should therefore
be avoided.
In the event of contact with the skin: remove with paper or a cloth,
wash with soap and water. If irritation persists, consult a doctor.
If swallowed: do NOT induce vomiting. Rinse the mouth, drink two
glasses of water and see a doctor.
In the event of inhalation: get some fresh air and rest.
Removing the fuel filter
1. Place a receptacle under the filter.
2. Remove the filter by turning it anti-clockwise.
Note:
The fuel fine filter is a disposable filter and, therefore, may not be cleaned and
reused.
Fitting the fuel filter
1. Lightly lubricate the sealing ring (see arrow in illustration) with clean engine oil
(not diesel fuel).
2. Fit the filter unfilled until the sealing ring abuts and manually rotate it a ∂ to •
turn further.
3. Bleed the fuel system. See "BLEEDING THE FUEL SYSTEM".
4. Start the engine and check for leaks. If necessary, retighten the filter by hand.
211
Emergency repairs
D0 00 583
BLEEDING THE FUEL SYSTEM
Note:
When the hand pump is used, the fuel system will be automatically bled. The hand
pump is fitted against the back of the fuel tank on the water separator.
Bleeding
1. Loosen the hand pump knob anti-clockwise.
2. Use the hand pump until a clearly higher resistance is felt.
Note:
Stop pumping as soon as the higher resistance is felt. If you continue pumping,
the fuel system may become internally damaged.
3. Secure the hand pump knob by turning it clockwise.
212
Emergency repairs
}
DRAINING THE WATER SEPARATOR
B
A
D0 00 620
When draining the water separator, an amount of fuel will escape.
Collect the fuel and avoid the risk of fire.
Water in the fuel system may lead to significant damage.
1. Place a container beneath the water separator.
2. Remove the connector.
3. Unscrew the ring-shaped drain cock (B) on the bottom of the water separator in
anti-clockwise direction.
4. Drain the filter until pure diesel fuel comes out of the drain cock (A).
5. Turn the drain cock (B) if it abuts, another 1/8 - 1/4 turn.
6. Check the drain cock (B) for leakage.
7. To prevent pollution, the drained water/diesel fuel mixture should be passed to
the relevant authorities for reprocessing.
D0 00 606
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Emergency repairs
}
RELEASING THE PARKING BRAKE
1.
2.
3.
4.
Never release the parking brake on an incline.
Place wheel chocks in front of and behind the wheels.
Turn the release bolt counter-clockwise as far as the stop using a ring spanner.
This operation should be carried out for each spring brake cylinder.
Bring the parking brake back in operating order as soon as possible by turning
the bolts clockwise as far as possible and tightening them to a torque of 70 Nm
(51.6 lb-ft).
D0 00 569
WHEEL WINCH
Self-braking wheel winch
1. Remove the wheel nut covers.
2. Unscrew the spare wheel nuts.
214
Emergency repairs
3. Lower the spare wheel.
Note:
Always fit the wheel on the spare wheel bracket with the valve facing outwards.
D0 00 626
JACKING UP THE FRONT AXLE
When jacking up the front axle, the jack must be positioned under the jacking point
near the shock absorber.
}
Always use stands to support the chassis when carrying out repairs
or service under a vehicle which is resting on a jack.
215
Emergency repairs
D0 00 719
JACKING UP THE REAR AXLE
When jacking up the rear axle, the jack should always be positioned under the
jacking point at the bottom of the spring bracket.
216
Emergency repairs
}
Always use stands to support the chassis when carrying out repairs
or service under a vehicle which is resting on a jack.
To prevent deformation of the axle housing, the jack must under no
circumstances be located directly under the axle housing or the
differential casing.
CHANGING THE WHEEL
Note:
After changing a wheel/tire, the difference between the diameters of the various
tires on the vehicle may have become too large (for example, as a result of
differences in tread depth and/or tire pressure).
{
The ABS system cannot cope with too great a difference in tire
diameter and the system will automatically be disengaged.
Consequently, the ABS warning symbol will be shown in the master
display.
Depending on the tire types on the front and rear axle, this phenomenon may
already with a worn tire that is underinflated by 2 bar. So first check the tire pressure
if the warning indicator is on after a tire has been replaced.
{
Hence, there will be no ABS control under extreme conditions!
This is the reason why the maximum permitted difference in tire diameter for new
tires is 14%.
(This may occur when different tire sizes are fitted on the front or rear axles.)
217
Emergency repairs
}
When removing a wheel with a cracked or damaged wheel rim,
always deflate the tire (remove the tire valve) in view of possible
tensions in the wheel rim.
General
-
Only use the original tire wheel rims specified for the vehicle concerned.
Make sure that tires of the same type are fitted on both sides of the axle.
Insufficient cleaning of the mating surfaces and/or uneven tightening of the
wheel nuts may cause vibrations during driving or braking.
Note:
If a wheel stud is renewed, the other wheel studs on the relevant wheel must also
be renewed.
Removing the wheel
1. Chock the wheels to prevent the vehicle moving off.
2. Clean the screw thread of the wheel studs using a wire brush.
3. Oil the wheel studs sparingly.
4. Unscrew the wheel nuts.
5. Fit a jack under the jacking point at the wheel to be replaced.
6. Jack up the vehicle and place a support under the axle.
7. Remove the wheel nuts and take the wheel off the hub.
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Emergency repairs
Installing the wheel
D000495
1. Clean the fitting edge of the wheel hub by scraping off dirt and corrosion with a
scraper.
2. Apply a thin layer of grease to the fitting edge of the wheel hub.
D000496
3. Also apply a thin layer of grease to the fitting edge of the wheel rim. This grease
layer should prevent the wheel rim and the wheel hub from becoming "rustbound".
219
Emergency repairs
4. Check whether the contact surfaces of the wheel rim and the drum brake are
clean. Clean if necessary.
D000520
5. Clean the wheel nuts and then apply a drop of oil between the thrust washer and
the nut.
6. Also apply a drop of oil to the first turn of the wheel-stud screw threads.
6
1
1
8
3
9
1
6
3
6
7
4
4
10
7
2
5
5
4
3
5
8
2
2
D0 00 615
7. Fit the wheel nuts and tighten them evenly according to the sequence in the
illustration.
For the specified tightening torque, see "TECHNICAL DATA".
Note:
Wheel nuts should always be tightened and retightened in cold condition.
However, tightening wheel studs in extreme cold should be avoided.
8. Check the tire pressure.
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Emergency repairs
9. Retorque the wheel nuts after 100 km (62 miles).
If new wheel studs are fitted, they need additional retorquing after 500 km
(31 miles).
Note:
When a wheel had to be replaced, have the wheel nuts torqued to the correct
tightening torque by a dealer.
TIRE INFLATING CONNECTION
Next to the brake system air dryer to the left rear of the cab there is a tire inflating
connection.
1. Remove the rubber protective cap from the tire inflating connection.
2. Connect the tire inflating hose.
3. Pump up the tire. Inflate the tires while the engine is running and with maximum
pressure in the air reservoirs.
4. Refit the protective rubber cap to the tire inflating connection after the tire has
been inflated and store the hose.
Check as soon as possible that the tires have the correct pressure using a pressure
gauge. See the tire pressure table under "TECHNICAL DATA".
Note:
The entire air pressure system of the vehicle can be filled with air from an outside
source using the tire inflating connection. When doing this, check that the system
pressure is correct using the air pressure gauge.
221
Emergency repairs
D0 00 723
TOWING
It is possible to install a towing eye behind the grille.
Always use a towing bar when towing. Departure from this rule is only allowed in
emergencies.
When towing, the fault message "Engine management fault" may appear in the
master display when the ignition is turned on.
Note:
The maximum permissible vehicle speed, weight and distance vary per country.
222
Emergency repairs
Tractors may be fitted with a small towing hook at the rear end of the chassis. This
towing hook must only be used for light shunting work.
{
}
{
Do not tow the vehicle when fully loaded or with a drawn vehicle
attached.
Being towed by another vehicle
When the engine is not running, there is no power steering and no
air is supplied to the braking system.
If the service brake is applied or in the case of air leakage, the
parking brake might be applied.
The towed vehicle can be located asymmetrically (left or right)
behind the tractor. Towing may not take place at an angle larger
than 20 with the vehicle centreline.
D0 00 722
-
To clear the towing eyes, the black grid must be removed from the lower grille by
turning the attachment screws a quarter turn.
223
Emergency repairs
-
Always fix the tow rod with its original attachment pin (part of the vehicle tool kit)
in the towing eyes.
Turn the ignition key so that the steering wheel is released (unless the vehicle is
in a hoist, see below).
To prevent damage to the gearbox, the propeller shaft must always be
disconnected from the differential.
If there is insufficient pressure in the air reservoirs, release the parking brake.
See "Releasing the parking brake".
If the differential is damaged:
-
Hoist the vehicle at the rear and lock the steering wheel in the straight-ahead
position.
Tow starting
If the vehicle has to be towed to start the engine, the ignition key must first be turned
clockwise to position D of the starter/ignition switch (ignition on).
Long-distance towing
If the vehicle is to be moved over a larger distance, this must be done by a recovery
vehicle that lifts the vehicle to be towed under its front axle.
REPLACING BULBS
-
224
Do not touch the glass of the halogen lamps with bare fingers. If necessary, this
glass can be cleaned with a cloth, which has been dampened with industrial
alcohol (methylated spirits).
When fitting a new bulb, make sure that the lugs on the bulb holder engage in
the slots of the reflector.
Emergency repairs
Dipped beam
1.
2.
3.
4.
Tilt the cab forwards.
Detach the rubber cover (2) from the rear of the headlamp unit.
Detach the spring clamp and pull the bulb away from the reflector.
Detach the double plug from the rear of the bulb.
Parking light
1
2
3
D0 00 594
1.
2.
3.
4.
Tilt the cab forwards.
Detach the rubber cover (2) from the rear of the headlamp unit.
Pull the holder of the parking light from the headlamp unit.
Pull the bulb out of the bulb holder.
Main beam
1.
2.
3.
4.
Tilt the cab forwards.
Detach the rubber cover (1) from the rear of the headlamp unit.
Detach the spring clamp and pull the bulb away from the reflector.
Detach the spring clamp and pull the bulb away from the reflector.
Direction indicator
1.
2.
3.
4.
Tilt the cab forwards.
Detach the plug from the rear of the bulb holder (3).
Screw the bulb holder anti-clockwise out of the headlamp unit.
Pull the bulb carefully out of the bulb holder.
Rear lights
1. Unscrew the four Philips screws and remove the lens cap.
225
Emergency repairs
1
2
3
4
5
D0 00 628
1.
2.
3.
4.
5.
Fog light
Reversing light
Rear light
Stop light
Direction indicator
D0 00 618
226
Emergency repairs
Direction indicators
1.
2.
3.
4.
Detach the plug on the inside of the wheel arch.
Remove the two screws and detach the lamp unit of the direction indicator.
Unscrew the bulb holder anti-clockwise out of the indicator lamp unit.
Pull the bulb carefully out of the bulb holder.
D0 00 590
Stepwell lighting
1. Remove the stepwell lighting housing from the bottom of the door by inserting a
screwdriver in the notch.
2. If necessary, remove the plug.
3. Unscrew the bulb holder anti-clockwise out of the stepwell lighting housing.
4. Pull the bulb carefully out of the bulb holder.
227
Emergency repairs
D0 00 580
Contour lighting
1. Unscrew the bulb holder anti-clockwise from the housing.
2. Pull the bulb out of the bulb holder.
D0 00 571
Roof light
The transparent covers of the roof lights have a slot allowing the lens to be tilted out
of the housing using a screwdriver.
228
Emergency repairs
1. Remove the transparent cover of the roof light carefully from the roof upholstery.
2. Pull the bulb carefully out of the bulb holder.
D0 00 591
Interior lighting/reading lamp
The transparent covers of the interior lighting/reading lamp have a slot allowing the
cover to be tilted out of the housing using a screw driver.
1. Insert a screwdriver into the groove of the correct lens. Press in the internal
attachment slightly. Then pull the lens carefully down and out of the lighting unit.
2. Remove the bulb(s) carefully from the bulb holder.
229
Emergency repairs
}
FUSES AND RELAYS
D0 00 617
230
To prevent overload and the risk of fire you must NEVER replace a
burnt-out fuse with a fuse with a higher rating than specified. If a
specific fuse repeatedly blows, this means there is a fault in the
circuit, which MUST be inspected and remedied.
NEVER replace or remove a fuse if:
- the contact is on.
- the engine is running.
- a consumer is switched on.
The fuses are behind a cover in the dashboard on the co-driver's side.
Attached to the inside of the cover is a sticker with an overview of the fuses.
For replacing fuses there is a special fuse clamp on the fuse board.
Each fuse is colour-coded to show the rating:
Orange
5A
Red
10 A
Blue
15 A
Yellow
20 A
Transparent
25 A
Green
30 A
Emergency repairs
Fuses
E004
Fuse, dipped beam, driver's side
E005
Fuse, dipped beam, co-driver's side
E006
Fuse, main beam, driver's side
E009
Fuse, front fog lights
E013
Fuse, brake lights
E018
Fuse, windscreen wiper motor
E019
Fuse, horn
E023
Fuse, tachograph timer switch
E025
Fuse, windscreen wiper/washer motor
E026
Fuse, cigar lighter/door switches/electronic unit converter 24/12 V with
power supply for radio memory
E027
Fuse, electronic converter 24/12 V with power supply for radio memory
E028
Fuse, interior lighting, bunk lamps/central door locking
E031
Fuse, heater fan
E035
Fuse, generator voltage regulation/ECS-DC3
E039
Fuse, seat heater
E043
Fuse, trailer ABS
E044
Fuse, mirror heating/adjustment/window control
E048
Fuse, trailer power
E051
Fuse, ECAS
E052
Fuse, work lamp
231
Emergency repairs
Fuses
E053
232
Fuse, diagnostic connector/alarm system/ECAS
E058
Fuse, auxiliary heater
E062
Fuse, ECAS
E091
Fuse, heating element, air dryer/water separator/RAS-EC/engine speed
control application connector
E108
Fuse, VIC
E114
Fuse, auxiliary heater/warning lamps
E143
Fuse, tachograph/alarm system/immobiliser/ABS-D/ABS/ASR-E
E144
Fuse, automatic gearbox AGC
E153
Fuse, main switch power supply
E156
Fuse, accessories
E158
Fuse, DIP-4 instrument panel
E160
Fuse, ECS-DC3
E163
Fuse, rotating beacons/roof hatch
E165
Fuse, FPH-E fuel heater, after contact
E190
Fuse, ABS-D/ABS/ASR-E
E198
Fuse, central door lock
E277
Fuse, VIC
E279
Fuse, generator voltage regulation
E280
Fuse, VIC
E282
Fuse, engine brake switch/brake light switch
Emergency repairs
Fuses
E283
Fuse, headlamp height adjustment/width marker light, 1st, left and right/
tail light, right
E284
Width marker light, 2nd, left and right/tail light, left/search lighting
E285
Fuse, VIC/fog lights switch
E286
Fuse, power supply
E290
Fuse, RAS-EC
E297
Fuse, airbag and seat belt tensioner system
E299
Fuse, windscreen heating
E330
Fuse, main switches "sens" wire
E349
Fuse, cab power supply
E354
Fuse, automatic gearbox, AGC fan
233
Emergency repairs
234
Technical Data and Identification
235
Technical Data and Identification
ENGINE
Type
Types
LF 45 SERIES
BE 99 C
BE 110 C
BE 123 C
CE 136 C
CE 162 C
LF 55 SERIES
BE 123 C
CE 136 C
CE 162 C
CE 185 C
Engine
236
Engine type
Model
BE ... C ENGINE
Euro 3, water-cooled, four-stroke diesel
engine with electronically controlled fuel
injection system, 4 valves per cylinder and
turbo-intercooling.
Number of cylinders
Bore x stroke
Total capacity
Capacity of lubrication system,
including filter and oil cooler
Sump capacity, maximum level
Sump capacity, minimum level
Capacity of cooling system,
including heater
4
102 x 120 mm
3.9 litres
CE ... C ENGINE
Euro 3, water-cooled, four-stroke
diesel engine with electronically
controlled fuel injection system,
4 valves per cylinder and turbointercooling.
6
102 x 120 mm
5.9 litres
13.5 litres
11.5 litres
9.5 litres
20 litres
19.5 litres
17.5 litres
15.5 litres
22 litres
Technical Data and Identification
Output and torque
Type
BE 99 C
BE 110 C
BE 123 C
CE 136 C
CE 162 C
CE 185 C
Maximum output
P (kW/hp)
99/135
110/150
123/170
136/185
162/220
185/250
Engine speed at max.
output np (rpm)
2500
2500
2500
2500
2500
2500
Maximum torque
M (Nm)/(lb ft)
500 / 368.7
550 / 405.6
600 / 442.5
700 / 516.3
820 / 604.8
950 / 700.7
Engine speed at max.
torque nm (rpm)
1200-1600
1200-1600
1200-1600
1200-1700
1200-1700
1200-1700
237
Technical Data and Identification
ELECTRICAL SYSTEM
Voltage
Alternator
Batteries
Starter motor
24 V
80 A / 29 V (extra: 100 A / 29 V)
2 x 12 V / 125 Ah (extra: 2 x 12 V / 170 Ah)
4 kW / 24 V
Bulbs
Dipped beam
Main beam
Parking light
Tail light
Rear fog light
Reversing light
Stop light
Direction indicator
Registration plate
Cab interior lighting
Bunk light
Contour marker light
Stepwell lighting
Marker light
Combi-light: fog light
Spotlight
Work light, white
Work light, yellow
238
H7 70 W
H1 70 W
5W
10 W
21 W
21 W
21 W
21 W
10 W
10 and 21 W
21 W
5W
5W
5W
H 70 W
H 70 W
H 70 W
35 W
Technical Data and Identification
WHEELS
Whenever the wheel nuts have been slackened or removed, they must be retorqued
with a torque wrench after 100 km (62 miles).
}
If a wheel stud is renewed, the other wheel studs on the relevant
wheel must also be renewed. If new wheel studs are fitted, the nuts
must be retorqued after 500 km (310 miles).
Wheel nut tightening torques
LF45
Version with 6 M18 wheel nuts
Version with 8 M18 wheel nuts
370 Nm (272.9 lb ft)
370 Nm (272.9 lb ft)
LF 55
Version with 8 M20 wheel nuts
Version with 10 M22 wheel nuts
485 Nm (357.7 lb ft)
700 Nm (516.3 lb ft)
239
Technical Data and Identification
TIRE PRESSURE TABLE (METRIC)
Recommended pressure (bar) at various loads (kg) E= single fitting D= twin fitting
Tires
2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000
size
10 R17.5 E
D
10 R22.5 E
D
12 R22.5 E
D
205/75
E
R17.5
D
215/75
E
R17.5
D
225/75
E
R17.5
D
235/75
E
R17.5
D
245/75
E
R17.5
D
245/70
E
R19.5
D
265/70
E
R19.5
D
285/70
E
R19.5
D
275/70
E
R22.5
D
275/80
E
R22.5
D
295/80
E
R22.5
D
305/70
E
R22.5
D
315/80
E
R22.5
D
240
4.1
5.1
6.1
7.0
5.5
6.2
5.6
6.7
4.2
5.2
6.3
4.0
5.1
6.2
7.5
4.7
5.7
6.5
3.3
4.4
5.4
6.4
7.5
3.3
4.4
5.5
6.5
7.5
3.9
4.7
5.5
6.2
3.5
4.3
5.1
6.1
5.3
4.2
3.8
4.5
5.4
6.0
6.5
7.0
7.5
6.5
7.2
7.7
5.7
8.5
6.0
6.5
9000
10000
11000
12000
5.6
6.0
6.7
7.5
8.2
13000
7.0
6.0
4.4
4.9
8500
5.0
7.0
5.5
6.2
4.9
5.4
6.0
4.7
5.3
5.8
6.4
5.2
5.5
6.2
6.5
4.4
4.9
5.4
5.8
6.2
6.8
7.3
4.2
4.7
5.2
5.7
6.2
6.7
7.2
5.1
5.7
6.2
6.7
7.7
3.9
8.6
4.6
6.9
4.6
5.2
5.6
6.0
6.5
7.3
6.2
7.0
7.7
8.5
5.5
6.0
6.5
7.2
8.2
6.0
6.7
7.5
8.2
5.7
6.2
7.0
7.7
5.5
6.0
6.5
7.2
7.7
5.6
6.0
6.7
7.5
8.2
6.0
6.7
7.4
5.3
5.7
6.5
7.2
8.0
5.8
6.3
6.0
6.5
7.2
4.7
5.1
8.2
8.5
4.4
8.9
7.0
7.5
8.0
8.5
7.7
Max.
axle
load
(kg)
4240
8000
5000
9200
7100
12600
2900
5600
3200
6200
3600
6600
3800
7200
4480
8000
4360
8240
4480
8480
5600
9200
6300
11600
6300
11600
7100
12600
7100
12600
8000
13400
Pressure
at
maximum
axle load
7.5
7.5
8
8
8.5
8.5
6.8
6.3
6.8
6.3
7.5
6.5
7.3
6.8
8.3
7.5
8.3
7.5
7
7
7
7
9
8.5
8.5
8
8.5
8.5
9
8.5
8.5
8
Technical Data and Identification
TIRE PRESSURE TABLE (US)
Recommended pressure (psi) at various loads (lb) E= single fitting D= twin fitting
Tire size
10 R17.5 E
D
10 R22.5 E
D
12 R22.5 E
D
205/75
E
R17.5
D
215/75
E
R17.5
D
225/75
E
R17.5
D
235/75
E
R17.5
D
245/75
E
R17.5
D
245/70
E
R19.5
D
265/70
E
R19.5
D
285/70
E
R19.5
D
275/70
E
R22.5
D
275/80
E
R22.5
D
295/80
E
R22.5
D
305/70
E
R22.5
D
315/80
E
R22.5
D
4400 5500
6600
7700
8800
59.45
73.95
88.45
101.5
79.75
89.9
9900
11000 12100 13200 14300
97.15
60.9 75.4
91.35
58
73.95
89.9
108.75
68.15
82.65
94.25
47.85 63.8
78.3
92.8
108.75
47.85 63.8
79.75
94.25
108.75
56.55
68.15
79.75
89.9
50.75
62.35
73.95
60.9
55.1
16500
17600
94.25
101.5
108.75
71.05
78.3
87
94.25
104.4
82.65 87
111.65 123.25
18700
19800
22000
24200
26400
81.2
87
97.15
108.75 118.9
101.5
87
63.8 81.2
15400
101.5
79.75
89.9
71.05
78.3
87
68.15
76.85
84.1
92.8
75.4
79.75
89.9
94.25
63.8
71.05
78.3
84.1
89.9
98.6
105.85
60.9
68.15
75.4
82.65
89.9
97.15
104.4
56.55
100.05 111.65 124.7
66.7
73.95
82.65
89.9
97.15
88.45
66.7
75.4
81.2
87
94.25
105.85
76.85
89.9
101.5
111.65 123.25
79.75
87
94.25
104.4
118.9
87
97.15
108.75 118.9
82.65
89.9
101.5
111.65
79.75
87
94.25
104.4
81.2
87
97.15
108.75 118.9
87
97.15
76.85
82.65
94.25
104.4
116
84.1
87
94.25
104.4
65.25
72.5
94.25
73.95
107.3
111.65 123.25
63.8
68.15
118.9 129.05
91.35
101.5
123.25
108.75 116
28600
Max.
Pressure
axle
at
load
maximum
(lb)
axle load
9328
108.75
9328
108.75
17600 108.75
11000 116
20240 116
15620 123.25
27720 123.25
6380
98.6
12320 91.35
7040
98.6
13640 91.35
7920
108.75
14520 94.25
8360
105.85
15840 98.6
9856
120.35
17600 108.75
9592
120.35
18128 108.75
9856
101.5
18656 101.5
12320 101.5
20240 101.5
13860 130.5
25520 123.25
13860 123.25
25520 116
15620 123.25
27720 123.25
15620 130.5
27720 123.25
111.65 17600 123.25
241
Technical Data and Identification
Checking the tire pressures
Tire pressures depend on axle load and tire size.
Tire pressure table*
-
The tire pressures shown in the table apply to cold tires.
Unnecessary tire wear is frequently caused by vehicle operation with tire
pressures which do not match the axle load.
When twin wheels are fitted:
both tires must be inflated to the same pressure;
the tread depth must be practically the same on both tires.
* The axle loads and corresponding tire pressures shown in the table apply to
normal operating conditions. For all other cases, refer to the specifications of the tire
manufacturer.
LUBRICANT-, ENGINE COOLANT- AND FUEL SPECIFICATIONS
To comply with the warranty terms and to guarantee the durability of the
manufacturers products, it is essential that the correct lubricants, engine
coolant and fuel are used and that the oil change intervals are adhered to.
Additives to lubricants, engine coolant and fuel - of whatever type - must not
be used except in those circumstances prescribed by the manufacturer.
Always follow the safety instructions below and the instructions that are
supplied with the product.
242
Technical Data and Identification
Ask your lubricant and fuel suppliers whether their products comply with
specifications.
The manufacturer is not liable for damage or problems in the following instances:
-
If oil has been used of a lower grade than specified.
If oil has been used of a different viscosity than specified.
If the specified oil change interval has been exceeded.
if fuel, lubricants or coolants have been used which do not meet the
requirements specified.
}
Avoid physical contact with:
- lubricants
- coolants
- Fuel
- battery acid
In the event of skin contact: remove substance with paper or cloth, wash with
soap and water.
Consult a doctor in the event of persistent irritation.
In the event of contact with the eyes: remove substance with soft cloth and
rinse with water.
Consult a doctor in the event of persistent irritation.
If any is swallowed: DO NOT induce vomiting. Rinse mouth, drink two glasses
of water and consult a doctor.
In the event of inhalation: get some fresh air and rest.
243
Technical Data and Identification
Battery acid:
In the event of skin contact: rinse the skin profusely with plenty of water.
Consult a doctor in the event of persistent redness or pain. Remove polluted
clothing and rinse in water.
In the event of contact with the eyes: rinse with plenty of water for at least
15 minutes and see a doctor.
If any is swallowed: do NOT induce vomiting. Rinse the mouth, drink two
glasses of water and see a doctor.
In the event of inhalation: get some fresh air, rest and consult a doctor.
ENGINE OIL
Specification lists refer to international standards, such as ACEA and API.
Viscosity is also subject to specific requirements.
Additional information:
ACEA E3: mineral oil
ACEA E5: further developed ACEA E3 mineral oil, geared to possible higher
requirements on Euro 3 engines.
ACEA E4: partially or completely synthetic oil, specially developed for extended oil
change interval and/or highly loaded engines.
Explanation of overview:
V = may be used
244
Technical Data and Identification
LF 45/55
Engine type
ACEA E3 ..W-40
ACEA E4 ..W-40
ACEA E4 ..W-30
ACEA E5 ..W-40
BE
V
CE
V
}
ACEA E5 ..W-30
COOLANTS
Coolant is a toxic fluid. Protect skin and eyes. In case of accidental
contact with skin and/or eyes, see "Lubricant, engine coolant and
fuel specifications".
Coolant is harmful to the environment; after use, it should be
processed as industrial chemical waste.
The cooling system should preferably be filled with a ready-mixed coolant
containing antifreeze and corrosion inhibiting additives.
The coolant present in the cooling system from the factory consists of an ethylene
glycol base: Texaco Havoline XLC.
Coolant identification
A sticker behind the grille states the information on the coolant used.
D001055
245
Technical Data and Identification
Coolant according to specification 74002
The below table lists the current suppliers that meet specification 74002.
It is not allowed to fill the cooling system with another product than the one specified
in this overview.
246
Brand name
Supplier
Long Life Coolant
N.V.
Havoline XLC/Havoline Extended Life
Antifreeze Coolant
ChevronTexaco
Caltex Extended Life Coolant
Caltex
Total Organifreeze
Total
Maxigel Plus/Ultracooling Plus
Renault Truck Oils
Bevercool Organic
Beverol
BP Procool
BP
Castrol Antifreeze SF Premix
Castrol
Inugel Optimal/Inugel Optimal Ultra
Motul
Yacco LR Organique
Yacco
Valvoline Antifreeze Extreme
Valvoline
Petrol Antifriz Koncentrat
Petrol
Orvema Protex Long Life/Coolmix LL
Orvema
SB-G12
Sotragel
Technical Data and Identification
DIESEL FUEL
Diesel fuel must meet the specifications according to EN 590.
Note:
It is prohibited to add petroleum (kerosene), petrol or any other additive to the diesel
fuel.
Sulphur content > 0.2%:
Halve engine oil change interval to max.
of 25,000 km (15,534 miles)
Fuel should have a lubricity effect according to the requirements below ("lubricity
standard"):
test method:
HFFR according to standard CEC-F
06-A96
test value:
< 460 µm
Always contact your authorized dealer to get to know whether it is or is not permitted
to use alternative fuels (e.g. biodiesel); the dealer can also tell you whether any
consequences are involved in using such fuels.
247
Technical Data and Identification
STEERING GEAR
Hydraulic power steering
ATF DEXRON III with valid approval
number
CAB TILTING MECHANISM
Cab tilting pump
The following may be used:
Oil must meet MIL-H-5606C
ESSO Univis J13
FINA Hydran B5219B
TEXACO Aircraft Hydraulic Oil 5606G
TOTAL Aerohydraulic 520
CLUTCH
Hydraulic clutch
248
Brake fluid DOT 3 or DOT 4
Technical Data and Identification
CHASSIS NUMBER
The chassis number is stamped on the right chassis side member close to the front
axle.
XX
XX
XX
X
D0 00 579
D0 00 597
ENGINE NUMBER
The engine number is stamped on the front right of the engine.
Cu
mm
ins
Cummins
Engine Company Inc.
Box 3005
Columbus, Indiana
47202-3005
Warning injury may result and warranty is voided
if fuel rate or rpm or altitudes exceed published
maximum values for this model and application.
Date of Mig
Made in Great Britain by
Cummins Engine Co Ltd
C.I.D./L
CPL
Engine Serial No.
Cust. spec.
Family
Engine model
Low idle RPM
Valve lash cold
Firing Order
Rated HP/KW
Int.
Exh. Fuel rate at rated HP
mm3/st
Timing-TDC
at
RPM
D0 00 599
249
Technical Data and Identification
ENGINE IDENTIFICATION PLATE
The engine identification plate is attached to the top of the flywheel housing. The
plate shows the engine number and some adjustment data.
K9620
H3279WHTE
DAFCODE # 0393796
DAFORDER # 123221
D0 00 607
PAINT IDENTIFICATION PLATE
The paint identification plate is attached to the bulkhead behind the front panel.
D000667
250
Technical Data and Identification
VEHICLE IDENTIFICATION LABEL
The vehicle identification plate is located on the door jamb.
Each vehicle uses a Vehicle Identification Number (VIN) that contains the model
year designation of your vehicle. The practice is in compliance with 49 CFR 565,
Code of Federal Regulations.The VIN contains 17 digits. The 10th digit is the code
for the model year of your vehicle. The example VIN below from a 1999 model
shows how this code works:
EXAMPLE VIN: 1XP 9D2X9 6 X D 345678
Model Year
Serial Number
ALR TYPE PLATE
D0 00 635
The ALR type plate (load-sensing valve) is on the right-hand door pillar.
The instruction plate contains details of the axle loads and output pressures; these
correspond to the order of the axles underneath the vehicle.
So "1" is the front axle, etc.
Therefore, the data on the instruction plate relating to the driven axle is important
when checking the load-sensing valve!
251
Technical Data and Identification
252
Consumer Information
253
Consumer Information
FEDERAL SAFETY STANDARD CERTIFICATION LABEL
The National Highway Traffic Safety Administration regulations require a label
certifying compliance with Federal Safety Standards, for United States and U.S.
Territories, be affixed to each motor vehicle and prescribe where such label may be
located.This certification label, which indicates the date of manufacture and other
pertinent information, is located on the left hand cab door post.
0295
How To Order Parts
When you need replacement parts for your Peterbilt vehicles, contact your nearest
authorized Peterbilt dealer, who may be located from the “Peterbilt Authorized U.S.
and Canadian Dealers” listing (Cat. No. 5212).
When you order, it is IMPORTANT than you have the following information ready:
Your name and address.
Serial number of the truck.
The name of the part you need.
The name and number of the component for which the part is required.
The quantity of parts you need.
How you want your order shipped.
NHTSA Consumer Information
The National Highway Traffic Safety Administration requires that the following
information be included in the owner’s manual of motor vehicles manufactured after
September 1, 1990:
If you believe that your vehicle has a defect which could cause a crash or could
cause injury or death, you should immediately inform the National Highway Traffic
Safety Administration (NHTSA) in addition to notifying Peterbilt Motors Company.
If NHTSA receives similar complaints, it may open an investigation, and if it finds
that a safety defect exists in a group of vehicles, it may order a recall and remedy
254
Consumer Information
campaign. However, NHTSA cannot get involved in individual problems between
you, your dealer, and Peterbilt Motors Company.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800424-9393 (366-0123 in Washington, D.C.) or write to: Administrator, NHTSA, 400
Seventh Street, S.W., Washington, D.C. 20590. You can also get other information
about auto safety from the Hotline.
Canadian Consumer Information
Canadian customers who wish to report a safety-related defect to Transport
Canada, Defect Investigations and Recalls, may telephone the toll free hotline 1800-333-0510, or contact Transport Canada by mail at
Transport Canada, ASFAD
Place de Ville Tower C
330 Sparks Street
Ottawa ON K1A 0N5.
For additional road safety information, please visit the Road Safety website at
http://www.tc.gc.ca/roadsafety/menu.htm
Environmental Protection
Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.
Other chemicals in this vehicle are also known to the State of California to
cause cancer, birth defects or other reproductive harm. This warning
requirement is mandated by California law (Proposition 65) and does not
result from any change in the manner in which Peterbilt trucks are
manufactured.
Some of the ingredients in engine oil, hydraulic oil, transmission and axle oil, engine
coolant, diesel fuel, air conditioning refrigerant (R12, R134a, and PAG oil),
batteries, etc., may contaminate the environment if spilled or not disposed of
properly. Contact your local government agency for information concerning proper
disposal.
State of California
255
Consumer Information
California Vehicle Code, Section 9951 - Disclosure of Recording Device
Your vehicle may be equipped with one or more recording devices commonly
referred to as “event data recorders (EDR)” or “sensing and diagnostic modules
(SDM)”. If you are involved in an accident, the device(s) may have the ability to
record vehicle data that occurred just prior to and/or during the accident.
For additional information on your rights associated with the use of this data, contact
the California Department of Motor Vehicles - Licensing Operations Division
or
http://www.dmv.ca.gov/pubs/vctop/d03_6/vc9951.htm
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
Other chemicals in this vehicle are also known to the State of California to cause
cancer, birth defects or other reproductive harm.
Battery posts, terminals, and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.
256
Alphabetical index
257
Alphabetical index
A
ABS 157
Adjustable steering column 83
Air conditioning switch 70
Air filter indicator 115
Air pressure gauge, circuits 1 and 2 54
Air suspension 176
Alarm system 32
ALR type plate 221
ALS-S
Diagnostics 36
Anti-dazzle sticker 18
Antifreeze 214
ASR (Anti Slip Control) 157
Automatic gearbox 170
B
Batteries 21, 120
Bleeding the fuel system 187
Brake system air drier 119
Bulbs 208
Bunk lamp 51
Bunks 46
C
Cab heater
air heating 83
Cab maintenance 123
Cab tilting mechanism 218
Central door locking 44
Centre console 74
Changing the wheel 190
Chassis number 219
Cleaning 123
Clutch 218
258
Clutch fluid level 118
Connecting up the brake lines of a
drawn vehicle 140, 141
Connecting up the drawn vehicle lights
(24V electrical system) 144
Control panel 64
Coolant 114
Coolant temperature gauge 54
Coolants 214
Cooling system 128
Cruise control 152
D
Dashboard 52
Diesel fuel 126, 217
Differential lock 155
Doors 43
Draining the water separator 119, 188
Driving style 154
E
Eaton gearbox 165
Electrical mirror adjustment 46
Electrical system 208
Electrically operated windows 44
Engine 206
Engine brake 159
Engine identification plate 219
Engine number 219
Engine oil 213
Engine oil level 113
Engine speed control 149
F
Fan opening selector switch 73
Fan speed selector switch 72
Alphabetical index
Fifth wheel 134
lubrication 122
Fluid level in screen washer reservoir 115
Fuses and relays 201
G
Glow system 147
H
Hazard warning lights 74
I
Immobiliser fault 149
Instrument panel 54
Interior lighting 51
ITS 11
J
Jacking
front axle 189
Rear axle 190
L
Lubricant, coolant and fuel specifications 211
Lubricating the fifth wheel/trailer coupling 122
M
Maintenance
air conditioning system 19
general 121
operations 18
operations after the winter season 128
operations before the winter season 126
Master display 97
Menu overview 102
Menu selector switch 100
Mirrors 45
Mobile telephones and transmitters 24
Modifications to the vehicle 15
O
Opening the front panel 112
Overview of daily checks 112
Overview of weekly checks 117
P
Paint identification plate 220
Parking brake 188
Parking brake and service brake 159
Power steering fluid level 118
R
RAS-EC system 156
Remote control 177
Replacing the fuel fine filter 186
Replacing the poly V-belt 185
Rev counter 54
Roof console 47, 79
Roof hatch 48
Roof spoiler 48
Rotating beacon 79
Running-in 20
S
Safety instructions
airbag 25
Seat belts 93
Seat settings 91
Starting
with auxiliary batteries 23
Starting procedure 148
Steering 156
Steering column switch
Engine brake 82
left 81
right 82
259
Alphabetical index
Steering gear 218
Steering lock/contact/starter switch 147
Stopping 161
T
Technical items of special importance 20
Temperature adjustment 72
Tilting the cab 182
Tool boxes/storage compartments 47
Towing 194
Trailer coupling 130
lubrication 122
Tire inflating connection 194
Tire pressure table 210
V
Vehicle identification plate 220
Vehicle speed limitation for special applications 154
Vehicle tool kit 182
W
Warning indicators 58
Warning symbols 105
Warnings and safety regulations 15
Welding 23
Wheel winch 189
Wheels 209
Windscreen washer reservoir 127
Z
ZF gearbox 164
260