Avia D60-D90 E3 (By 2006) Owner Manual

Dear driver,
This driver‘s manual was worked out for familiarising with operation and basic
maintenance of Your new AVIA truck and it should provide you with important
information from point of view of safe operation.
We recommend you to read it carefully and to follow instructions mentioned in it.
This way, you will gain pleasant and safe vehicle operation without problems.
For long-term vehicle life and certain operational reliability, it is necessary to have
vehicle repaired and maintained in some of our numerous authorised repair shops.
We would like to take advantage of this occasion to thank you for purchasing product
of AVIA company and assure you about our interest of your maximum
satisfaction..
We wish you to cover many thousands kilometres without accident.
AVIA ASHOK LEYLAND MOTORS s.r.o.

Praha - Letňany
Czech republic
Cargo truck Information Contents
documentation
Owner's Manual Components of equipment that are Description
To become perfectly familiar with the designated with * are series mounted Compartment ....................................... 4
vehicle, it is necessary to study thor- only on certain models or they are Keys ...................................................... 6
oughly Owner's manual and all addi- delivered only as exceptional equip- Door ...................................................... 6
tional instructions that are part of your ment. Electric window winder*...................... 7
vehicle documentation (e.g. Owner's Instrument panel - indicators ............. 8
Manual of automobile radio, certificate Warning! Indicator lamps .................................... 8
of warranty for battery etc.). Combined switch over switch .......... 12
n It is necessary to adhere at max-
Cruise control ISBe ........................... 14
imum rate the texts in this frame
Service Booklet (Warning!). Diagnostic sockets ............................ 17
Documentation also contains Service Switchbox and steering lock ........... 18
Booklet that contains: Gear-shifting lever ............................ 19
n Identification data of vehicle In the case of vehicle sale, it is neces- Steering-wheel inclination
n Basic warranty conditions sary to hand over complete documen- adjustment ......................................... 19
n W arranty registration certificate tation. Heating and ventilation ..................... 20
n Record of regular service inspec- Air conditioner* ...................................... 22
tions Seats .................................................. 24
n Labour activities, maintenance in- Headrests ........................................... 25
tervals Safety belts ........................................ 26
n Record of car body inspections Rear view mirrors .............................. 28
n Specific Activities and maintenance Rear view mirror remote control* .... 28
n Contract repair shops list Headlamps inclination adjustment .. 29
Cab interior illumination ................... 29
Digital clock* ...................................... 30
Socket / cigarette lighter................... 30
Sun visors .......................................... 30
Cup holder ......................................... 31
Ashtray ............................................... 31
2
Hanger, storage pocket .................... 31 Brake system ..................................... 58 Fuse box - under battery
Engine bonnet ................................... 32 Driving brake ..................................... 60 cover ................................................... 98
Tools and equipment ........................ 33 Brake lining inspection ..................... 62 Starting by means of jumper
Hydraulic tilting of cab ...................... 34 Anti - Blocking - System ................... 64 cables (D432) .................................. 100
Instructions for cab tilting ................. 34 Emergency brake .............................. 65
Chassis and cab ................................ 36 Parking brake .................................... 66 Technical data
Washer and wiper ............................. 67 Engine .............................................. 102
Operating instructions Tyres and wheels .............................. 68 Chassis ............................................ 104
Inspection before drive ..................... 38 Load transport ................................... 69 Brake ................................................ 167
Running-in of vehicle ........................ 38 Electric equipment ............................ 71 Dimensions of chassis-cabs .......... 108
Maintenance ...................................... 38 Battery attachment ............................ 72 Weights and weight on axles ......... 109
Engine starting .................................. 39 Battery ................................................ 73 Tyre inflation .................................... 110
During drive ....................................... 40 Alternator ........................................... 73 Truck circle diameter ...................... 110
Engine stopping ................................ 41 Headlamps and lamps - location .... 74 Gear ratios ....................................... 111
Engine for D family vehicles ............ 42 Care of vehicle .................................. 75 Maximum vehicle speed, climbing
Engine lubricating system ................ 42 performance .................................... 112
Turbocharger ..................................... 44 Malfunctions and their remedy Electric equipment .......................... 113
Fuel filter draining .............................. 45 Engine ................................................ 77 Bulbs ................................................ 114
Engine Cummins ISBe Electric equipment ............................ 83 Fuel consumption ............................ 115
- Tensioning of belts .................... 46,47 Monoblock hydraulic Service fluids ................................... 115
Engine Dwav D432 power-assisted steering ................... 84 Vehicle identification number ......... 116
- Tensioning of belts .................... 48,49 Brake .................................................. 84 Labels ............................................... 117
Fuel tank ............................................ 50 Parking and spring-actuated brake . 85
Fuel ..................................................... 50 Vehicle towing and rescue ............... 86
Cooling system .................................. 51 Spare wheel carrier (N, L, E) ........... 87
Air cleaner ......................................... 52 Wheel chock (N, L, E) ...................... 87
Steering .............................................. 53 Spare wheel carrier (K) ..................... 88
Gearbox ............................................. 54 Wheel chock (K) ................................ 88
Clutch ................................................. 56 Change of wheel ............................... 89
Rear axle ............................................ 57 Change of bulbs ................................ 90
Front axle ........................................... 57 Fuse box - cab ................................... 96
3
D E S C R IP T IO N
Compartment
9 7 5 8 2 4 17 6 3 1 11 10 25
20
18 26 19 20 16 15 14 27 13 28 22 21 23 24 12
FN0010
4
D E S C R IP T IO N
1 Combined change-over switch 10 Window winder*

-flash lamps 11 Door open and lock
-position lamps 12 Switchbox
-low-beam headlamps 13 Parking brake
-high-beam headlamps 14 Headlamp adjustment
2 Combined change-over switch 15 Rear-view mirror adjustment*
-windscreen wiper control 16 Gear-shift lever
-windscreen washer control 17 Horn
-exhaust brake 18 Loudspeaker
3 Controls 19 Ashtray
-front fog lamps 20 Storage compartment
-rear fog lamps 21 Steering-wheel inclination control lever
4 Controls 22 Clutch pedal
-warning lamps 23 Driving brake pedal
-rear-view mirror heating 24 Accelerator pedal
5 Controls 25 Safety belt height adjustment*
-auxiliary drive* 26 Storage compartment (with cover *), fuse box
-differential lock 27 Plug socket / cigarette lighter
-truck superstructure illumination* 28 Plug socket 12 V*
-air conditioner*
-cruise control (ISBe)
-cruise control - ON/OFF (ISBe)
-cruise control - SET/RESET (ISBe)
6 Measurement instruments and indicator lights
7 Digital clock*
8 Heating control
9 Controlled air outlet
5
D E S C R IP T IO N
Keys Door
2 A 4
1
B 3
FN0020 FN0030 FN0040
n Two keys are delivered - it is advised Exterior side inner side

to hide one of them outside vehicle as a It is possible to lock and unlock both n (item 4)
spare key. doors by means of key from exterior A - Unlocked door
n A label is fastened to keys where key side. Key is inserted into lock (item 1). B - Locked door (Door locked this way
number is stamped. It is advised to hide Grasping the door handle (item 2) and cannot be opened from both exterior
it outside vehicle and record the number. pulling outside results in door opening. and inner side).
n When vehicle is equipped with re- n Pulling lever (item3) door is opened
cording speedometer, key for opening it Unlocking - Insert the key, turn the key from inner side.
is delivered with vehicle. 90° counter clockwise and back to the n Turning winder handle (item 5) re-
basic position, where the key can be sults in window opening and vice versa.
removed.
Locking - Insert the key, turn the key
slightly clockwise and back to the basic
position.
6
D E S C R IP T IO N
Electric window winder*
Central door lock* n Pressing of rocker switch front side

Central door lock is possible to lock or results in opening window, pressing the
unlock from driver‘s side both doors. other side window is closed.
Warning!! Warning!
n Before leaving vehicle, always Take care of grip - mechanism is
remove ignition key from switch- 1 able to create such force that could
box. 2 result in injury.
n It is necessary to take care of
closing rear and side doors of van-
type truck and it is not permitted to FN0050
transport such cargo that disa-
bles proper door closing. If van-
n It is possible to wind windows only
type truck damage occur due to
when key is in position ON.
improper rear or side door closing
n W inding operates for the time of
manufacturer exclude the truck
pressing the button.
from warranty.
n Controls are placed on upper part of
doors.
n Both windows can be controlled from
the place of driver.
n Right side window can be controlled
from the place of front seat passenger.
n Control (item 1) - for window on driv-
er‘s side.
n Control (item 2) - for window on front
seat passenger‘s side.
7
D E S C R IP T IO N
Instrument panel - indicators Indicator lamps
!D432
1
FN0070
7
Direction indicator lamp

2
4 n According to switched on flasher light

control, left or right indicator lamp flashes.
n Shorter time interval of flashing indi-
3 cates damage of flasher lamp bulb (it is
necessary to replace burnt bulb imme-
diately).
5 6 8 9 FN0065 High-beam headlamps
It glows when high-beam headlamps

1 Recording speedometer 5 Fuel reserve indicator, reserve
are switched on.
2 Engine revolution indicator fuel indicator lamp
3 Pressure gauge of brake system 6 Coolant temperature indicator, Battery charging
circuit I. indicator lamp
4 Pressure gauge of brake system 7 Indicator lamp block I. n It glows when ignition is switched on,
circuit II. 8 Indicator lamp block II. after engine starting it should be
9 Indicator lamp block III. switched off.
8
D E S C R IP T IO N
n When indicator lamp is not switched Warning! Parking brake

off or it starts glowing during driving, it is
The indicator lamp may start shine
necessary to stop vehicle and engine n It glows when parking brake is ap-
throughin irregular intervals with
and proceed according to chapter Mal- plied and when air pressure is lower.
low light intensity. This shining
functions and their repair. n When it glows, it isn‘t possible to
through does not indicate failure,
move off or when it starts glowing during
bur it is caused by continuous in-
driving, it is necessary to stop vehicle
Engine lubrication spection of ABS control unit.
and proceed according to chapter Mal-
(only D432)
functions and their repair.
n It glows when key is in position ON,
Brake system failure
after engine starting it should be switched
Minimum level of braking
of f.
n It glows when key is in position ON (for fluid
n When indicator lamp is not switched
check of diode), after short time interval
off or it starts glowing (shine through)
it should be switched off. n It glows when key is in position ON (for
during driving, it is necessary to stop
n When indicator lamp is not switched check of diode function), after short time
vehicle and engine and proceed accord-
off after short time interval or it starts interval it should be switched off.
ing to chapter Malfunctions and their re-
glowing during driving, it is necessary to n When indicator lamp is not switched
pair.
stop vehicle and proceed according to off after short time interval or it starts
chapter Malfunctions and their repair. glowing during driving, it is necessary to
ABS (vehicle) stop vehicle and proceed according to
chapter Malfunctions and their repair.
n It glows when key is in position ON
(for check of diode function), after short
time interval it should be switched off.
n When indicator lamp is not switched
off after short time interval or it starts
glowing during driving, it is necessary to
stop vehicle and proceed according to
chapter Malfunctions and their repair.
9
D E S C R IP T IO N
Minimum washer fluid

level*
It glows in the case of washer fluid small
quantity.
FN0080 Air cleaner (clogged)
n It glows in case of clogged air filter.

Brake lamp n It ai necessary to replace air filter
element.
n It glows when brake lamp bulb is
burnt. Safety belt*
n It is necessary to replace the faulty
bulb. Necessity of safety belt fastening is
noticed.
Low-beam headlamps
It glows when low-beam headlamps

are switched on.
Tilting of cab
It glows when the cab is improperly fixed

in rear support (it is necessary to repair
at once).
10
D E S C R IP T IO N
Flasher lights of trailer* it will glow during drive, you must stop
vehicle and follow chapter "Malfunc-
n It glows when flasher lights are acti- tions and their remedy".
vated and trailer is towed.
n Shorter time interval of flashing indi- Glowing plugs
FN0090 cates damage of flasher lamp bulb (it is
necessary to replace burnt bulb imme- It glows after turning ignition key in
diately) switchbox to position „ON“. For ISBe
Exhaust brake*
only at lower evoironmental tempera-
Engine – stop tures. After switching off, it is possible to
It glows when exhaust brake operates ISBe start engine.
(only D432, 422). n It glows when switchbox is in posi-
tion "ON" (for checking operation) Engine – maintenance
Differential lock
After short time if must go out. ISBe
n It glows in a case of serious defect of n It glows when the switchbox is in
It glows when differential lock is activated.
engine. position ”ON” (for checking operation).
n If it will not go out after short interval, After short time if must go out.
Cargo area tipping or if it will glow during drive, you must n It glows in a case of necessary main-
stop vehicle and follow chapter "Mal- tenance (exchange of oil.
It glows when cargo area is tipped. functions and their remedy". n If it will not go out after short interval,
or if it flickers or if it will glow during drive,
Auxiliary drive* Engine-warning. you must stop vehicle and follow chap-
ISBe ter "Malfunctions and their remedy".
It glows when auxiliary drive is activated. n It glows when switchbox is in posi-
tion "ON" (for checking operation)
Reverse lamp After short time if must go out.
n It glows in a case of mistake or defect
It glows when reverse gear is engaged. of engine component.
If it will not go out after short interval or if
11
D E S C R IP T IO N
Combined switch over switch
n Audible signal indicates open doors

3 and burning lights.
3 Low and high beam switch

2 over
4 n To switch on high beam headlamp,
press control lever in direction from steer-
ing wheel (high beam is indicated by
1 indicator lamp).
n Switching over is performed by pull-
ing control lever to original position.
4 Headlamp flasher
n Pull slightly control lever to steering
wheel (high beam indicator lamp are
FN0100
switched on).
n Lamps glow for the time of holding
the lever.
1 Flasher lamps 2 Position lamps and low beam
Flasher lamps are active when key is in headlamps 5 Windscreen washer
position ON. They are set by vertical They are switched on by turning tip of n Wiper and washer are active when
movement, perpendicular to steering control lever. key is in position ON.
wheel centreline. Lamps that have their symbol aligned n Washer is switched on by pressing
right flasher lamps - shift control with notch shine to the end of control lever. Washer pump
lever upward OFF Lamps are switched off is activated for the time of pressing the
left flasher lamps - shift control Position lamps are switched on switch.
lever downward Low beam headlamps are
switched on (alternatively
main beam headlamps)
12
D E S C R IP T IO N
6 Windscreen wiper
It is switched on by turning the end of
control lever:
8 6
OFF Wiper is switched off 7
INT Position for selection of pulsating 5
wiper time interval (in this position
it is possible to select arbitrary in
terval that is gradually controlled
by rotary ring (item 7).
LO Slow and uninterrupted wiping.
HI Fast and uninterrupted wiping.
7 Selector of pulsating wiping

interval
Interval is the shortest in position F,
turning of ring increases the interval. FN0110
8 Exhaust brake*
accelerator pedal (at revolutions higher
Position 0 - push combined switch in Warning!
than idle speed).
direction from driver forwards and down-
Position 3 - pull the switch in direction to n By actuating the accelerator ped-
wards - the engine brake is switched off. al - the engine brake is disengaged
driver backwards and upwards - the
Position 1 -pull the switch in direction to engine brake is on after loosening ac- automatically from its action.
driver backwards and downwards - the celerator pedal or during operation of n Action of the engine brake is
engine brake is is on during operation break pedal as well. signalled by a warning lamp.
of break pedal.
n Signalling by the warning lamp
Position 2 - push the switch in direction It is recommended to engage &
disengage the engine brake at least depends on action of the engine
from driver forwards andupwards - the brake, not at all on the switch po-
engine brake is on after too sening once a week - engine brake serv-
ice-life is extended in this way. sition.
13
D E S C R IP T IO N
Controls
Warning!
1 2 7 8 9 10 11 6 3 It is possible to engage items 1. and
2. only under air pressure higher
than 0.55 MPa - otherwise engaging
isn‘t reliable.
It is recommended to engage &

disengage the differential lock at
least once a week - differential lock
service-life is extended in this way
(it is effective especially for the
EATON final drives).
3 Warning lights
n Indicated by lamp, placed in control.
5 4 FN0125
n It is possible to switch on even when
ignition is switched off.
1 Auxiliary drive * 2 Differential lock engaging
n It is engaged when vehicle is motion- n It is engaged when vehicle is motion- 4 Outside rear-view mirror
less when engine speed is low for about less when engine speed is low for about heating
6s. 6s. It is indicated by bulb in control.
n When engine is running, it is neces- n Use only for the time necessary to
sary to press clutch pedal. overcome more severe driving condi-
n Engaged drive is indicated by indica- tions. Warning!
tor lamp. n Engaged lock is indicated by indica- Allow heating to operate for ne-
tor lamp. edful time.
14
D E S C R IP T IO N
5 Rear fog lamps 9 Reset / coast

n It is possible to switch rear fog lamps ISBe
on only when low beam, high beam or n It resets speed, adjusted on cruise
front fog lamps are switched on. control.
n Owing to dazzle effect they are al- n It is possible by this switch to reduce
lowed to use under fog, heavy rain and revolution of engine during drive or with
snow conditions. P.T.O..
n It is indicated by bulb in control.
10 Cruise control switch
6 Front fog lamps ISBe
n Fog lamps shine when position n It is used for switch ON cruise control FN0135
lamps and low or high beam lamps are or P.T.O..
switched on.
n It is indicated by bulb in control. 11 Set / accelerate Acoustic horn
ISBe Control of acoustic horn is located in the
7 Cargo space illumination* n It sets real speed to memory of cruise centre of steering wheel.
It is indicated by bulb in control. control.
It is possible to increase revolution of
8 Air conditioner engine during driving or using P.T.O..
* n During diagnostic testing, of switch
n Cooling device operates only when
engine is running. pressing will set next defect code.
n Air conditioner does not operate, when
rotary switch of blower is in off position.
n Signalled by bulb in control.
15
D E S C R IP T IO N
Cruise control
ISBe
Adjustment of cruise control Adjustment of P.T.O. revolutions
n Press ”Cruise control” switch ON. at parking of vehicle.
n Reach required speed and than n Adjustment of P.T.O. revolutions when
press shortly switch ”Set/accelerate”: the truck is at stand still.
Now the speed is adjusted in memory n Press switch "Cruise control".
and the engine will keep this speed n Increase revolutions by pressing
without using accelerator pedal. "Set / accelerate" switch (range of ad-
n It is possible to increase speed by justable revolutions is 950 - 3000 rev./
FN0136 accelerator pedal . After releasing ped- min.). By holding switch, revolutions in
al, the speed of the vehicle will be influ- crease continuously. By pressing
n Cruise control keeps adjusted speed enced again by the cruise control (of switch, revolutions increasle by steps
(engine revolution during driving or us- course, ”Cruise control (main)” switch (approx. 25 rev./min.).
ing P.T.O.) without using accelerator ped- must be in the ON position. n By pressing switch "Reset / coast",
al. n All functions will be cancelled after 1200 rev./min. will be set automatically.
n Three control elements in central actuating clutch pedal, brake pedal or
panel of dashboard are used. by switching ”Cruise control” switch to Warning!
n Cruise control begins operation OFF position. Operation of cruise con- n If cruise control is not used,
above approx. 48 km/h, using P.T.O. up trol will be restored by short pressing of ”Cruise control” switch must be in
to 48 km/h (optional). switch ”Reset / coast” it means that it is the OFF position.
not necessary to adjust cruise control n Speed of the vehicle can be influ-
again. enced by climbing or by weight of
load . Therefore use cruise control
only during driving on level ground
or when differences of landscape
elevation are only small.
16
D E S C R IP T IO N
Diagnostic sockets
1 Socket for ABS diagnostics

2 Socket for engine diagnostics
4
ISBe
3 Switch of engine diagnostics
2
ISBe
4 Fuse box for voltage changer
(fuses 2x 5A)
3
1 FN0132
n Diagnostic sockets are placed un-

der package compartment in the instru-
ment panel.
n Access is facilitated after removing
bottom of the package compartment
that is loosened by rotating two turnable
holders (rotation direction is marked on
the cover).
17
D E S C R IP T IO N
Switchbox and steering lock
remain to glow: battery charging, (engine

lubrication only D432), possibly glowing
plugs. After glowing indicator lamp will
go out, engine is ready to start. Electrical
circuits, connected to switchbox, are
under voltage.
Warning!
If after short time any indicator
FN0140
lamp, which is tested only itself,
will glow, it is necessary to follow
Switching positions Chapter "Malfunction and their rem-
n Position "LOCK" edy".
Only in this position, it is possible to
insert and remove ignition key. Merely
recording speedometer, electric clock FN015cu
or radio are connected. Only in this po-
sition, steering wheel shaft is automat- n Position "ON"
ically locked. Following indicator lamps glow: (see
fig.)–battery charging, (engine lubrication
n Position "ACC" only D432), brake system malfunction,
Steering is unlocked, electric circuits parking brake, minimum level of brake
that are connected through switchbox liquid, glowing plugs, ABS, coolant tem-
are without voltage. After switching over perature, fuel reserve. In the case of
from position "ON" to this position, en- engine ISBe, also following indicator
gine is stopped. lamps glow:engine–stop, engine–
warning, engine–maintenance. After few
seconds,only following indicator lamps
18
D E S C R IP T IO N
Gear-shifting lever Steering-wheel inclina-

tion adjustment
n Position "START"
The engine can start only if gears are
disengaged, without using accelerator
pedal. Position is not locked. For re-
starting, turn back ignition key to posi-
tion "ACC" - that prevents from restart-
ing of running engine that could result in
starter motor damage.
1 2
Warning!
n Function of switchbox is assured FN0160 FN0170
when battery master switch is on.
n Do not switch off battery master
n Release steering wheel pulling con-
switch or disconnect battery ter- Position Gearbox type Number of
gears
trol lever in direction to yourself and
minals when engine is running to
adjust steering wheel position to re-
prevent alternator or some elec-
1 ZF S5-42 5 quired position.
tric device damage.
n After adjustment, press control lever
2 ZF 6 S 850 6 in forward direction up to stop.
Warning!
Gear changing is performed mechani-
cally by means of gear shifting lever, To adjust steering wheel during
when clutch pedal is depressed. drive isn‘t acceptable.
19
D E S C R IP T IO N
Heating and ventilation
n The truck cabin is heated by a hot

water heating. It is possible to use it
after coolant is heated up in the
cooling&heating water circuit after the
engine is started.
n Heating is controlled and regulated
by turning of heating controls located
on instrument panel.
n Heating valve control (item 3) regu-
lates quantity of water flowing through
heating element and so temperature 1 4 2 3 FN0185
of outlet air (when turning to red field,
hot air is produced and vice versa).
n Control (item 1) regulates fan speed n Rib inclination (item 5) of air outlet 1 Heating fan control
and so quantity of air that comes through can change angle of air flow. Quantity of 2 Air flow direction control
the system. Speed is adjustable in four air flowing from individual vent hole can to heads of crew
steps. be controlled by wheels (item 6).
to legs and heads of crew
n Air flow direction control (item 2) en-
to legs of crew
ables to select direction of air outlet
(The way of cab heating). to legs, windscreen and side
n Button (item 4) switches on or off windows
mode of circulating air in cab.
to windscreen and side windows
3 Heating valve control - temperature
regulation of outlet air.
4 Mode of circulating air.
20
D E S C R IP T IO N
5 5 5 5
6 6 6 FN0195
Removing hoarfrost and be- Maintaining windows in status n (item 3) to required heating output.
dewed windows without bedew under higher n (item 2) turn to position .
n (item 1) up to stop to position IV. humidity.
n (item 3) to the left up to stop. W hen windows are constantly be- Maximum heating
n (item 2) turn to position . dewed (e.g. in rain), it is necessary: n (item 1) to position IV.
n Close vent holes by control wheels. n (item 1) to position II or III. n (item 2) turn to position
n (item 2) turn to position . n (item 3) to the left up to stop.
Removing icing from n (item 3) if necessary to area of heating. n Switch on mode of circulating air.
windscreen
n (item 1) up to stop to position IV. Ventilation Warning!
n (item 3) to the left up to stop. n (item 1) to required position. Heating output is dependent on cool-
n (item 2) turn to position . n (item 3) to the right stop. ant temperature. Maximum heat-
n Switch mode of air circulation, n (item 2) turn to position ing output is obtained after heating
n Close vent holes by control wheels. engine to operation temperature.
Pleasant heating
n (item 1) to position II or III.
21
D E S C R IP T IO N
Air conditioner*
6 6 7 6 6
7 2 2 5 3 4 7 FN0195
n Air conditioner is combined cooling Controls system. Speed of air flow is adjustable
and heating equipment. n Air conditioner is switched on (off) by in four steps.
n Cooling unit of air conditioner cools control (item 1) designated with sym- n Control of air flow direction (item 2)
air and removes moisture out of air. bol (indicated by bulb located in enables to select direction of air outlet
n Cooling device operates only when control). n Air conditioner doesn‘t (way of cab heating)
engine is running. operate when rotary switch is in off n Button (item 5) switches on (off)
position. mode of air circulation in cab (indicated
n Control of heating valve (item 4) reg- by bulb located in control).
ulates temperature of inlet air (turning n Travel of air outlet fins (item 6) can
to red field - hot air and vice versa). It is change angle of air flow. Air quantities
possible to use it even when air condi- regulated by wheels (item 7).
tioner is switched on.
n Control (item 2) regulates fan speed
and so quantity of air passed through
22
D E S C R IP T IO N
Warning!
It isn‘t recommended to smoke
when air circulation in cab mode is
on.
Warning!
n If vehicle is parked on direct
sun, open windows before switch-
1 2 3 ing on of air conditioner.
FN0185
n It is recommended to operate
air conditioner at least once a
Optimal cooling Maximum cooling week - it extends life of air condi-
n (item 1) to requested position (posi- n Close all windows tioner.
tions II and III are optimal) n (item 1) to position IV
n (item 3) up to stop to the right, tem- n (item 3) up to stop to the right
perature can be regulated according to n (item 2) turn to position
need by means of turning to the left. n Press control with symbol . (bulb
n (item 2) turn to position in control starts to glow)
n Press switch with symbol (bulb n Switch mode of air circulation on
in control glows)
n In this mode, exterior air is sucked
and cooled.
23
D E S C R IP T IO N
Seats
1 1 a b
4
3
c d
2 FN0200 2 FN0210
Adjustment of seat backrest then it is possible to adjust seat to Proper adjustment of seats
inclination (a) required position. The seat is released n Backrest should be adjusted so that
Tilting of seat backrest backwards is by releasing the small lever. driver could hold steering wheel in its
performed by control lever (item 1) lift- n Seat should be adjusted so that driv- highest point by slightly wrinkled hands.
ing and pressing to backrest in back- er can safely control pedals. n Quick and safe manipulation with
ward direction.Tilting of seat backrest necessary controls that are important
forwards is performed by control lever Adjustment of seat squab for driving must be secured.
(item 1) lifting and slight pressing to incline (c) and height (d) on n It must result in free holding of body
backrest in backward direction and con- the driver´s pneumatically for maximal protective effect of safety
sequential release of backrest that au- sprung seat* belts.
tomatically tilts forwards. The backrest n Front part of seat is adjustable by
is secured by releasing the small lever. lever (item 3).
n Rear part of seat is adjustable by Warning!
Adjustment in longitudinal lever (item 4).
direction (b) n Regulation in upward direction is For precautionary reasons, driv-
n Longitudinal shift is released by pull- performed in released status. er‘s seat is allowed to adjust only
ing control lever (item 2) upwards and when vehicle stops.
24
D E S C R IP T IO N
Headrests
Warning!
n Good adjustment of headrest ef-
fectively supports nape during rear
impact.
n For precautionary reasons, driv-
er‘s headrest is allowed to adjust
only when vehicle stops.
FN0220
n Headrests are height-adjustable.

n For height adjustment of headrest,
press stop in direction to back wall.
n Adjust headrest so that its position
recommends to physical dimensions
of driver‘s figure.
25
D E S C R IP T IO N
Safety belts
FN0230
n The truck cabin is equipped with pre- n The middle seat features two-point n Safety belts must be used during
loaded three-point seat belts of out- seat belt with mechanical adjustment. each drive - even in city traffic.
ward seats. n Safety belts are used as passenger
protection in case of accident.
26
D E S C R IP T IO N
Use of safety belts Height-adjustment of safety Warning!

n Necessity to use safety belts is sig- belts* n Belt must not lie over rigid or
nalled by relevant indicator lamp*. n Due to height adjustable upper bear- easy fractured objects that could
n Take safety belt catch and slowly ing of belt, it is possible to adapt belt be e.g. in your clothing, in pockets.
draw over thorax and pelvis. best way to physical dimensions of fig- n Safety belts that went through
n The belt must fit tightly to centre of ure. accident or they are damaged must
shoulder and pelvis. n For height-adjustment, press button be unconditionally replaced by new
n When the belt is during pulling out in downward direction, turn upper belt belts.
locked, release it and let it wind back bearing in direction to yourself (up- n Take care of the belt not to be
and than pull it out again. wards) and adjust to requested posi- twisted and to lie over pelvis and at
n Insert catch into belt lock that corre- tion. least over soft parts of body.
sponds to the seat.The belt is properly n Maximum effect can be reached
fixed after snap into lock. with proper seating position in cab.
n The belt is released after pressing n One seat belt is allowed to bind
red lock stopper. only one person.
n Maintain safety belts clean (dirt
influences on winding mechanism).
For cleaning, it is recommended to
use soft soap solution.
n When safety belt is damaged,
let it replaced.
27
D E S C R IP T IO N
Rear view mirrors Rear view mirror remote

control*
n Vehicles are equipped with heated
rear view mirrors. A B
n Heating is switched on by control
that is placed on instrument panel and
it is indicated by indicator lamp placed
directly on control.
n Heating is used for necessary time.
Warning!
FN0240
n For safety reasons, mirrors
must be adjusted before drive.
n It is necessary to pay attention n Turn control to select between left
of judgement about size and dis- and right mirror.
tance of vehicle or another objects To the left - left mirror - position A.
that are visible in side convex mir- To the right - right mirror - position B.
ror (objects look smaller and they n Requested position of mirror is
are displayed more distant then it reached by skewing of four-position
is in reality. control.
28
D E S C R IP T IO N
Headlamps inclination adjustment Cab interior illumination
Percentage of payload 1 2 3
30% 50% 70% 100%

K 1 2 3
N 1 2 3
L 1 2
FN0255 E 1 2 FN0260
n Regulation wheel changes head- Warning! n Ceiling light bulbs are switched on
lamp inclination. by controls located directly on lamp.
It is obligatory for driver to adjust
n Basic adjustment is performed with n Controls (item1) and (item 2) switch
headlamps inclination according
vehicle without cargo load (notch of on (off) illumination of driver‘s side.
to actual vehicle load with cargo.
adjustment control aligned with nought). n Control (item 3) switches on (off)
n Payloads of given version are men- illumination of front-seat passenger ‘s
tioned in table Weights and weight on side.
axles.
29
D E S C R IP T IO N
Digital clock* Socket / cigarette Sun visors

lighter
B
A
FN0270 FN0280 FN0295
n Button „HOUR“ adjusts individual n Socket (pos. A) may be used for con- n Sun visors are located above wind-
hours. nection of cigarette lighter or additional screen in ceiling panel.
n Button „MIN“ adjusts individual min- current consumer having 24V supply. n They can be lowered according to
utes. To use the socket * (pos. B) for current need.
n Button „SET“ clears minutes to whole consumers having 12 V supply n Adjust sun visors to protect against
hours. n Cigarette lighter is switched on by bedazzlement.
n Button „DISPLAY“ illuminates clock pressing to extension piece. After of
when switchbox is in position „LOCK“. heating of heating element in lighter,
Clock is illuminated for time of button extension piece springs up. Remove
holding. heated lighter and use it immediately
(element quickly looses heat energy).
Warning!
n During manipulation with lighter
take a good care of burn.
n When lighter does not spring up
after about 30 seconds, it is necessary
to remove it to prevent heat damage.
30
D E S C R IP T IO N
Cup holder Ashtray Hanger, storage pocket
FN0300 FN0310
n Eject holder by pressing and subse- n Open by pulling to yourself.

quent release. n For cleaning, remove only metal
n After use drop it in. shied insert.
Warning! Warning!
n Do not use cup holder when Due to danger of fire, do not put FN0320
vehicle moves. paper or another inflammable ob-
n Do not use cup holder for car- jects.
rying another objects.
31
D E S C R IP T IO N
Engine bonnet
Warning!
B It is necessary to check bonnet
1 lock before every drive.
FN0330 FN0345
Opening of engine bonnet Shut the bonnet

n Press bonnet in its lower part, de- n Raise bonnet.
press releasing lever (item 1) in direc- n Remove strut and place it to holders
tion to the left. (item A).
n Lift the bonnet. n Lower bonnet to its vertical position
n Remove strut from holder (item A) and press its lower edge, till it engages
and lock lifted bonnet so that the end of lock (item 2).
strut is fixed in hole (item B). n Engaging features acoustic effect.
32
D E S C R IP T IO N
Tools and equipment
A - Front-seat passenger‘s seat

5 B - Driver‘s seat
n Tools and equipment are placed

under the co-driver´s seat and access
2 to them is facilitated after lifting the seat
B squab.
A
n Hydraulic jack is fixed to floor behind
driver‘s seat.
n Tools must be properly fixed.
Warning!
4 3 1 n Improperly fixed tools can injure
FN0350 FN0360
passengers during drive or it can
cause unpleasant vibrations -
therefore it is necessary to fix them
Wrench 19 x 24
properly.
2 x Bolt for sprig brake actuator unlocking n Jack that is delivered with vehi-
Bar extension item 1 cle is intended only for this vehicle
Cartridge of bulbs type. The jack must not lift another
First aid kit vehicle or weight.
Warning triangle item 2 n Proper fixing of tools and equip-
ment is necessary during driving
Wheel nut spanner item 3
and cab tilting.
Bar for jack and cab tilting item 4
Hydraulic jack item 5
33
D E S C R IP T IO N
Hydraulic tilting of cab Instructions for cab

tilting
Lowering of cab Warning!
n Adjust lever of distributor (item 3) to
n Before tilting stop engine, shift
vertical position in downward direction.
neutral gear.
2 n Pump until locks of rear bearings fix
n Secure free objects and proper-
the cab.
ly close doors.
n After fixing the cab by hydraulic locks,
n Before tilting open bonnet.
adjust lever of distributor to horizontal
n During tilting proceed with max-
position.
imum care.
1 3 FN0395 n Work under tilted cab also de-
mands maximum care.
n To stay under tilted cab isn‘t
Tilting of cab acceptable.
n Adjust lever of distributor (item 3) to n To stay under partially tilted cab
vertical position in upward direction (see isn‘t acceptable.
schematic figure on pump). n Require height of workshop for
n Insert bar (item 1) into hydraulic pump tilting is 3000 mm, with supple-
(item 2) and pump. Hydraulic locks of mentary body 3800 mm.
rear bearings will be opened and then
cab starts tilting.
n It is necessary to tilt cab up to com-
pletely tilted state - partial tilting is not
acceptable for entry under cab.
n When the cab is tilted, let lever of
distributor in upward direction.
34
D E S C R IP T IO N
Tilting of special version cabs
Tilting of cab
n to set the distributor to the position ↑
n to pump up to the complete cabin
tilting (the cabin is not tilted over beyond
the zero point)
a note: the cabin starts lifting only after
several strokes of a lever
Lowering of cab
n to set the distributor to the position ↓
n to pump up to closing of locks, and
further, till there is an increased re-
sistance on the lever
n to set the distributor to the position ↑
n to pump approx. 15 strokes for deli-
miting position of the cabin pin in the
middle of an oval hole in a cylinder eye
n to set the distributor to the position O
Jihlavan, a.s.
FN0391
35
D E S C R IP T IO N
Chassis and cab
!D432 11
8 24 13
22 12 9 10 11
FN0402
1 Strut
2 Bonnet
2 3 Bonnet lock
4 Place of fixing for towing
5 Washer tank
1 6 Clutch fluid tank
7 Coolant expansion tank
6 8 Fuel tank filler neck
9 Fuel tank draining plug
10 Air cleaner
11 Power assisted steering fluid
tank
12 Spare wheel (two positions -
5 4 3 7 FN0345 according to vehicle versions)
36
D E S C R IP T IO N
13 !D432
11 17
18
FN0422
13 Oil level dipstick

14 Gearbox
15 Propeller shaft
16 Air pressure equaliser with air drier
17 Brake fluid tank 14 15
18 Draining valve 19 16 20
19 Air tank 4.5 l
20 Load dependent brake control device
21 Battery box with battery master switch
22 Wheel chock
24 Fuel filter 21
FN0430
37
OP E R AT IN G IN ST RU CT IO NS
Inspection before drive Running-in of vehicle Maintenance
n Adjustment of headlamps in depend- n Running-in of new vehicle or vehicle n For maximum use value, economic
ence on load of cargo. after overhaul is finished after covering and safe operation and for maximum
n Lock of cab in rear bearings. 3 000 km (nevertheless engine of vehi- possible vehicle life, it is necessary to
n Lock of bonnet. cle will feature maximum possible pow- perform all maintenance works in de-
n Quantity of oil in engine. er practically after covering additional fined and regular intervals according to
n Quantity of fuel in fuel tank. several thousands kilometres. service booklet.
n The condition of tensioning belts. n During running-in, do not use engine n Vehicle maintenance shall be per-
n Quantity of coolant in coolant-ex- at speed above 3/4 maximum engine formed by authorised repair shops
pansion tank. speed or under full power at low engine that are familiar with vehicle design,
n Quantity of fluid in clutch circuit. speed. they do their job proficiently, they have
n Quantity of fluid in tank of mono- n It is necessary to avoid sudden ac- necessary equipment and they are in
block power assisted steering. celeration, drive at high engine speed contact with manufacturer.
n Quantity of fluid in equalising brake and sudden braking.
fluid reservoirs. n Cold engine must not be run at high
n Operation of driving and parking engine speed. Warning!
brake. n Do not drive at too low engine speed. n It is recommended to engage &
n Quantity of liquid in washer tank. n Vehicle must not be loaded with an disengage the engine brake at
n Tire pressure and state. excess cargo. least once a week - engine brake
n Function of exterior illumination, service-life is extended in this
flasher and brake lamps. Warning! way.
n Check air intake piping system.
The way of running-in is decisive n It is recommended to engage &
n Check air cleaner restriction. disengage the differential lock at
for vehicle life.
n Drain fuel-water seperator. least once a week- differential lock
n Inspect cooling fan. service-life is extended in this way
n Inspect engine. (it is effective especially for the
EATON final drives).
38
Engine starting
n Insert ignition key into switchbox and Warning! found out according to chapter Mal-
turn it to position „ON“. Indicator lamps functions and their remedy.
n When after switching over to
displayed in picture on previous page of
position „ON“, indicator lamps of
the manual.
brake system malfunction, park-
Warning!
n Engine starting is possible only when n If indicator lamp of battery
ing brake, minimum level of brake
no gear is engaged. Leave accelerator charging, (lubrication only D432), park-
fluid or ABS (and for engine ISBe
pedal in idling position. ing brake (and for . engine ISBe
also indicator lamps: engine-stop,
n After glow plug indicator lamp switch- also indicator lamps: engine-stop,
engine - warning, engine-mainte-
ing off, start engine by turning ignition engine-warning, engine-mainte-
nance) remain glow even after
key to position „START“ and hold it nance) aren‘t switched off after
short time interval, driving is not
(engine cranks for time of holding the engine starting, driving isn‘t ac-
acceptable and it is necessary to
key in this position) till engine start ceptable.
identify malfunction according to
running, but at the most 10 seconds . n Vehicle must not move what-
chapter Malfunctions and their
.W hen restarting, minimum interval of ever way, when master switch isn‘t
remedy.
restarting is 30 seconds. on, ignition key isn‘t inserted into
n When starting warm engine,
you should also wait for glow plug switchbox and turned to position
indicator lamp switching off. "ON". In this position, steering is
n During winter season, use win- unlocked. Before beginning of
ter fuel and engine oil of oil grade drive, verify free rotation of steer-
for ambient climate conditions. ing wheel.
n Do not run cold engine at high
speed - hazard of damage.
n After engine starting, release key. It
turns back to position „ON“. After reach-
ing regular engine run, indicator lamps
Warning!
(of lubrication only D432) and battery charg- Only D432. It is not permitted to bleed fuel
ing must be switched off. When they system by towing the vehicle (injection
aren‘t switched off, a malfunction must pump is lubricated by fuel).
39
During drive
n After vehicle start up, test opera- temperature glows, it is necessary to

tion of driving brake. Testing of brake reduce vehicle speed, shift gear down,
effect is important namely in winter stop vehicle as soon as possible and
season, after washing vehicle by pres- cool engine at higher speed (1200 -
sure stream or after wade (running 1500 rpm).
through deep water-hole). Rapid drying
is performed by repeated braking. Warning!
n Do not brake intensively, it results in Engine must not be stopped, after
too rapid and excessive wear of tires engine coolant temperature indi-
and brake system and also this way of cator lamp starts glow.
braking threatens road traffic.
n Press accelerator pedal fluently.
n Depress clutch pedal up to stop. When reserve fuel indicator lamp starts
n Engage gears fluently to prevent 1 glow, approx. 16 l of fuel is available.
engine from load shock. Before engag-
FN044cu
ing the gear of opposite direction then
vehicle movement, stop vehicle com-
pletely to prevent damage of gearing n During drive, it is necessary to watch
mechanism. indicator lamps.
n Prior to shifting the reverse gear on n When during drive any indicator lamp
the ZF 6 S 850 gearbox, it is necessary (shown in the figure above ) starts
- after releasing the clutch - to wait for glow, you must stop the truck. When
3 to 5 seconds (because of stopping a indication lamp „Lubrication of engine
shaft in the gearbox) and then to shift D432“ or „Engine-stop ISBe“ glows - it
the reverse gear. is necessary to stop engine as well.
n Drive without running engine and Follow procedure given chapter Mal-
also without engaged gear is not ac- functions and their remedy.
ceptable. When indicator lamp of engine coolant
40
Engine stopping The Neutral gear
n Stop engine by switching over the Warning!

ignition key in switchbox from position
"ON" to position "ACC". Do not leave the engine running
idle or having revolutions up to
(Only D432) Electromagnet of stopping 1,000 per minute without engine
device that is located on injection equip- load within the period more than
ment is instrumental to engine stopping. 10 minutes. When there is a long-
After switching over the ignition key, it er engine run using these two
closes fuel into injection equipment. modes - temperature of combus-
FN0441
tion space is going down to val-
ues when fuel combustion is not
Warning! complete any more. This fact can
n Never stop engine by means of cause creation of carbon in sur-
switching off the battery master roundings of injection nozzle
switch - there is danger of electric holes and piston rings which
system and alternator damage. leads - through its results - to
n (only ISBe) Switch OFF battery engine damage. As well during
master switch only after 30sec- lower temperatures, all oil which
onds after switching OFF the penetrates through valve seal-
switchbox (computer calculates ings into exhaust ducts can not
data during this time) be burned there . This non-burned
n You can remove ignition key oil can cause damaging to a tur-
from switchbox only after entire bocharge.
vehicle stopping.
n Before stopping engine from full
load leave engine running in low
speed for 1 minute minutE (see the
label on the dashboard).
41
Engine for D family Engine lubricating

vehicles system
n Oil change interval according to
Service booklet.
ISBe 150 30
n Marking of engine oil that is filled in
- Diesel
- Sixteen valve
- Maximum power
Warning!
110 kW / 2 500 rpm-1 n Oil and oil filter change is per-
formed by Authorised workshop.
ISBe 170 30 FN0450 n Insufficient quantity of oil in en-
- Diesel gine can result in engine damage.
- Sixteen valve n Pay attention to cleanness dur-
- Maximum power Inspection and oil type ing manipulation with oil.
125 kW / 2 500 rpm-1 n It is necessary to check regularly n When suspicion of oil degrada-
quantity of oil in engine (during operation appears (presence of water),
D432.100 tion, part of oil is consumed). immediately contact authorised
- Diesel n During inspection, vehicle must stand workshop.
- Sixteen valve on horizontal plain. n Oil should be disposed with
- Maximum net power acc. EEC 85 n Perform inspection before starting respect of environment.
100 kW / 2 400 rpm-1 when oil level is steady.
n Pull out oil dipstick, dry it by clean patch
and insert it back into hole up to stop.
n After subsequent pulling out, oil lev-
el must be between notches on oil dip-
stick. It must not exceed MAX margin
because excessive smoke of engine
could occur.
n When oil level is under notch MIN, it
is necessary to fill-in oil.
n For filling-in use same oil.
42
production plant is printed on self-ad-

Engine Recommended
hesive label that is stuck on cover of oil
oil oil
filler neck on cylinder head cover.
specification grade
n Fundamentally use only approved
ACEA SAE
engine oils
n We do not recommend use special
E5 10 W - 40
ingredients of oil because some ingre-
dient in contact with current marked
lubrication oil may result in their degra- FN0461
dation and subsequent engine dam-

age. Filling-in engine oil
n Screw out cap of oil filler neck.
Warning! n During filling-in, keep maximum
n Losses caused by neglecting cleanliness of surrounding area.
of oil system are excluded from n After filling-in, oil level must not ex-
warranty. ceed notch MAX.
n Engines, that are damaged by n After filling oil to required level, close
use of additional ingredient in oil, filler neck with cover.
are excluded from warranty.
43
Turbocharger
n Keep maximum cleanliness and pre- Warning!

vent from mechanical damage of im- For maximum life of turbocharg-
peller of centrifugal blower by intake of er, it is necessary to take care of
mechanical impurities (for example air cleaner and all intake system
operation without intake air cleaner). cleanliness.
n Before stopping engine from full load
leave engine running in low speed for 1
minute minute (see the label on the
dashboard) to enable tubocharger cool-
ing by oil and so prevent from turbo-
charger shaft coking .
FN0441
44
Fuel filter draining
D432 - engine
ISBe - chassis
FN0472
Warning!
Exchange interval
of inlet
Fleetguard FS 19584
- max. 36 000 km
FN0473
The fuel filter is drained by draining

water after unscrewing drain screw at
the bottom of the filter. To screw in the
drain screw after dripping off imputi-
ties.
45
Cummins ISBe engine
3 5 7
4 1 2 6
FN0482
46
Tensioning of belts -
ISBe
1 Fuel filter
2 Starter motor
3 Tightening pulley
4 Fan with viscous fan clutch
5 Filler neck for oil filling
6 Oil filter
7 Compressor A
FN04821
n The belt is automatically tensioned

by pulley (item A) that provides con-
stant tension.
n W hen the belt is damaged, it is
necessary to replace it at once.
47
DWAV D432 engine
11 3 7 10
5 6 1 4 2 9 8
FN0481
48
Tensioning of belts
- D432
1 Injection equipment
2 Single stage fuel filter with manual pump
3 Coolant pump with thermostat
4 Starter motor
5 Tightening pulley
6 Fan with viscous fan clutch
7 Filler neck for oil filling
8 Oil filter
9 Oil heat exchanger A
10 Oil separator
11 Compressor
FN04811
n The belt is automatically tensioned

by pulley (item A) that provides con-
stant tension.
n When the belt is damaged, it is nec-
essary to replace it at once.
49
Fuel tank Fuel
n Fuel level gauge that is located on n For engine operation use only diesel
instrument panel is operational after fuel according to SN EN 590 (656506).
inserting and turning ignition key in Preferably use diesel fuel with low con-
switchbox to position „ON“. tents of sulphur (0.05% mass) that is
n Fuel tank neck is secured by locka- commonly available in the market.
ble fuel filler cap. n In winter season, it is necessary to
use such diesel fuel that features filter-
ability (brand CFPP) corresponding to
climate conditions.
FN0520 n To ensure operation under low tem-
peratures, ingredients improving its fil-
terability could be applied. Mixing is
n To prevent from aeration of fuel sys- performed according to instructions of
tem, never must occur empty fuel tank. manufacturer.
n Fuel tank volume is 120 l (200 l*).
Float device is installed into fuel tank.
Warning!
Fuel quantity in tank is monitored by
fuel level gauge on instrument panel. n Use of bio-diesel fuel is pro-
n Minimum fuel reserve is 16 l (20 l*) hibited.
and it is indicated by indicator lamp in n Do not mix diesel fuel with pet-
fuel level gauge. rol.
50
Cooling system
protects cooling system and heating Warning!

system from corrosion and deposits.
n Authorised workshops perform
Therefore antifreeze chemical concen-
coolant change.
tration must not be decreased by add-
n Do not open coolant expan-
ing water not even in summer season
sion tank cap of hot engine, it
(always fill in with portion of antifreeze
could result in scald.
chemical).
n Engine must not run without
n Beware of paint muck.
thermostat.
n Before winter season, carry out pro-
n Coolant expansion tank pre-
phylactic inspection of antifreeze cool-
vents from aeration of cooling
ant state and concentration in cooling
and heating circuit. Therefore it is
system.
necessary to inspect its level.
n To clean the radiator using pressure
n When engine is used to be over-
air or a flow of heat water from the
heated, it is necessary to advice
FN0530 engine side before start of the summer
authorised repair shoop.
period and whenever there is contami-
nation of the front surface.
Coolant inspection and filling Check coolant expansion cap.
in
n Check level regularly.
n Level must vary between MAX and
MIN notches at cold engine (level can
slightly exceed MAX notch at hot en-
gine). W hen the level is lower, it is
necessary to fill in coolant.
n Use antifreeze coolant in correct rate
of distilled water (see instructions in
packing of chemical).
n Year-round use of antifreeze coolant
51
Air cleaner
Warning!
n Filter element change is per-
formed in authorised repair shop.
n After drive through dusty area
filter element change interval is
shorter.
FN0540
n Interval of filter element replacement

is specified in service booklet.
n Clogged filter element is indicated
by indicator lamp. When indicator lamp
starts glowing, contact immediately
authorised repair shop.
n Regardless of indicator lamp glow-
ing, interval of replacement, according
to service booklet, must be kept.
n State of air cleaner and intake sys-
tem features substantial influence to
life of turbocharger.
52
Steering
n When you find out clearance in steer- Warning!

ing mechanism, it is necessary to per-
n Change of oil and oil filter per-
form adjustment or repair in authorised
form authorised repair shops.
repair shop.
n When filling in of oil must be
n When sudden increase of steering
performed unusually often, ad-
wheel control forces occur, stop vehicle
vice authorised workshop.
immediately and check quantity of oil in
n Do not start engine, when oil
tank of monoblock power-assisted steer-
isn‘t in circuit of power assisted
ing and damage of hydraulic circuit.
steering.
n Take care of cleanliness dur-
ing manipulation with oil.
n Oil should be disposed with
respect of environment.
FN0550
Inspection and filling in of

steering oil
n Check level regularly.
n Oil level in tank must vary near notch
„LIVELLO OLIO“. when the level is
lower, it is necessary to fill in oil of
Specification ATF D II.
53
Gearbox
Specification Viscosity Warning!

of gear oils oil grade n Oil change is performed in au-
API SAE thorised repair shop.
n For towing vehicle with stopped
80 W engine and without engaged gear,
disconnect propeller shaft to pre-
GL - 4 80 W - 90 vent from gearbox damage due to
85 W - 90 insufficient lubrication.
n Do not start engine, when oil is
not in gearbox.
FN0560
n Inspections of oil quantity and state

are performed during service inspec-
tions.
n Inspect visually leaking of gearbox.
W hen you find out leaking, contact
authorised repair shop.
54
55
Clutch
Check of fluid and filling in Warning!

n It is necessary to inspect regularly n Authorised workshop carry out
quantity of fluid in circuit. change of fluid.
n Level must vary between MIN and n After air escape from air sys-
MAX notches. W hen level is lower, it tem (e.g. due to leaking during
is necessary to fill-in liquid of specifi- long-lasting immobility of vehi-
cation DOT3, DOT4, DOT4+ or SAE cle) disable of air booster occur
J 1703. that increases force for pedal de-
press up to 500 N.
n When filling in of fluid must be
performed unusually often, ad-
vice authorised workshop.
n Fluid is harmful.
FN0600
n Clutch control is performed by hy-

draulic transmission with compressed
air booster.
n When aeration of liquid circuit oc-
curred (poor clutch disengaging), ad-
vice authorised repair shop.
n During clutch disc wear, automatic
adjustment of clutch system occur, that
result in fluid press up to reservoir
(increase of fluid in reservoir).
56
Rear axle Front axle
Gear oils Recommended

specification oil grade
API SAE
90 H
GL - 5 80 W - 90 H
85 W - 140 H
FN0610 FN0620
Warning!
Authorised workshop carry out
n Inspections of oil quantity and state n When wear of front wheel tire tread
change of oil.
are performed during service inspec- is irregular, check and possibly order
tions. front axle geometry adjustment in au-
n Inspect visually leaking of rear axle. thorised repair shop.
W hen you find out leaking, contact n Life of dampers and their function
authorised repair shop. depend on way of driving and kind of
service.
Warning!
Order all repairs, change of charg-
es or adjustment in authorised
repair shop.
57
Brake system
18 3 2 19 15
17
14
7 16 19 5 8 10 12 4 13 11 9 6 19 15 FN0630
58
1 Compressor
2 Air pressure equaliser with air drier
3 Air tank 4.5 l
4 Four-way valve
5 Air tank 14 l
6 Air tank 14 l
7 Brake control valve
8 Air-hydraulic converter (I. circuit)
9 Air-hydraulic converter (II. circuit)
10 Brake fluid tank (I. circuit)
11 Brake fluid tank (II. circuit)
12 ABS valve (I. circuit)
13 ABS valve (II. circuit)
14 Load-dependent automatic regulator - air
15 Spring brake actuator
16 Manual brake valve of parking brake
17 Minimum air pressure switch of spring actuated
18 Front brake device
19 Rear brake device
59
Driving brake
n Front axle features disc brake, rear Air pressure in driving brake
axle features drum brake with built-in circuit
parking brake device. Nominal pressure
n Driving brake system is double cir- 0.81±0.02 MPa (8.1 bar)
cuit, air-hydraulic.
n Vehicles are equipped by default ABS Minimum pressure
system. 0.45 MPa (4.5 bar)
n First circuit of air valve controls air-
hydraulic converter of rear brake de- Warning!
vice. Driving with glowing indicator
n Second circuit of air valve controls lamp of driving brake minimum
air-hydraulic converter of front brake air pressure isn‘t acceptable. If it
device. isn‘t possible to reach minimum
n Braking force of rear axle wheels is air pressure level i.e. indicator
controlled in dependence on vehicle lamp glows after longer engine
load by means of automatic load-de- run, malfunction is in air section FN0640
pendence regulator. of driving brake circuit that must
be repaired immediately.
Correct function of driving Brake fluid inspection and
brake system is indicated by: type
1. Air pressure gauge monitoring pres- n It is necessary to check quantity of
sure in I and II circuit. brake fluid.
2. Indicator lamp of minimum air pres- n Level must vary between MAX and
sure. MIN notches.
3. Indicator lamp of brake fluid level in n Tanks are equipped with indicators
tank. of brake fluid level.
4. Indicator lamp of ABS. n Use brake fluid according to stand-
ard DOT 3, DOT 4 or SAE J 1703.
60
Brake fluid filling in Change of drier filter (item 1)

n For filling in use the same brake n Change drier filter after 1 to 2 years
fluid. 1 of operation or immediately in case of
n Remove protective cover of brake finding condensed water in air tank
devices. The cover can be removed (condensed water is found out in drain-
after dismantling of three bolts. Re- ing valves during regular inspection).
move cover in direction backwards and n Drier must be without pressure.
down. n Before change, clean surface of dri-
n Remove protective cover. er and release cup nut (item 2) of inlet
n Open filler neck of tank. 2 to release pressure.
n During filling in, keep maximum FN0650 n Clean upper part of body, slightly
cleanliness of surrounding area. grease sealing of new cartridge and
n After filling in of liquid between notch- manually tighten to torque of about
es MIN and MAX close tank, place Air pressure equaliser with 15 Nm.
protective cover and covering lid of air drier
brake devices. n It is used for cleaning and drying of Warning!
air that is delivered from compressor
Warning! and for regulation of service pressure in Used filter should be disposed
tanks. with respect of environment (it
n Drive with indicator lamp of
contains oil).
brake fluid level glowing isn‘t
acceptable.
n Mixing with brake fluid of an-
other specification isn‘t accept-
able.
n Fluid is harmful.
61
Brake lining inspection
Warning!
Brake pads change is performed
by authorised repair shops.
FN0660
Automatic load-dependent
regulator
n Load-dependent regulator is used to
regulation of air pressure that flow into
FN0670
diaphragm cylinder.
n Perform all adjusting works in au-
thorised repair shop. During operation, Front brake equipment
perform only visual inspection of con- n Front axle features disc brake.
nection between regulator lever and n Replace brake pads when grove in
rear axle, free run of regulator lever and their centre (see fig.) isn‘t visible.
leaking or equipment. n Minimum thickness of brake pads is
n Operator only order, according to 1.5 mm.
vehicle type, adjustment in the case n Replace brake lining only by lining of
that values printed in label, placed in approved type.
cab, do not correspond to reality.
62
n Replace brake linings when cut-out Warning!

isn‘t visible.
Brake lining change is performed
n Minimum thickness of brake linings
by authorised repair shops.
is 1.5 mm.
n Replace brake linings only by linings
of approved type.
1 2 3
FN0680
Rear brake equipment

1 Drum
2 Brake lining
3 Metal shoe
n Rear axle features drum brake.

n Decrement of brake lining is visible
in inspection window of brake support
plate that is closed by rubber cap.
63
Anti - Blocking - System
ABS considerably contributes to im- Warning!

provement of active driving safety of
n After turning key in position
vehicle. Decisive asset comparing with
ON, indicator lamp of ABS must
common brake system is in the fact
always glow. When ABS indicator
that maximum possible manoeuvrabil-
lamp together with indicator lamp
ity is maintained under full brake on
of brake fluid level aren‘t switched
slippery road because wheel blocking
off within several seconds after
does not occur.
ignition switching on or when they
It cannot be expected that ABS shorten
start glow during drive, equip-
braking track under all circumstances.
ment is in disorder, vehicle is
When wheel circumferential speed ow-
braked without ABS function. In
ing to vehicle speed is too low and
this case, it is necessary to ad-
wheel has tendency to blocking, brake
vice authorised repair shop.
pressure of this wheel is decreased.
n Higher safety that ABS brings
Brake pressure is controlled separately
must not lead to suffer whatever
for each axle. This way, brake effect is
risk!
equalised and maximum of driving sta-
n All repairs and modification are
bility is maintained.
performed in authorised repair
This regulation process results in pul-
shop.
sation movement of brake pedal. To
enable ABS to regulate most effective-
ly, brake pedal must remain depressed
- never cadence brake!
64
Emergency brake
Brake system is solved so that in case Conclusion Warning!

of brake system malfunction, emergen- n Before every drive and during
Whatever unprofessional inter-
cy braking effect is secured. drive, check state of braking system
vention to brake system isn‘t ac-
by means of indicator lamps.
ceptable, because it is necessary
When loss of driving brake effects n Verify state of bulbs of brake system
to do all repairs and modifica-
occur, reason could be the indicator lamps by turning ignition key
tions in authorised repair shops.
following: in switchbox from position „ACC“ to
n Failures of hydraulic circuit (loss of position „ON“, when indicator lamps
brake fluid). Malfunction is indicated by should be on.
indicator lamp of brake fluid minimum n After several seconds, indicator
level. lamps must be automatically switched
n Failures of driving brake air part. off.
Due to loss of air it is indicated by n After switching off, it is possible to
indicator lamp of minimum air pres- start drive.
sure.
n In both cases, brake system secures Brake system devices
emergency braking. Operator performs continuous in-
spections of state and function of
Warning! brake system. When failure or even
Emergency brake use always suspicion of failure is found out it is
means jeopardy of vehicle oper- recommended to order diagnostics
ation safety because emergency and possible remedy in authorised
brake effect is substantially low- repair shop.
er than driving brake effect.
65
Parking brake
Brake, brake release

n For state „Brake“ it is necessary to
shift brake valve lever to rear position
B (item A), where it is locked by slight lift
A (to prevent from spontaneous brake
release).
n For brake release slightly lift the 1
lever and shift it to front position (item
B).
FN0695 FN0700
Warning!
n Parking brake is spring-actuated, ef- n Use of parking brake during Unlocking of spring brake
fecting by means of mechanical gear to drive is dangerous, skid and de- actuator cylinder
rear axle wheels. creased vehicle manoeuvrability - only for purposes of towing.
n Energy that is necessary for vehicle might occur. During drive, use n Secure vehicle against movement
braking is accumulated in spring of parking brake only in case of high- by wheel chock.
spring brake actuator, loaded by com- est need. n Screw in special bolt (item 1) that is
pressed air. n Driving with indicator lamp of part of vehicle equipment, instead of
n Parking brake is controlled by man- spring actuator minimum pres- screwed plug in centreline of actuator
ual brake valve that is located behind sure glowing isn‘t acceptable - up to bolt head.
gear shift lever. vehicle is braked.
n Nominal pressure in spring Warning!
brake actuator: 0.81 ± 0.02 MPa. Use only bolts that were delivered
Minimum pressure in spring as part of vehicle equipment.
brake actuator: 0.52 ± 0.05 MPa.
66
Washer and wiper
Replacement of wiper blade.

n Tilt wiper arm.
n Turn wiper blade to horizontal posi-
tion.
n Depress spring plastic lock and con-
currently pull wiper blade out of attach-
ment.
n For mounting, proceed opposite way.
FN0710 FN0720 Warning!

n Do not use wiper with dry wind-
Washer tank Wipers screen - glass can be scratched.
n Washer tank is located in front bump- n To secure required outlook for the n Do not use wiper when wind-
er. safety reasons, it is necessary to main- screen is covered by snow layer -
n W asher tank features volume of tain wiper blade in good conditions. clean it at first.
7.5 l. n To ensure good wiping it is neces- n In winter season, make sure
n It is possible to fill in fluid after open- sary to clean regularly wiper blades by whether wipers aren‘t frozen to
ing front bonnet. solution for glass washing. windscreen.
n Minimum level of washer fluid is n Nozzles for washing wiped surface
indicated by appropriate indicator are placed on wiper arm.
lamp * . n Stream direction from nozzles can
n For filling in the tank, use water with be adjusted by needle.
ingredient of glass cleaning chemical n Complete housing with nozzles is
(e.g. Glacidet). In winter season, mix freely movable along wiper arm.
the chemical in such ratio that fluid
does not freeze (see instructions print-
ed in packing).
67
Tyres and wheels
n Check pressure in tyres before every n When vehicle is put out of service for Tyre life depends on:
drive. It is also important to check their longer period, it should be slightly lifted n Way of driving
state (let inspect their damage in tyre to release tyres. n Proper tyre inflation
repair shop). n Keep dismantled wheels (tyres) in n Environment where vehicle serves.
n Label of tyre inflation is located in dry and dark place n Front axle geometry
cab or in chapter Technical data. n Check tightening of wheel bolt nuts n Proper load distribution over the
n Tyres must not have on tread or in intervals according to Service book- freight surface
side-wall any cracks or another dam- let.
age that uncover tyre cord layer. n Instead of that check tightening of Wheels and their parameters
n When wear of front wheel tire tread wheel bolt nuts after covering first 50 - Front axle wheels - 2 balanced
is irregular, check and possibly adjust 100 km after each dismantle of wheel Rear axle wheels - 4 unbalanced
front axle geometry. by torque of 330 ± 25 Nm. Spare wheel - 1 balanced
n Depth of tread profile grooves and
notches must be at least 1.6 mm. Disk wheel 17,5 x 6,00
Tyres designated as REGROOVABLE Tyres 205/75R 17,5
can be deepen by cutting profile grooves (radial) 215/75R 17,5
(specialist must perform it). ALL STEEL TUBELESS
n Only balanced tyres in good condi-
tions are allowed to mount on front
wheels and all wheels must be in good
technical condition.
n Only tyres determined for given ve-
hicle type by vehicle manufacturer and
tyre manufacturer are allowed to be
used.
n Protect tyres from oil and fuel.
68
Load transport
OK OK
OK OK
FN0721
Especially when operating the vehicle n To increase tire pressure of the front n If tires will be exchanged, it is neces-
on a highway and when transporting to axle by 80 to 100 kPa. However, the sary to prefer:
a major distance, it is necessary to maximum permitted tire pressure as- a) tires having higher carrying capacity -
follow subsequent instructions signed by the tire producer must not be (215/75R17,5).
n Not to exceed the maximum permit- exceeded. b) tires that are determined by the pro-
ted weight upon the front axle. n To take care of correct load distribu- ducer to be used on highway traffic.
D 60 - D 75 = 2800 kg, tion on loading area.
D 80 - D 90 = 3200 kg - to place the load in the middle of
loading area.
- to place the load evenly on loading
area.
69
70
Electric equipment
n Connectors of all vehicle electric ap- Warning!

pliance must be connected properly
n When engine is stopped, use of
and polarity must not be confused.
electric appliance discharges bat-
n Perform battery charging always out
tery.
of vehicle.
n To weld using electric arc is
n Battery master switch and battery
prohibited - there is a danger of
terminal must not be disconnected when
damaging the alternator, engine
engine is running.
control unit and ABS control unit.
n During manipulation on vehicle when
short circuit could occur, battery mas-
ter switch must be disconnected.
n During splashing and washing of
vehicle, protect starter motor, alterna-
tor, glowing regulator and battery case
against penetration of water, to prevent
from short circuit.
n For safety reasons, During standstill
(garage etc. ), during long operational
brake, leaving vehicle or after finding
out failure of electric system, switch off
battery master switch.
n During risk of fire, switch off electric
system.
71
Battery attachment
1 Plastic cover
2 Clip of holder
3 Rubber holder
4 Profiled battery holder
7
5 Bolt of battery holder
6 Fuse box
7 Central earthing point
6
4
3
n
io
ct
5
re
di
ive
FN0730
dr
72
Battery Battery master Alternator
n Regulations for operation and main- Warning!

tenance are part of certificate of war-
When engine is running, alterna-
ranty that is handed over with vehicle.
tor terminals must not be discon-
n To check regularly each six month :
nected and battery master switch
battery condition, electrolyte level and
must not be switched off - alter-
retightening of ground screw (pos. 7 -
nator must not run without load.
figure on the adjacent page).
n During disconnecting of battery ter-
A
minal, always start with negative pole
terminal ("-"). Dismantling of battery
terminal, it is necessary to work care-
fully to prevent from short circuit be-
tween ("+") battery connector and vehi- B
cle ground by means of tools. After
cleaning and connecting back of termi- FN0740
nals, positive terminal of battery ("+")
must be connected again to battery
master switch. A Battery master switch connected
n Damaged battery must be replaced B Battery master switch
by battery of the same capacity, volt- disconnected
age, current rating and the same size.
Warning!
n Always charge battery outside
vehicle.
n Used battery should be dis-
posed with respect of environ-
ment.
73
Headlamps and lamps - location
1 Front headlamps
2 Front auxiliary position lamps
3 Front fog lamps
4 Flasher lamps
5 Brake lamps
6 Rear position lamps
7 Reverse lamps
8 Rear fog lamps
9 Licence plate illumination
10 Side marker lamps
11 Side flasher lamps
4 3 1 2 4 5 6 7 8 9
11 10 10
FN0750
74
Care of vehicle
Warning! Cleaning compounds Care of vehicle interior

In the case when vehicle is n the matter of cleaning compounds or it is important to use proper cleaning
equipped with superstructure another chemicals it is necessary to compounds and procedures (see in-
which tail board in tilted state follow advice of manufacturer namely structions of cleaning compounds).
regarding to interior or exterior of vehi- When you don‘t keep this principles,
covers rear lamps, driver is
cle. after cleaning, spots on interior materi-
obliged, under reduced visibility,
tilted tail board and staying on n Unsuitable cleaning compounds can al can appear that are removable very
public road, to place warning tri- degrade of vehicle parts. difficult way.
angle behind vehicle. Driver is n Some evaporable chemicals as ace-
also warned about this obligation tone, thinners, cleaning compounds as Components of plastic
detergents, bleachers or another ag- n For cleaning of plastic components
by special label that is located in
gressive chemicals should not be used in interior, moist cloth is enough.
cab and visible from driver‘s
place. instead of compounds that are recom- n After basic cleaning by moist cloth,
mended cleaning spots from textile. use chemicals that are determined to
Also petrol and diesel fuel must not be this purpose.
used.
n Work only when doors are open (va- Safety belts
pours of some chemicals are harmful. Clean only by soapy water.
Warning!
n It is necessary to maintain safe-
ty belts clean - dirt influences
operation of winding device.
n Before winding in, safety belts
must be completely dry.
n Do not clean safety belts chem-
ical way.
75
Door and window seal Washing of vehicle Waxing and polishing

Occasionally use chemicals for preser- n The best way how to maintain paint n Regular waxing and washing result
vation of rubber and so improve their in good condition as long as possible is in superb shine and easier following
life and resistance against frost. frequent washing of vehicle. washing.
n Wash vehicle by warm or cold water. n Wax is applied on dry body.
Windows n Do not use hot water and do not
n Use window cleaning compounds. wash in direct sunshine. Warning!
n In winter, scratch off ice by scraper n At first soak out impurity in bigger
Polish and wax must not be ap-
determined to this purpose. quantity of water.
plied to components of plastic.
n After soaking out, clean by soft
Care of vehicle exterior sponge from roof downwards by solu-
n Frequent wash and conservation are tion of water and car-shampoo in ratio Body paint damage
good protection of vehicle against neg- according to instructions of manufac- Every paint damage should be repaired
ative influences of environment. turer on packing. During washing, it is at once due to rapid corrosion of bare
n Regular care maintains value of ve- necessary to wash sponge frequently. metal. Do the work in professional work-
hicle. n After washing, flush vehicle thor- shop.
n It is necessary to use proper clean- oughly (chemicals must not dry on paint)
ing compounds and procedures (see and wipe by deerskin.
instructions on packing). W hen you
don‘t keep this principles, spots that is Warning!
very difficult to remove can remain on It is necessary to wash vehicle
vehicle exterior. with respect of environment.
76
M A L F U NC T IO N S A N D T H E IR R E M E D Y
Engine
1. Starter motor does not turn engine 2. Starter motor turns engine crankshaft
crankshaft slowly
A) Malfunction: Battery master switch is switched off A) Malfunction: Battery is discharged

Remedy: Switch on battery master switch Remedy: Charge battery according to certificate of
warranty of manufacturer handed over with vehicle
B) Malfunction: Battery is discharged
Remedy: Charge battery according to certificate of B) Malfunction: Faulty electric system
warranty of manufacturer handed over with vehicle Remedy:
- Clean poles and terminals of battery
C) Malfunction: Faulty electric system - Check and possibly clean interconnection between
Remedy: engine and battery
- Clean poles and terminals of battery - Check connection of cables to starter motor and
- Check and possibly clean interconnection between possibly tighten
engine and battery
- Check connection of cables to starter motor and C) Malfunction: Faulty starter motor
possibly tighten Remedy:In authorised repair shop
D) Malfunction: Faulty starter motor

Remedy: In authorised repair shop
E) Malfunction: Blown fuse

Remedy: Replace fuse, When new fuse is blown
immediately, let it check in authorised repair shop
77
Engine
3. Starter motor turns engine crankshaft,

impossible to start engine
A) Malfunction: No fuel in tank

Remedy: Fill in fuel and bleed fuel system
B) Malfunction: (only D432) Interrupted electric

current supply to electromagnet of injection equipment
stopping device
4. Engine stops after starting
A) Malfunction: Too low idle speed adjusted

B) Malfunction: Faulty fuel supply

Remedy: See paragraph 3, items A)
C) Malfunction: Fuel filter element is clogged

D) Malfunction: Penetration of air into fuel system

78
Engine
5. Engine doesn‘t feature full power 8. Engine is overheating
A) Malfunction: Fuel filter is clogged with impurities A) Malfunction: Insufficient quantity of coolant
Remedy: See paragraph 4, item C) Remedy: Check leaking of cooling circuit Remedy
Malfunction and fill in coolant
B) Malfunction: Improper function of injection
equipment B) Malfunction: Insufficient efficiency of radiator
Remedy: In authorised repair shop Remedy: Clean radiator surface
6. Engine knocks C) Malfunction: Thermostat Malfunction

Remedy: In authorised repair shop Remedy: In authorised repair shop
7. Engine excessively smokes D) Malfunction: Improper function of viscous fan clutch

A) Malfunction: Faulty or improperly adjusted injection
equipment or fuel injectors Warning:
Remedy: In authorised repair shop When indicator lamp of engine coolant temperature
glows, it is necessary to reduce vehicle speed, shift
B) Malfunction: Faulty turbocharger gear down, stop vehicle as soon as possible and
cool engine at higher speed (1200 - 1500 rpm).
Engine must not be stopped, after engine coolant
temperature indicator lamp start glow.
79
Engine
9. Thermometer of heated engine doesn‘t

operate
10. Engine lubrication indicator lamp glows

or shines through (only D432)
Remedy: Check engine oil level height, if need fill in.
When malfunction proceeds, let vehicle tow in author-
ised repair shop Do not startengine till malfunction
remedy
80
Engine
11. "Engine . stop" indicator lamp glows 12. "Engine – warning" indicator lamp
(only ISBe) glows (only ISBe)
Defect: Serious problem of the engine ( mostly Defect: Defect in engine system or defect of engine
temperature of coolant, temperature of filling air, component.
oil pressure) Repair: Vehicle can operate, but only to the nearest
Repair: Vehicle must stop as soon as possible. authorized repair shop, which must repair defect.
Make diagnostic test by accelerator pedal – press This situation is not emergency case.
pedal three time and loosen pedal. If indicator lamps
flicker code of defect, the problem with engine is very 13. "Engine – maintenance" indicator
serious and you must contact authorized repair shop lamp glows (only ISBe)
Cummins.
Driving is strictly prohibited. If during diagnostic test Defect: It is necessary to make maintenance.
indicator lamp “engine – stop” together with indicator Repair: If this lamp flickers during starting,
lamp “engine – warning” glow permanently, it is it is necessary to make maintenance
possible to drive vehicle. (exchange engine oil etc.) After maintenance
(e.g. oil exchange), it is necessary to restart
signal of this indicator lamp.
Warning:
When indicator lamp 11,12,13 glow, driver will
stop engine, check engine oil level and coolant level,
fill the engine oil and the coolant if necessary and
follows procedures 11, 12, 13,
given above.
81
Engine
14. Diagnostic test (only ISBe) 3

Turning on of the defect code (the
red light) permanently repeats; if
Defect: The warning light will remain glowing: another defect occurs it is necessary
„engine-stop“ to press a switch of the cruise control
red 3 having the sign +
„engine -warning“ FN075 4r And the process of turning on of the
orange numerical defect code starts
„engine maintenance“ repeating, and that, either turning on
blue the same defect code (that means
1 A defect kind (a three to four- no another defect code exists any
4
d ig it n um erical def ec t co de) more) or another one turns on that
decides on the fact which of the is noted down, and by repeated
FN075 1
warning lights is glowing. pressing the cruise control switch +
To start a diagnostic test: FN075 6 another turning on of the defect code
An ignition lock key must be in occurs till the period that the first
the position ON (1) – warning 5 defect code 115 is turned on again.
2A lights are glowing After termination of the diagnostic
2A by the accelerator pedal - 3x test: to return the switch 4 of the on-
to depress and release or board diagnostic and the ignition box
FN075 2r 2B through the separate switch key 5 to the initial position (turned
of on-board engine diagnostic FN075 7 off). And to wait approx. 30 seconds.
that is placed under a glove box
in the instrument panel. Warning!
Turning on will occur: of the
2B If the blue warning light of “engi-
orange engine warning indicator
ne maintenance” is lighting,
lamp and after turning off – the
make a visit to the nearest
FN075 3 red light of stop of engine check
contractual repair shop.
up starts to flash a defect code.
82
Engine Electric equipment
Example of defect codes 1. Battery charging indicator lamp glows

P=Pause Defect code 115:
IT WILL A) Malfunction: Malfunction is in circuit of charging
1 A flash 1 A flash 5 A flash
TURN OFF Remedy: At first inspect whether all lines of alternator,
storage battery and battery master switch are properly
P P P P tightened, perhaps connected to proper terminal. Also
inspect whether connections including ground cable of
1 IT TURNS ON IT WILL TURN ON storage battery aren‘t corroded.
Defect code 244: IT WILL B) Malfunction: (only D432) Released or broken
2 A flash 4 A flash 4 A flash TURN OFF
alternator belt
Remedy: Tension belt properly, Replace damaged belt
P P P P by new one in authorised repair shop.
1 IT TURNS ON FN075 8 IT WILL TURN ON 2. Battery charging indicator lamp

doesn‘t glow with switchbox switched
Stop of engine check up will turn on a numerical defect code.
Example of classifying the code number is obvious from the figure. over to position „ON“
-after turning off the orange warning lamp
-1x the red one will flash Remedy: In authorised re pair shop
-a pause 1 to 2 sec
-1x the red one will flash
-a pause 1 to 2 sec
-5x the red one will flash
-a pause 1 to 2 sec
-the orange one will turn on again (an end of turning on the
defect codes) the defect code = 115
83
Monoblock hydraulic Brake
power-assisted steering
1. Oil leaking from hydraulic circuit 1. Reduced braking effect
Malfunction: Leaking connections Malfunction: Aired brake system

Remedy: Tighten released connections, check oil Remedy: In authorised repair shop
level height and perhaps fill in nand contact author-
ised repair shop. Malfunction: Worn brake pads or linings
Remedy: Inspection of brake pads or linings, when
2. Malfunctions of individual equipment they are worn replace them in authorised repair shop
2. Reduced braking effect - brake fluid

level indicator lamp glows
Remedy: Failure of hydraulic circuit I or II
Stop vehicle immediately. Find out reason of failure
and according to possibility remedy directly
on the spot. Fill in brake liquid. W hen malfunction
cannot be repaired directly, continue driving with
respect of lower efficiency of emergency brake
(see chapter Emergency brake).
It is necessary to have it repaired in contract repair
shop.
84
Parking and spring-actuated brake
3. Reduced braking effec with indication 4. Parking brake locked, indicator lamp of
of pressure decrease in driving brake air minimum air pressure in spring-actuated
circuits and in spring actuated brake brake glows, vehicle cannot move
Remedy: Unlock spring actuated cylinders
Malfunction: Failure of driving brake air circuit I or II. (se chapter Parking brake) and tow vehicle
Remedy: Unlock spring actuated cylinders into authorised repair shop
(see chapter Parking brake) and tow into authorised
repair shop
5. Indicator lamp of ABS glows
Malfunction: Released or torn belt Remedy: Equipment isn‘t in order, vehicle is
Remedy: Tighten belt, replace damaged belt in braked without function of ABS. Only ordinary brake
authorised repair shop. system of the vehicle is functional. In this case it is
necessary to advice authorised repair shop. Drive
must be accommodated to given situation.
85
MA L FU NCT ION S AN D TH E IR R EM E DY
Towing Towing hook
Warning!
n When engine is stopped, boost-
ers of steering and brakes do not
operate.
n For towing, use only tow bar,
another connection is not accept-
able.
FN0760 Operating sequence of propeller FN0770

shaft disconnecting
n Secure vehicle against spontaneous
Towing movement. Special hook for safe fixing of cable
n Fix towing bar to central part of front n Dismantle bolts fixing propeller shaft during vehicle rescue is welded to vehi-
bumper by means of pin. from gearbox flange. cle frame.
n When you tow vehicle with stopped n Fix propeller shaft to vehicle frame
engine without engaged gear, discon- suitable way.
nect propeller shaft to prevent gearbox n After towing and repair of vehicle,
damage due to insufficient lubrication mount propeller shaft back to gearbox
and unlock spring-actuator cylinder flange, tighten self-locking nuts to torque
according to chapter Parking brake. Mk = 60 ± 10 Nm.
n W eight ratio of towed and towing
vehicles must be at least 1.4 : 1.
86
Spare wheel carrier (N, L, E) Wheel chock (N, L, E)
n Lift wheel by tyre (fig. B) in place of

point 1 and depress lifted wheel in place
of point 2 in direction to vehicle centre
(vehicle swing follows (fig. C) - beware
A of injury).
n Remove wheel from carrier.
Spare wheel mounting

n Lift wheel by means of cab lift bar so
that it remains hanging in slots of car- FN0790
B
rier front bracket (fig. D).
n Swing wheel into horizontal position
21 to you so that it descents to supporting
plate of rear bracket and also to sup-
1 porting plate of front brackets in front of
stop protrusions.
C D n From below, fix supporting plate by
means of two nuts and secure by wire
lock of one bolt.
Warning!
FN0780
Owing to wheel weight, be careful
during manipulation.
Dismantle of spare wheel

n Dismount spring cotter pin and two
nuts to release thrust plate (fig. A).
87
Spare wheel carrier (K) Wheel chock (K)
A B
FN0800 FN0810 FN0820
A - left hand side Spare wheel mounting

B - right hand side n When mounting spare wheel back,
proceed opposite way of work sequence.
Dismantle of spare wheel n After mounting, depress stops to
n From below, screw out bolt from disc and tighten properly counter-nuts,
welded nut on left side of carrier. to prevent knocking of released spare
n After dismantling of right side bolts, wheel.
pull handle of wagon in direction to
yourself and descend to ground. Warning!
n Slightly lift clamp of right side and Owing to wheel weight, be careful
after hooking out from pin, descend to during manipulation.
ground.
n Drive spare wheel out of vehicle.
88
Change of wheel
Warning!
Never start engine of lifted vehi-
cle.
FN0830 FN0840
n If it is possible, perform change of n Contact surfaces of disc and hub

wheel on horizontal plain. must be clean.
n Secure vehicle by wheel chocks and n Partially and uniformly tighten wheel
brake it. nuts.
n Remove spare wheel from carrier. n After slow opening of jack valve,
n Release wheel nuts by spanner (part descend vehicle to ground carefully and
of equipment) by one revolution. slowly.
n Place jack (see figure). Jack must be n Tighten completely wheel nuts to
well placed on hard foundation. torque of 330 ± 25 Nm.
n Lift wheel, by lever movement, (with n Retighten nuts after covering
closed valve) by several centimetres 50 - 100 km.
above ground.
n Screw out wheel nuts, remove wheel
and mount spare wheel.
89
Change of bulbs
n Before change of bulb, switch off the Warning!

lamp.
n Perform headlamp adjustment
n Replace blown bulbs by bulbs of the
in authorised repair shop.
same parameters (designation and
n New bulb type and power must
parameters are marked on bulb).
correspond to defined original
n Halogen bulbs must not came in
bulb.
contact with fingers - after switching on,
bulb loses its efficiency.
FN0850
Headlamp
n For replacement of blown bulbs, it is
necessary to tilt cab.
n Swing plastic cover of headlamp in
counter clockwise direction and remove
it.
90
1 FN0860 FN0870 FN0880
Low and main beam Front position lamps

n Disconnect terminal board (item 1) n Remove lamp holder out of lamp.
from bulb n Pull out bulb out of lamp holder.
n Hook off wire spring holder (item 2). n Insert new bulb and proceed oppo-
n Remove blown bulb and insert new site way.
one (protrusions of bulb (item 3) base
must match with their slots on lamp).
n During mounting, proceed opposite
way.
Front H4 24 V 70/75 W 2 headlamp - low and

part main beam
24 V 5W 2 position lamps
91
FN0890 FN0900
Front flasher lamps Front auxiliary position lamps

n For replacement of blown bulbs, it is n Remove light housing cover by
necessary to open door for easier ac- means of bigger screwdriver.
cess. n Press blown bulb, turn it counter
n Turn plastic bulb socket counter clockwise and remove it.
clockwise and pull it out with bulb out of n Insert new bulb, press it and turn it
light housing. clockwise.
n Press blown bulb, turn it counter n Mount cover and depress it to its
clockwise and remove it. place.
n Insert new bulb, press it and turn it
clockwise.
n Insert bulb socket into light housing
and turn it clockwise up to stop.
Front 24 V 21 W 2 flasher lamps
part 24 V 5W 2 auxiliary position lamps
92
Front fog lamps

n Screw out plastic holders (item 1) of
fog lamp housing.
n Remove the housing.
1 n Bend ground terminal to perpendicu-
3 lar position (item 2).
n Disconnect wire (item 3) pulling out.
n Hook off and bend wire spring holder
(item 4).
n Remove blown bulb and insert new
one (protrusions of bulb base must
match with their slots on lamp).
n During mounting, proceed opposite
way (do not forget to bend back ground
2 terminal to original position).
4 n Designation TOP must direct up-
wards.
FN0910 n Let lamp adjustment checked in au-
thorised repair shop.
Front H3 24 V 70 W 2 fog lamps

part
93
FN0920 FN0921
Rear cluster lamps n Insert new bulb, press it and turn it Licence plate illumination
n Screw out lamp cover. clockwise. lamp
n Press blown bulb, turn it counter n Insert and screw up the cover. tight- n Screw out lamp cover.
clockwise and remove it. en very slightly - easy to crack. n Press blown bulb, turn it counter
clockwise and remove it.
n Insert new bulb, press it and turn it
clockwise.
n Insert and screw up the cover. tight-
Rear 24 V 10 W 2 red tail lamp en very slightly - easy to crack.
part 24 V 21 W 2 red brake lamp
24 V 21 W 2 orange flasher lamp
24 V 21 W 2 red fog lamp
24 V 21 W 2 white reverse lamp
24 V 10 W 2 licence plate illumination lamp
94
FN0930 FN0940 FN0950
Ceiling of interior illumination Side flasher lamp Side position lamps

n Remove cover from lamp housing n Screw out the lamp. n Screw out lamp cover.
by means of small screwdriver (two n Press blown bulb, turn it counter n Press blown bulb, turn it counter
slots are visible on cover for screwdriv- clockwise and remove it. clockwise and remove it.
er inserting). n Insert new bulb, press it and turn it n Insert new bulb, press it and turn it
n Press blown bulb, turn it counter clockwise. clockwise.
clockwise and remove it. n Insert light behind fastener in front n Insert and screw up the cover. tight-
n Insert new bulb, press it and turn it part and screw it. en very slightly - easy to crack.
clockwise. n Tighten very slightly - easy to crack.
n Carefully insert an depress cover to
its place.
Interior 24 V 12 W 3 ceiling lamp
Side 24 V 21 W 2 side flasher lamps
part 24 V 4W 6 side position lamps
95
Fuse box - cab
Fuses
F1 10A brake lamp, „+“ onto the instrument panel F20 10A headlamps washer*
F2 10A cigarette lighter F21 25A heating of mirrors
F3 10A acoustic horn F22 10A air conditioner*
F4 10A cab interior and superstructure illumination* F23 25A control of windows*
F5 10A Digital clock* F24 free
F6 25A voltage charger 24V / 12V; F25 10A left main beam + indicator lamp
pluf of ISBe engine diagnosis F26 10A right main beam / R04 of rear fog light
F7 10A sengine speed sensor / exhaus F27 free
brake relay (D432) F28 10A left low beam + indicator lamp
F8 10A injection advance device / glowing F29 10A right low beam / + R04 of rear fog light
regulator / fuel stopping (D432) F30 10A headlamp corrector
F9 10A „+“ for differential lock control / auxiliary F31 10A left position lamp / right auxiliary position
drive / dashboard clock display lamp /instrument panel illumination
F10 25A "+" for towed vehicle F32 10A right position lamp / left auxiliary
F11 10A warning lamp position lamp
F12 10A central lock* F33 10A control circ. fog lamps
F13 10A IGN relay control via ignition lock / F34 10A illumination of controls
starter relay control F35 10A left front fog lamp*
F14 10A "+" for rear fog lamps F36 10A right front lamp*
F15 10A reserve F37 free
engine brake relay control with running F38 free
braking and pedal relay (ISBe) F39 10A ABS control unit
F16 10A wipers F40 10A ABS control unit
F17 10A ventilator engine
F18 10A flasher lamps
F19 10A reverse lamps / “+” pole for instruments
96
Relays
R01 heating of mirrors

R02 headlamp washer
R03 brake lamps - check
R04 rear fog lamp control
R05 flash lamps
R06 switchbox
R07 window control 1
R11 position lamps
R12 low beam
R13 main beam
R14 front fog lamps
R15 free
R16 free
R17 wipers
R18 speed relay of wipers
R19 wiper-speed switch
R20 air conditioner
FN0970
R21 warning lamps 1
R22 warning lamps 2
R23 brake lamps - control
R24 air-conditioning ventilator
97
Fuse box - under battery cover
Change of fuse
ISBe D432
n Fuse box is located under storage
compartment in instrument panel.
n Entry is possible after removing bot- A A
tom of storage compartment that is
released by turning of two revolving B B
holders (direction of rotation is visible C
C
on cover).
n Individual electric circuits are se- D D
cured by fuses. E
n Blown fuse has melted metal strip.
n During replacement, switch off bat- F
tery master switch.
n New fuse must have the same cur- 4 3
rent value.
n It is necessary to have spare fuses in
vehicle. 1 1
2 2
FN0980
98
Cummins ISBe Warning!

A 80A air heater n Replace blown fuse only with
B 30A electromagnet for starter motor fuse of the same nominal value.
C 50A " + " before switchbox Higher value can result in dam-
age of electric wiring and even
D 50A " + " after switchbox
fire.
E 30A " + " permanent for engine control unit n When immediately after switch-
F 30A fuel heating ing on of appropriate appliance,
1 20A " + " without battery master switch replaced fuse is blown, it is nec-
(permanent current for recording essary to inspect electric wiring
speedometer, clock, radio) in authorised repair shop.
2 relay for starter motor electromagnet (12 V) n Do not repair blown fuses in
any case.
3 relay of fuel heating n It is forbidden to use screw-
4 relay driver or another metal subject
for removing fuses.
Dwav D432
A 80A glowing
B 30A electromagnet for starter motor
C 50A " + " before switchbox
D 50A " + " after switchbox
1 20A " + " without battery master switch
(permanent current for recording
speedometer, clock, radio)
2 relay for starter motor electromagnet (12 V)
99
Starting by means of jumper cables
n It is possible to start vehicle with

2 5 discharged battery only by intercon-
necting with battery of another vehicle
with the same nominal voltage.
24V Warning!
Battery of the second vehicle must
have nominal voltage of 24 V.
n Certified jumper cables with suffi-

cient cross section must be used.
n Use only cables with insulated clips.
1 n During starting, engine of vehicle
whose battery is used must run.
4
3
FN0990
100
Procedure of interconnection Engine starting Warning!

1. Connect one end of ("+") cable (item n Start engine according to chapter
n During starting by means of
1) to positive pole of front discharged Engine starting.
jumper cables, radio must be
battery (item 3). n After engine starting, disconnect
switched off - its damage cold
2. Connect the second end of the same jumper cables in opposite sequence.
occur.
cable to positive terminal of 24 V source
n Parts of jumper cable clips that
(item5).
aren‘t insulated must not come to
3. Connect end of the second ("-")
contact. Jumper cable that is con-
cable (item 2) to negative terminal of 24
nected to positive pole of battery
V source (item 5).
must not come to contact with
4. Connect firmly of the same cable to
vehicle ground due to risk of short
("-") pole of rear discharged battery
circuit.
(item 4).
5. Engine of vehicle that helps to start
must run all the time.
101
TEC H NICA L D ATA
Engine for D family vehicles
n diesel n turbocharged n with intercooler n four stroke OHV n four cylinder in line n liquid cooled
with direct injection
Engine type designation

CUMMINS ISBe 150 30 ISBe 170 30
Number of cylinders 4 / 16 4 / 16
Cylinder bore 102 mm 102 mm
Piston stroke 120 mm 120 mm
Displacement 3 922 cm3 3 922 cm3
Compression ratio 17,2 17,2
Maximum power 110 kW / 2 500 min-1 125 kW / 2 500 min-1
Maximum torque 550 Nm / 1 200-1 600 min-1 600 Nm / 1 200-1 600 min-1
Injection system CommonRail Bosch; CommonRail Bosch;

Electronic control unit Electronic control unit
102
TECH NICAL DATA
Engine type designation

Daewoo Avia D432.100
Number of cylinders 4 / 16
Cylinder bore 102 mm
Piston stroke 120 mm
Displacement 3 922 cm3
Compression ratio 17,5
Maximum net power acc. ECE 85 100 kW / 2400 min-1
Maximum net torque acc. ECE 85 580 Nm / 1 220 min-1
Specific fuel consumption at

maximum torque 225 g / kWh
Injection system Mechanical rotary

pump Bosch
103
TEC H NICA L D ATA
Chassis
Engine cooling system Propeller shaft n ratio of hypoid transmissions:

n liquid cooling n Versions K have one-shaft with two Final drive Eaton
n liquid pressurised-type forced cool- universal joints - spiders supported by 4,11 3,70
ing system by means of centrifugal pump needle bearings, with sliding sleeve Final drive Avia
n cooling circuit is equipped with twin yoke. 3,55 3.82 4.11
flap thermostat and coolant expansion n Versions N, L, E have two-shaft ar-
tank rangement with three universal joints Front axle
with shaft bearing and with sliding sleeve n rigid with forged axle beam
Air cleaner yoke. n longitudinal leaf spring or parabolic
dry filter element n Versions S have three-shaft arrange- spring suspension with anti-roll bar and
DONALDSON P 781039 ment with for universal joints with two fluid-type dampers with bottom stops
shaft bearing and with sliding sleeve wheel adjustment
Clutch yoke. toe in 0 ± 2mm
n dry camber 0°30‘
n single disc Rear axle king-pin inclination 8°± 20‘
n asbestos free lining n rigid drive banjo axle with cast centre king-pin castor (horizontal
n with clutch mass damper, axial spring and welded tubes position of frame) 3°± 30‘
and hydraulic control n final gear with single hypoid gear Maximum king-pin castor difference
and bevel gear differential of left and right side (horizontal
Gearbox n mechanical differential lock position of frame) 0°30‘
n mechanical n suspension by longitudinal leaf spring internal wheel displacement 48°± 2°
n countershaft or parabolic spring suspension with external wheel displacement 36.5°± 2°
n constant mesh gears anti-roll bar
n synchronised n fluid-type dampers with bottom stops
n controlled by gear shift stick lever n rubber top stop
n gearboxes enable mounting of pow- n some versions with leaf springs are
er take-off shaft with pump, shaft or without anti-roll bar and dampers
flange
104
TECH NICAL DATA
Steering Cab nal direction and backrest can be tilted

n monoblock power assisted steering Forward control cab, welded of steel in range 14° till 25°.
n gear ratio 14 - 16.6 - variable during pressings, tilted by hydraulic cylinder is Cab is equipped with pre-loaded safety
turning of steering wheel between stops equipped with noise and heat insula- belts. Instrument panel with storage
n monoblock power assisted steering tion. To limit transfer of chassis vibra- compartment in front of front seat pas-
with cardan universal joint with longitu- tion, cab is supported by two spring senger is of colourfast shatterproof plas-
dinal slots blocks in front part and two damping tic materials as well as interior equip-
units under rear suspension locks. ment of cab, rear wall and doors.
Total angle of steering gear arm incli- All glasses are safety. Laminated-glass Ceiling rack under windscreen upper
nation to achieve total angle of front windscreen is stuck into body, side edge enables mounting of radio. Mount-
wheels 87° windows are divided, rear part is mov- ing places of loudspeakers are in door
Number of steering wheel revolutions able by mechanical equipment, electric pockets and in rear wall pocket. Cab is
for maximum inclination of steering gear winder is optional. equipped with two sun visors.
arm 3.8 rev. For rear view, three windows are in rear heating is hot-water type. Air for heat-
Steering wheel diameter 450 mm wall. Version without rear windows are ing is aspirated behind bonnet by four-
also available. speed fan, it flows through heating ele-
Frame Doors are secured in open position by ment and then it is distributed to adjust-
n ladder type balancer to prevent from spontaneous able outlets for blowing to windscreen,
n cold riveted closing. Doors are locked by locks place heads and legs of crew according to
n screwed in doors that are lockable by key from selected combination. Air-conditioning
n brackets and fasteners for fixing of outside, central lock is optional. is optional.
chassis subassemblies and parts are For easier getting in and out of cab,
riveted or screwed to frame vehicle has steps and handles. Stan-
n holes in chassis beam for super- dard equipment of cab is driver‘s seat
structure carrying brackets or brackets and double seat for two co-drivers. Cab
are prepared with seat for one co-driver and sprung
n towing hook for vehicle rescue is driver‘s seat is also available.
located on rear bumper bracket Driver‘s seat is adjustable in longitudi-
105
TEC H NICA L D ATA
Brake
System of driving brake n Drop of brake liquid under minimum

n double-circuit acceptable value is signalled by appro-
n air-hydraulic braking system priate indicator lamp.
n with automatic load-dependence reg-
ulator of rear axle wheel braking force Emergency brake
(check data of adjusted load-depend- emergency braking is secured by one
ence regulator are printed in LDR ad- unbroken circuit
justment label, located in cab).
n system of brake circuit connection it Equipment for parking braking
TT. n parking braking is secured by spring-
n Vehicles are equipped by default ABS actuated brake
system. n it is controlled by manual brake valve
that is placed beside driver behind gear
Brake equipment shift lever
n front axle features disc brake with n air pressure drop in spring-actuated
fixed calliper cylinders to the value when brake starts
n rear axle feature drum brake with its activity is indicated to driver by cor-
built in parking brake device and with responding indicator lamp
equipment for automatic adjustment of
clearance between brake drum and
brake shoe
n air pressure in brake system is indi-
cated by two pressure gauges in instru-
ment panel
n air pressure drop under minimum
level is indicated by corresponding indi-
cator lamp
106
TECH NICAL DATA
Brake fluid DOT3, DOT4 nebo SAE 1703

Air tank volume according to type and make 14 l
Minimum air pressure for
operation of converter 0.45 MPa (4.5 bar)
Operational air pressure 0.81 ± 0.02 MPa (8.1 bar)
Front brake equipment

Disc diameter 315 mm
Disc thickness 26 mm
Brake lining thickness 18 mm
Brake lining area 243,5 cm2 (total487 cm2)
Cylinder diameter 56 mm
Rear brake equipment

Drum diameter 325 mm
Brake lining width 100 mm
Brake lining thickness 12 mm
Brake lining area 448 cm2 (total 896 cm2)
Cylinder diameter 38.1 mm
107
TEC H NICA L D ATA
Dimensions of chassis-cabs
For dimensi-
ons, tolerance
of ± 1% is
valid, providing
that it wasn‘t
defined another
way.
FN1001
108
TECH NICAL DATA
Weights and weight on axles
Vehicle type D60/65 D70/75 D80/90
Vehicle version K N L E S K N L E S K N L E S
Curb weight of serviceable 3030 3070 3080 3100 3250 3030 3070 3080 3 100 3250 3060 3100 3120 3140 3300
chassis-cab
Weight - on front axle 2020 2010 2040 2040 2065 2020 2010 2040 2040 2065 2040 2030 2060 2070 2125
- on front axle 1010 1060 1040 1060 1185 1010 1060 1040 1060 1185 1020 1070 1060 1070 1175
Carrying capacity of chassis-cab 2960 2920 2910 2890 2740 3960 3920 3910 3890 3740 4930 4890 4870 4850 4700
Including crew 3460 3420 3410 3390 3240 4460 4420 4410 4390 4240 5940 5900 5880 5860 5700
Total vehicle weight 5990 / 6490 6990 / 7490 7990 / 9000
Axle weight - front 2800 2800 3200
limit - rear D60 - 4200 D65 - 4550 D70 - 4900 D75 - 5250 D80 - 5650 D90 - 6200
Towed weight - without brake 750 750 750
- with brakes 3500 3500 3500
Note: on vehicles having the tank with a capacity of 200 litters - weights are increased by 80 kg.
For weight values, tolerance of ±3% is valid.
Warning!
Distribution of momentary load
is permitted to be in ratio mini-
mum 30 - 35 % to front axle and
65 - 70 % to rear axle.
109
TEC H NICA L D ATA
Tyre inflation
Vehicle Front Rear Spare Size

type axle axle whee tyre
kP a
D60 / K,N,L 525 500 525 205 /75R1 7,5

D60 / E,S 550 500 550 205/75R17,5
D75 / K,E,S 600 575 600 205 /75R1 7,5
D75 / N,L 575 575 575 205/75R17,5
D90 / K,N 625 700 700 215 /75R1 7,5
D90 / L 600 700 700 215 /75R1 7,5
D90 / E,S 675 675 675 215/75R17,5
Table of tyre inflation is located in label in door area

on driver‘s side. Values are specified in terms of kPa.
Truck circle diameter
K N L E S
Truck circle diameter
of external wheel 10,0 m (+0,5 m) 12,0 m (+0,5 m) 13,5 m (+0,5 m) 16,0 m (+0,5 m) 17,8 m (+0,5 m)
Turning clearance circle
diameter 11,1 m (+0,5 m) 13,1 m (+0,5 m) 14,8 m (+0,5 m) 17,3 m (+0,5 m) 19,1 m (+0,5 m)
110
TECH NICAL DATA
Gearratios
Ratio of transmission Total power take-off shaft transmission ratio

(engine speed / speed of take-off shaft)
ZFS5-42 ZFS6-850 ZFS5-42 ZFS6-850
I 5,72 6,72 1,15 1,88 ; 1,47
II 2,94 3,68
III 1,61 2,15
IV 1,00 1,41
V 0,76 1,00
VI 0,79
R 5,24 6,03
111
TEC H NICA L D ATA
Maximum vehicle speed, climbing performance
Engine Gearbox Rear axle Theoretical max. Min. theoretical gradeability (%)
ratio speed (km/h) Vehicle type
D60/75 D80/90
3,55 128 35
ZF S5-42 3,7 122 29,5
ISBe 135 30 3,82 118 38
4,11 110 41 33
ZF S6-850 3,7 118 44 35,5
4,11 106 50 40
3,55 128 39
ZF S5-42 3,7 122 33
ISBe 150 30 3,82 118 42
4,11 110 46 37
ZF S6-850 3,7 118 50 40
4,11 106 57 45
ZF S5-42 3,7 122 44 35
ISBe 170 30 4,11 110 50 40
ZF S6-850 3,7 118 54 43
4,11 106 63 49
3,55 122 41,5
ZF S5-42 3,7 117 35
D432.100 3,82 114 45
4,11 106 49,5 39,5
ZF S6-850 3,7 113 53 42
4,11 102 61 48
112
TECH NICAL DATA
Electric equipment
Nominal voltage 24 V
Storage battery Varta 562 19, 12 V - 62 Ah (installed by manufacturer)

Topla 55 414, 12 V - 60 Ah
Banner 56 093, 12 V - 60 Ah
Akuma L 61WG, 12 V - 61 Ah
Varta 12 V - 88 Ah heavy duty (only ISBe)
Way of grounding negative pole (-) directly to battery
Alternator Magneton 28 V / 43 A (70 A)

Bosh 28 V / 70 A (only ISBe)
Glow plugs Brisk Tábor 22,5 V
Electric wiring fuses 34 fuses 10 A

1 fuse 20 A
4 fuse 25 A
3 fuse 30 A
2 fuses 50 A
1 fuse 80 A
Horn 24 V electromagnetic
113
TEC H NICA L D ATA
Bulbs
Front H4 24 V 70/75 W 2 headlamp - low and main beam

part 24 V 5W 2 front position lamp
24 V 21 W 2 front flasher lamp
24 V 5W 2 front auxiliary position lamp
H3 24 V 70 W 2 front fog lamp
Rear 24 V 10 W 2 position lamp

part 24 V 21 W 2 brake lamp
24 V 21 W 2 flasher lamp
24 V 21 W 2 rear fog lamp
24 V 21 W 2 reverse lamp
24 V 10 W 2 licence plate illumination
Side 24 V 21 W 2 side flasher lamp

part 24 V 4W 6 side position lammp
Interior 24 V 12 W 3 ceiling lamp

OSRAM 24 V 1,2 W 3 instrument panel illumination
OSRAM 24 V 1,2 W 1 main beam indicator lamp (other fixed LED diodes)
114
TECH NICAL DATA
Fuel consumption
Engine n ISBe 150 30 n ISBe 170 30 n D432.100

D 60 / 65 / 70 / 75 D 80 / 90
at speed 40 km/h 7 - 8,5 l / 100 km 8 - 9,5 l / 100 km
at speed 60 km/h 9,5 - 11 l / 100 km 10 - 11,5 l / 100 km
at speedi 80 km/h 13 - 15 l / 100 km 13,5 - 17 l / 100 km
service consumption 14 - 17 I / 100 km 15 - 19 I / 100 km
consuption with trailer +15 % +15%
Service fluids
ISBe D432
Engine oil 13 l 12,5 l
Cooling circuit including heating circuit 19 l 18 l
Gearbox ZF S5 -42 3,2 l
Gearbox ZF 6 S 850 7,5 l (auxiliary drive 8 l)
Fuel tank volume 120 l
Minimum fuel reserve 16 l
Rear axle - final gear 4l
Monoblock power-assisted steering 1,7 l
Windscreen washer tank 7,5 l
Brake fluid circuits 1,6 l
Clutch release hydraulic circuit 0,5 l
Cab tilting hydraulic circuit 0,65l
115
TEC H NICA L D ATA
Vehicle Identification Number
VIN number
(Vehicle Identification Number)
n Identification number VIN according
to international unified system of vehi-
cle numeration is used for this vehicle.
Identification number VIN is stamped in
right chassis beam wall in front of damp-
er carrier.
n Factory label with VIN number is
also on right door jamb above door
lock.
FN1010 FN1020
T N A A2 X 0 0 0 X A 0 1 2 3 4 5
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nt
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s .r
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mb
p la
ec E u ro
cti
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nu
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ic le
N,
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p ro
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YL
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of
mo
Cz
OK
ch
as
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116
TECH NICAL DATA
Labels
FN1030 FN1040 FN1053
On right door jamb above door On left door jamb above door On right hand side of cab,
lock lock rearwards
n ALR (A) n Tyres inflation (F) Information about cab tilting (J)
n VIN number (B) n Warning - information about alter-
n certification (C) nator (G)
n certification (H)
n Headlamp adjustment (D)
n Cab (E)
117
AVIA ASHOK LEYLAND MOTORS s.r.o.
Beranových 140
199 03 Praha - Letňany
Czech Republic
Version 3j / Aj / 12/2006
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Dear driver,

AVIA ASHOK LEYLAND MOTORS s.r.o.

1 Combined change-over switch 10 Window winder*

FN0020 FN0030 FN0040

n Two keys are delivered - it is advised Exterior side inner side

Electric window winder*

Central door lock* n Pressing of rocker switch front side

Instrument panel - indicators Indicator lamps

Direction indicator lamp

4 n According to switched on flasher light

5 6 8 9 FN0065 High-beam headlamps

It glows when high-beam headlamps

n When indicator lamp is not switched Warning! Parking brake

Minimum washer fluid

FN0080 Air cleaner (clogged)

n It glows in case of clogged air filter.

It glows when low-beam headlamps

It glows when the cab is improperly fixed

Combined switch over switch

n Audible signal indicates open doors

3 Low and high beam switch

7 Selector of pulsating wiping

It is recommended to engage &

5 Rear fog lamps 9 Reset / coast

1 Socket for ABS diagnostics

n Diagnostic sockets are placed un-

Switchbox and steering lock

remain to glow: battery charging, (engine

Gear-shifting lever Steering-wheel inclina-

Heating and ventilation

n The truck cabin is heated by a hot

n Headrests are height-adjustable.

Use of safety belts Height-adjustment of safety Warning!

Rear view mirrors Rear view mirror remote

Headlamps inclination adjustment Cab interior illumination

30% 50% 70% 100%

Digital clock* Socket / cigarette Sun visors

FN0270 FN0280 FN0295

Cup holder Ashtray Hanger, storage pocket

n Eject holder by pressing and subse- n Open by pulling to yourself.

Opening of engine bonnet Shut the bonnet

Tools and equipment

A - Front-seat passenger‘s seat

n Tools and equipment are placed

Hydraulic tilting of cab Instructions for cab

Tilting of special version cabs

Chassis and cab

13 Oil level dipstick

Inspection before drive Running-in of vehicle Maintenance

n After vehicle start up, test opera- temperature glows, it is necessary to

Engine stopping The Neutral gear

n Stop engine by switching over the Warning!

Engine for D family Engine lubricating

production plant is printed on self-ad-

dation and subsequent engine dam-

n Keep maximum cleanliness and pre- Warning!

Fuel filter draining

The fuel filter is drained by draining

Cummins ISBe engine