Avia D 100 User Manual Download Page 95

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

Engine

Diesel

turbocharged

with charge-air

OHV, four-stroke

four-cylinder,

water

with direct injection by one turbocharger

cooling

in-line

cooled

Engine type designation

CUMMINS

ISBe4 160

ISBe4 185

Number of cylinders / valves

4 / 16

Cylinders bore

104 mm

Pistons stroke

132 mm

Displacement

4,500 cm

Compression ratio

17.3

Maximum output

117 kW / 2,500 rpm

136 kW / 2,500 rpm

Maximum torque

602 Nm / 1,200 ÷ 1,600 rpm

700 Nm / 1,200 ÷ 1,600 rpm

Injection system

CommonRail Bosch;

electronic control unit

Summary of Contents for D 100

Page 1: ... safety information We recommend you to read it thoroughly and to follow instructions and warnings mentioned We would be pleased if you manage to make a full use of its advantages and possibilities We believe that the vehicle AVIA will serve you many years to your complete satisfaction Avia Ashok Leyland Motors s r o Beranových14 Praha Letňany CzechRepublic ...

Page 2: ...ctory installed on certain models or are delivered as option only If you sell your vehicle remember to overhand the complete vehicle docu mentation to a new owner Warning n The texts in frames named Warning mustbeunconditional ly observed Operation Manual To get acquainted with the vehicle pro perly it is necessary to read through the Operation Manual and all manu als which were delivered together...

Page 3: ...gency brake 58 Parking brake 58 Windshield washer and wipers 60 Tyres and wheels 61 Transport of loads 62 Electronic vehicle height adjustment ECAS 63 Draining the condensate from air tanks 64 Basic rules for the trailer coupling 65 Electrical equipment 67 Location of battery 68 Battery 69 Battery circuit breaker 69 Alternator 69 Headlamps and lights location 70 Vehicle care 71 Troubleshooting Eng...

Page 4: ...DES CRIPT ION 4 Interior FN0015a 5 7 9 8 2 4 17 6 3 1 11 26 19 20 16 15 14 27 22 21 23 24 20 25 18 28 13 10 12 ...

Page 5: ... resume 6 Measuring instruments and indicator lamps 7 Digital clock 8 Heater control 9 Adjustable heater vents 10Window lift mechanism 11 Door opening and locking 12 Ignition switch 13 Parking brake 14 Headlamps beam adjustment 15 Main rear view mirrors remote control 16 Gearshift lever 17 Horn 18 Loudspeaker 19 Ashtray 20 Storage compartments 21 Steering wheel positioning lever 22 Clutch pedal 23...

Page 6: ...k into the initial position From inside n item 4 A door unlocked B door locked when the door is locked in that manner it cannot be opened neither from the outside nor from the inside n Pull the lever item 3 to open the door n Turn the handle item 5 to open or to shut the window n Your vehicle is delivered with two keys you should keep one in a safe place outside the vehicle as a spare one n Keys a...

Page 7: ...river s side 2 1 Warning n Remember always to remove the key from the ignition switch before leaving the vehicle n Take care that the tailgate and side door of the box body are loc ked properly It is not allowed to transport the loads which do not allow a safe closing of the door Should the box body be damaged due to the tailgate or side door closed wrong the manu facturer doesnotprovideanyguarant...

Page 8: ...or lights I 8 Group of indicator lights II 9 Group of indicator lights III Turn signals n The left or the right indicator light flashes when you operate the turn sig nal lever n A short interval of flashing indicates a defective bulb in the turn signal light replace it immediately High beam It lights with the high beam on Batteries charging n It lights when the ignition is turned ON and it must go...

Page 9: ...apter Trou bleshooting Brake system malfunction n It lights when the ignition is turned ON to check the function after the air brake system circuit is fully pressured it must go out n If it does not go out after a short while or lights up on the move it is necessary to stop and proceed per Chapter Trou bleshooting ASR n It glows whilst ASR is in operation n Svítí při poruše systému ASR Ne fukčnost...

Page 10: ... safe distance off the road stop the engine and proceed per Chapter Troubleshooting Stop light n It comes on whilst brakes are being ap plied and a bulb of brake lights is defective n Replace the faulty bulb immediately Low beam It lights with the low beam turned on Cabin tilting It lights when the cabin does not rest properly in its rear location correct it immediately Air filter polluted n It li...

Page 11: ...ation of AdBlue on components of the SCR system a certain amount of AdBlue remain in the tank so called unusable amount approx 9 l SCR system malfunction n It lights with the ignition in position ON to check the function it must go out after a short while n It lights when a fault or malfunction in the SCR Selective Catalytic Reduc tion system occurs n If the warning light flashes the fluid AdBlue ...

Page 12: ...ward the steering wheel the high beam indica tor light will come on n Headlights are on until you release the lever 1 Turn signals Turn signals are active when the igniti on is in the position ON Move the lever perpedicularly towards the stee ring wheel axis to switch the turn sig nals on right turn signal lever up left turn signal lever down 2 Side marker lights and low beam Turn the rotary end o...

Page 13: ...ping interval is the shortest in the position F increase it by turning the ring 8 Engine brake Position 0 move the controller away from you and down the engine brake is off Position 1 move the controller toward Warning n For the sake of proper opera tion the engine brake has to be switched on switchedoff at least once a week Its lifetime will be prolonged by this measure n Depress the accelerator ...

Page 14: ...me to overcome the hard driving conditions n The indicator light comes on to indicate the differential lock enga gement Warning Positions 1 and 2 can be engaged whentheairpressureexceeds 0 55 MPa otherwise the engagement cannot be guaranteed Warning Operate the heating for the necessarily required time only We recommend you to switch the differential lock on off once a week at least hereby the ser...

Page 15: ...iddle of the steering wheel 5 Tail fog lamps n The tail fog lamps can be turned on only when the low beam or front fog lamps are on n With regard to a dazzling effect it can be turned on only in fog heavy rain or snow n The bulb in the switch comes on to indicate the function 6 Fog headlights n Fog headlights can be turned on when the side marker lights and low beam and or high beam are on n The b...

Page 16: ...11 adjust increase now the speed is stored and maintained by the engine without applying the accelerator pedal n The speed can be increased by depressing the accelerator pedal after releasing it the cruise control function is resumed however first the cruise control must be activated n All functions will be cancelled by depressing the clutch or brake pedal and or by switching off the button 10 The...

Page 17: ...d by remote control device placed in the holder on the rear wall of the cab in extended cab versions at the driver s seat FN0134_b System switch on indicated by control lamp on the remote control device Memory 1 memory input move to saved position Memory 2 memory input move to saved position Automaticadjustmenttonormal operational driving height Move Upwards Move Downwards STOP the operation raisi...

Page 18: ... indicator lights see Fig of battery charging brake system malfunction parking brake ASR function glowing ABS coolant temperature and reserve fuel amount engine stop engine warning engine maintenance SCR and ECAS system malfunction will come on After several seconds only the indi cator lights of battery charging parking brake and or glowing and the operation fluids levels dependent also the indica...

Page 19: ...rcuit breaker on n Do not switch off the battery circuit breaker or do not discon nect battery clamps to avoid da mage to alternator or some elect ric consumers n START position The engine can be started only when no gear speed is shifted Do not depress the accelerator pedal while starting The position is not arrested When starting repeatedly move the key back to position ACC this prevents to star...

Page 20: ...ing into the cab turn the control knob to the red zone to supply the hot air n Use the control knob item 1 to ad just the fan speed and thus the air volume circulating through the system The airflow speed can be set in four steps n The control knob of the airflow direction item 2 allows you to change the direction of airflow way of cabin heating n Push the button item 4 to turn on off the regime o...

Page 21: ...ther it is ne cessary n item 1 to position II or III n item 2 to position n item 3 if necessary turn on hea ting Ventilation n item 1 to desired position n item 3 to extreme right n item 2 to position or to desired position Optimum heating n item 1 to position II or III n item 3 to desired heating output n item 2 to position Maximum heating n item 1 to position IV n item 3 to extreme left n item 2...

Page 22: ...n Push the button item 5 to switch on off the regime of circulating air in cabin signalled by the bulb in the button n Deflect the fins item 6 at air vents to adjust the airflow in desired angle The air volume is controlled by thumbwhe els item 7 Control elements n Switch on off the air conditioning by means of the switch item 1 signal led by the bulb in the switch n The air conditioning does not ...

Page 23: ...ptimum cooling n item 1 to desired position position II or III are optimum n item 3 to extreme right turn it slightly to left to adjust thetemperature if needed n item 2 move it to position n Push the button with symbol the bulb comes on in the switch n The outside air is being sucked up and cooled in that regime Maximum cooling n Close all windows n item 1 to position IV n item 3 to extreme right...

Page 24: ...heel at its top point with hands slightly bent n A quick and safe handling the con trols required for the drive must be secured n Keeping your body at ease for the maximum protection offered by seat belts must be obtained FN0210 Seatback adjustment a Lift the control lever item 1 with your bodyweight taken on the seatback to tilt the seatback to the rear To adjust the seatback to the front lift th...

Page 25: ...re height adjustable n To adjust the head restraint vertically push the stop toward the rear cab wall n Adjust the head restraint so that its position is adapted to fit the seating height of occupant Head restraints Sleep couch On vehicle versions with a long cab there is an emergency couch with a storage compartment in the rear part of the cab The storage compartment is acces sible after unlockin...

Page 26: ...eat belts and retractors on two side seats n The middle seat has got the two point seat belt and mechanical adjusting equipment n Seat belts offer a protection for passengers in case of an accident n Seat belts have to bebuckled whenever youdrivethevehicle even in urban driving ...

Page 27: ...a ged it is necessary to have it replaced Warning Use of seat belts n The respective warning light reminds you of necessity of the use of seat belts n Grasp the belt holding it at tongue and slowly fit it across the chest and pelvis n The belt must fit snugly to the centre of arm and to your pelvis n If the belt locks when being pulled out release it let it rewind and after that pull it out again ...

Page 28: ...ing n Forreasonsofsafetythemirrors mustbeadjustedpriorto moveoff n Pay extreme attention when consideringthe sizeanddistances of cars and other objects when seen in a convex mirror Always remember that they will look smaller and appear farther away than in reality A B FN0240a n Turn the controller to select adjust ment of the left or right mirror to left left mirror position A to right right mirro...

Page 29: ...d vehicle the control thumbwheel mark is against zero n Payloads for the respective vehicle version are mentioned in table Weights and axle loads 2 3 1 FN0260 n Bulbs of the dome light are turned on off by switches situated in the light directly n Use the switch item 1 and item 2 to turn on off the light on the driver s side n Use the switch item 3 to turn on off the light on the co driver s side ...

Page 30: ...sors to protect you against sun glare A B FN0015a FN0280b n The socket item A can be used for cigarette lighteronly The socket item B can be used for 12 V appliances n Push the knob in to switch on the ciga rettelighter Whenthespiralisreadyforuse itwillspringback Pulloutthelighteranduse it immediately the heating spiral will loose the thermalenergysoon Warning n It is forbiddent to use the ciga re...

Page 31: ...lease n After use slide it back Warning n Do not use the cup holder ifthe vehicle is in motion n Do not use the cup holder to hold other objects FN0300 FN0310a n Pull it to open it n To clean it remove the sheet insert Never put paper and other flammable objects in the ashtray danger of fire Warning FN0320 ...

Page 32: ...to left n Raise the bonnet n Take strut out of holder item A and insert the strut end in hole item B to secure the lifted bonnet Closing the bonnet n Raise the bonnet slightly n Unhook strut from hole and put it in holder item A n Tilt the bonnet in the vertical position and push its lower edge until it clicks into lock item 2 n When the bonnet snaps in you can hear it Bonnet 2 1 B A ...

Page 33: ...ls whichisnotstoredproperly maycauseapersonalinjuryor disturb youbyvibrationsduringdriving n Thejackdeliveredwiththevehicle is determined to be used with this vehicle model only It must not be used to lift other vehicles or other loads n Tools and equipment must be attached properly on the move or during the cabintilting Wrench 30 x 30 Lever adaptor item1 Box with bulbs First aid kit Warning trian...

Page 34: ...llowable for entering beneath the cabin n Let the distributor lever be in vertical position with the cabin lifted 3 1 3 FN0395 2 Instructions for cabin tilting Warning n Prior to tilt the cabin shut the engine off and shift into neutral n Set the vehicle parking brake n Secure the objects which are placed inside the cabin and shut the doors properly n Prior to start tilting we recom mend to open t...

Page 35: ...er strokes Cabin lowering n Move the distributor into position n Continue to pump until the locks click in place and until you feel an increased resistance on the lever n Move the distributor into position n Go on pumping by about 15 strokes to adjust the position of the cabin pin into a centre of the oval hole in the cylinder eye n Move the distributor into position O FN0391 Cabin tilting at spec...

Page 36: ...4 Front coupling for towing 5 Washer tank 6 Clutch tank 7 Expansion tank 8 Fuel tank filler neck 9 Fuel tank drain plug 10 Air filter 11 Power steering tank 12 Spare wheel four positions vehicle version dependent 9 10 11 12 21 FN0404 22 8 23 24 6 5 4 3 7 1 2 FN0345 13 ...

Page 37: ...r pressure regulator c w air drier 17 Drain valve 2x 18 Regenerating air reservoir 4 5 l 19 Brake pressure regulator 20 Battery case c w circuit breaker 21 Wheel chock 22 Fuel filter 23 AdBlue fluid tank filler neck 24 Air intake filter into the SCR unit 17 11 FN0422cu 19 18 16 FN0431a ...

Page 38: ... of proper operationtheenginebrake has to be switched on switchedoff atleastonce a week Its lifetime will be prolongedbythismeasure n The differ lock should beengaged diseng once a week atleast Its service life will be increased Warning n engine lubricating oil level check top up n urea AdBlue level check top up n drive belts belts tensioner check correct n fuel check top up n fuel water separator...

Page 39: ...tarting the engine do not move off n The vehicle must not be put in motioninanywayunlessthebatte ry circuit breaker is on and the ignitionkeyisinsertedintoignition switchandturnedinposition ON The steering is unlocked in this position Before you move off check whether thesteering wheel is free to turn n Do not run the cold engine at high speed it could be damaged n Should the indicator and war nin...

Page 40: ...press the accelerator pedal gra dually n Depress the clutch pedal as far as it goes n Shift to gears smoothly not to stress the engine extremely Before engaging the reverse run put the vehicle to a full stop not to cause damage to gearbox n Before shifting to reverse gear at the gearbox model ZF 6 S 850 it is neces sary to wait 3 to 5 seconds after depres sing the clutch pedal to allow stopping of...

Page 41: ...at idle or at speed to 1 000 rpm withoutload for more than 10 minutes When the engine is running for a long time in these regimes the tempe rature of the combustion space willdrop sothat the fuel cannot be burned completely This may re sult in creation of carbon in the surrounding of holes of injection nozzlesandpistonringswhatmay lead to damage the engine In ad dition low temperatures will cau se...

Page 42: ...ST RU CTIONS 42 Engine FN0482a 7 2 9 4 6 3 10 1 Alternator 2 Oil filter 3 Engine starter 4 Fuel filter 5 Engine control unit 6 Fan c w visco coupling 7 Tension roler 8 Water pump 9 Oil filler neck 10 Compressor 1 5 8 ...

Page 43: ...utput 117 kW 2 500 rpm Cummins ISB4 185 Diesel engine four cylinder 16 valves max power output 136 kW 2 500 rpm n The belt is tensioned automatically by the pulley item A which cares of the constant tension n When the belt has been damaged it must be replaced immediately Belt tensioning A FN04821a ...

Page 44: ... Pull dipstick out again The oil level is correct when it is between marks on the dipstick It must not be above the MAX mark because the engine could be damaged n Add the oil in time not to allow the oil level to drop below the MIN mark Lubrication system Engine oil Recommended specification oil viscosity grade A C E A S A E E5 10 W 40 or E7 5 W 40 Warning n The manufacturer is not responsible for...

Page 45: ... in the mechanical dirt for example during operation without installed coarse air filter n Before stopping the engine from a full load operation allow it to run at idle for one minute at least see the label on the instrument board to secure the cooling down of turbocharger by oil and thus to avoid burning in of carbon on the turbocharger shaft U FN0441 n If the turbocharger is defective have it re...

Page 46: ... is not permitted n It is not allowed to add petrol into Diesel fuel n Your Diesel engine has been spe cifically designed to operate on Diesel fuel per ČSN EN 590 656506 Prefer using the Diesel fuel with a low sulphur content 0 05 hm which is available on the market n In the winter months from Novem ber 1 to March 31 you should use the Diesel fuel whose filtering ability CFPP specification meets t...

Page 47: ...pacity item 1 is 23 l total capacity 30 l In the tank the fluid level measuring device is installed The shortage of fluid is indicated by the indicator light on the isntrument board n When the AdBlue fluid level drops below 3 l of the usable capacity the warning lamp engine warning co mes on and when the AdBlue fluid level of the usable capacity drops below 10 l the warning lamp SCR system mal fun...

Page 48: ... summer season comes and anytime when the face body area has been polluted clean the radiator with compressed air or stream of hot water from the engine side Check the expansion tank cap n Havethecoolant changedatthe authorized service station n Do not open the cap of coolant reservoir when the engine is hot danger of scalding n Never run the engine with the thermostat removed n The expansion rese...

Page 49: ...ave a great influence upon the service life of turbocharger Warning n Have the air filter cartridge re placed at the authorized service station n When the vehicle is operated in very dusty conditions reduce the replacement intervals accordin gly Air filter Steering FN0550 Checking and adding the steering oil n Check the oil level regularly n The oil level in the tank must reach the LIVELLO OLIO ma...

Page 50: ...op immediately and check the oil level in the tank of monoblock hydraulic power steering and check the hydraulic circuit for condition Gearbox n Have the oil changed at the authorized service station n When the vehicle is towed with engine at standstill and no gear shifted disconnect the propeller shaft at the rear axle to avoid damage to gearbox due to insufficientlubrication n Do not start the e...

Page 51: ...ding the fluid n Check the fluid level in circuit regularly n The fluid level must be between MIN and MAX marks If it drops below MIN mark add the fluid of the specification DOT3 DOT4 DOT4 or SAE J 1703 Warning n Have the fluid changed at the authorized service station n Keep the environment clean when handling the fluid n When air leaks from the air sys tem for example during a long termvehiclest...

Page 52: ...out leakage have it repaired at the authorized service station FN0610n Warning Have the oil changed at the authorized service station Warning Entrust some authorized service station to carry out all repairs refills or adjustments n If you notice that tyre treads wear unevenly on the front axle check and or have the front axle geometry adjusted at the authorized service station n The life of shock ...

Page 53: ...re regulator 11 Combined brake cylinder 12 Manual brake valve of parking brake 13 Switch of minimum air pressure of spring loaded cylinder 14 Front axle brake system 15 Rear axle brake system 16 Air reservoir of parking brake circuit 17 Valve relay 18 Trailer brake valve 19 ASR valve 20 Minimum air pressure sensor in circuits of service brake 21 Membrane brake cylinder Brake system 15 14 2 3 5 6 7...

Page 54: ...is dual circuit controlled pneumatically n Vehicles are standard equipped with ABS the ASR is installed as option n The first circuit of the master brake valve controls the rear brake system n The second circuit of the master brake valve controls the front brake system n The automatic brake pressure regulator controls the braking force of rear axle wheels in dependence on the vehicle load Correct ...

Page 55: ...djustments must be carried out at the authorized service station Du ring operation check visually the con nection of regulator lever with axle a free travel of the regulator lever and instrument tightness n The vehicle operator only gives the adjusting values of the brake pressure regulator according to vehicle version in case that real values do not respond to ones given on the label in the cabin...

Page 56: ...s 2 mm n The minimum total thickness of the brake pad is 9 mm n Replace the pads with ones of the approved type only 2mm Brake system inspections n To assure a correct function of the brake system it is necessary to check it for a good condition at regular terms n Daily drain the air reservoirs n Once a month clean the air reservoirs from outside and check whether they have not corroded and if att...

Page 57: ...orcomes on during driving the system is defe ctive and the vehicle is braked wi thout ABS Only the normal brake system is operative on vehicle Proceed to your nearest authori zed service station in that case n The enhanced safety which is offered bythe ABS must not tempt you to undergo any risking n All repairs and interventions in ABS may be performed by the au thorized service station only Warni...

Page 58: ...k a good function of the brake system so that you are watching air gaugesandwarninglampsofthebrake system n Check a good function of bulbs of the brake system indicator lights by turning the ignition key from ACC to ON position when the indicator lights must come on n After full operating air pressure in the system is reached the warning lamps must go out n After the indicator lights have gone out...

Page 59: ...king position before the parking position is achieved you have to overcome a point of pressure resistance and then the lever is automatically secured in the parking position n Checkposition it applies to some vehicle versions only This position is designed to check if the parking brake system of the towing vehicle is capable to brake up the vehicle combination in a certain gradient in a safe manne...

Page 60: ...gent to add thefluid In winter keep the stipulated ratio not to allow the fluid will freeze up follow instructions mentioned on the antifreeze package Warning n Do not use wipers to wipe dry glass they may scratch it n Do not use wipers when there is a layer of snow on the windshield clean the glass first n In the winter months make surefirstwhetherthewipershave not frozen up to the glass FN0720 F...

Page 61: ...ls geometry n The depth of tread grooves of tyres must be 1 6 mm at least If tyres treads are marked REGROOVABLE the tre ads can be cut through to make them deeper only a specialist may perform it n Only balanced tyres may be mounted on front wheels and all wheels must be in a good technical condition n Only tyres stated for the given type of the vehicle and recommended by the tyre manufacturer ma...

Page 62: ...es trailer trailer with fixed towbar it is necessary to consider for calculateing the total load of the towing vehicle a vertical statica load coming from the trailer developing load strain onto the coupling point up to 10 of the total trailer weight max 1000kg This addi tional load surcharges the rear axle and simultaneously discharges the front axle of the towing vehicle OK OK OK OK FN0721a Warn...

Page 63: ...r saving two different heights To reach the height desired push the button STOP and simultaneously push button or Desired height is saved in the selected Memory Then in case you operate the button or the height saved in the selected memory is automatically adjustedi Dif ferent height can be adjusted in the same way FN0134_b n Button utilisation By pushing the button the opera tion raising lowering...

Page 64: ...operational air pressure must be in the system Water condensate must be drained by swing ing the handling levers of draining valves placed at the bottom part of air tanks FN0655 n In winter season and humid weather the draining has to be done several times a day n If the draining is not done regu larly as a consequence the vehi cle safety can be compromised and instrumentscanbe damaged for such ca...

Page 65: ...ds and plug connectors of electric con ductors n Check the brake system and lights for a correct function n Proceed very carefully when towing a trailer and do not exceed the allo wable load limits n When stopping during uphill or down hill driving check the manual brake for a good efficiency It must hold the whole vehicle combination in a gradient on the spot Basic rules for the trailer coupling ...

Page 66: ...OPE RAT IN G INST RU CTIONS 66 ...

Page 67: ...tarter alternator glowing regulator and battery case against water to avoid short circuit n For reasons of safety during vehicle standstill when parking in garage etc when leaving the vehicle or when you find out any fault in the electrical equip ment switch the battery off n When the fire could occur use the battery circuit breaker to disconnect the electrical equipment n Whenthe engine is not ru...

Page 68: ... G INST RU CTIONS 68 Location of battery d r i v i n g d i r e c t i o n 1 Plastic cover 2 Holder clip 3 Rubber holder 4 Profiled battery holder 5 Battery holder screw 6 Central ground point 1 2 6 3 5 4 FN0731cu ...

Page 69: ...ed battery must be disposed of with regard to environmental regulations Warning Battery circuit breaker Alternator With the engine running the alternator terminals must not be disconnected and the battery circuit breaker must not be switched off the alternator must not run without load Warning Battery Acircuit breaker on Bcircuit breaker off Warning n Turnoffthebatterymasterswitch only30secondsaft...

Page 70: ...3 Front fog lamps 4 Turn signals 5 Stop lights 6 Rear side marker lights 7 Reverse lights 8 Tail fog lamps 9 License plate light 10 Side positioning lamps 11 Side turn signals If thevehicle is fitted with a superstructure 2 550mmwide mountthesidemarkerlamps of the superstructure manufacturer 10 2 10 5 4 6 9 7 8 11 FN0750 ...

Page 71: ...nd procedures see instruc tions mentioned on cleaning agents When not observing these instructi ons hard removable spots may stay on interior materials after cleaning Plastic parts n Use wet rag to clean the plastic parts n After arough cleaning by wet rag you can apply the agents recommended Seat belts Clean them with a soap water solution Warning In case that the vehicle is fitted with a superst...

Page 72: ...aterials after cleaning Washing the vehicle n The best way how to maintain the paint in a good condition is to wash it very often n Use the lukewarm or cold water to wash the vehicle n Do not use hot water or do not wash the vehicle in direct sunlight n First use plenty of water to wash off the dirt thoroughly n After washing off the dirt use a soft sponge to clean the body from the roof down usin...

Page 73: ...from battery to engine Check the cables connection of starter and or tighten F Fault Faulty neutral switch Remedy Contact and have it repaired at the auth serv station G Fault Faulty starter Remedy Contact and have it repaired at an authorized service station 2 Starter cranks the engine but the engine cannot be started A Fault No fuel in tank Remedy Fill the fuel and bleed the fuel system 3 Engine...

Page 74: ...ized service station B Fault Faultyturbocharger Remedy Contact and have it repaired at an authorized service station 7 Engine overheats A Fault Insufficient coolant level Remedy Check the cooling circuit for leaks repair the fault and add the fluid B Fault Insufficient function of cooler Remedy Clean the cooler surface C Fault Faultythermostat Remedy Contact and have it repaired at an authorized s...

Page 75: ...nk If the indicator light still remains ON you can continue to operate the vehicle but when you reach ther nearest service station have the fault repaired this situation is not considered to be a state of emergency Engine 10 Indicator light engine warning flashes Fault If the indicator light flashes for about 30 seconds when the ignition is in the position ON It reminds you of carrying our the nec...

Page 76: ... the next Diesel refuelling 13 Diagnostic test Fault The indicator lights engine stop engine warning are ON the fault code The fault code blinking repeats itself continuously It is neces sary to put down the fault code number To detect other faults it is necessary to push the cruise control switch item 3 marked and the procedure of fault code blinking will begin to repeat itself either the same fa...

Page 77: ...se 1 2 s the orange light come on again end of fault code lighting fault code 115 it comes on Electrical equipment 1 The battery charging indicator light is on A Fault Fault in the charging circuit Remedy First check whether all cables of alternator accumulator batteries and battery circuit breaker are tightened thoroughly and or connected to respective terminals Check also whether connections inc...

Page 78: ...sary to visit the authorized service station Adapt the driving to the situation 5 The ASR indicator light is on Remedy The equipment is not OK the ASR system is not working It is necessary to visit the authorized service station Note When theASR systemisout offunction thecommon vehicle operation is not influenced 6 Warning lamp is flashing Air suspension system failure red warning lamp Repair The ...

Page 79: ...have the vehicle towed to the nearest repair shop 4 The ABS indicator light is on Remedy The equipment is not OK the vehicle is braked without ABS function Only the normal brake system is functioning on the vehicle In that case it is promptly necessary to visit the authorized service station Adapt the driving to the situation 5 The ASR indicator light is on Remedy The equipment is not OK the ASR s...

Page 80: ...e propeller shaft to the vehi cle frame in a suitable manner n After the vehicle towing and repair have been accomplished remount the propeller shaft to the axle final drive housing flange again tighten the self locking nuts to Mk 60 10 Nm n Use the pin to attach the towing bar in the middle part of the front bumper n When towing the vehicle with the engine at standstill and no gear speed shifted ...

Page 81: ...es of front holder brackets Fig D n Swing the wheel into the horizontal position towards you so that it rests on the contact surface of the rear bracket and simultaneously on contact surfa ces of front brackets ahead of stop lugs n Tighten the thrust plate from below by two nuts and secure with the wire clip at one of two bolts Removal of spare wheel n Dismount the spring split pin and two nuts to...

Page 82: ...r on ground n Dismount four bolts c w nuts 5 and remove the wheel from hanger Wheel chock K N 5 Warning Proceed with extreme care with regard to the wheel weight FN0820 FN0801 4 Installation of spare wheel n During installation first attach the spare wheel by four bolts c w nuts to the hanger use the winch to attract the hanger c w spare wheel to the frame and secure the hanger with bolt 1 c w nut...

Page 83: ...83 TRO UBLES HOOT ING ...

Page 84: ...the leaf spring shackle n Raise the wheel by several centimet res above the ground by moving the lever with the valve closed n Unscrew the wheel nuts remove the wheel and fit the spare wheel in place n The contact surfaces of disc and wheel hub must be clean n Tighten the wheel nuts partially and evenly FN0840n Front axle Rear axle Warning The jack must stand firmly on the firm subgrade Warning Wi...

Page 85: ...d on the bulb n Do not touch the halogen bulb glass with bare fingers it would loose its efficiency after switching on Main headlamp n Tilt the cabin to replace the bulb n Slightly turn the cover plastic lid of the headlamp counterclockwise and remove Warning n Onlythe authorized servicesta tion may adjust the main head lamps n A new bulb must correspond to the specified bulb by its type and outpu...

Page 86: ...nner FN0880 Front part H4 24 V 70 75 W 2 headlamp low and high beam 24 V 5 W 2 side marker light Low and high beam n Unplug the connector item 1 from the bulb n Unhook and fold the flexible wire holder item 2 n Remove the faulty bulb and fit a new bulb lugs item 3 on the bulb base must engage into recesses of the headlamp n Installation is reverse of removal 3 FN0860 1 2 ...

Page 87: ...t of the light housing n Push the faulty bulb into socket twist counterclockwise and remove n Fit a new bulb push it and turn clock wise n Install the bulb socket into a light housing and turn clockwise as far as it goes Front auxiliary side positioning lights n Use a screwdriver to remove cover from the light housing n Push the faulty bulb into socket twist counterclockwise and remove n Fit a new...

Page 88: ...em 3 by pulling it out n Unhook and fold the flexible wire holder item 4 n Remove the defective bulb and insert a new one slots on the bulb socket must engage into lugs in the fog lamp housing n To reinstall reverse the above procedure do not forget to bend the ground connector back into the initial position n The designation TOP must be directed up n Have the headlamps adjusted at the authorized ...

Page 89: ... turn clockwise n Install and screw the cover Tighten the cover carefully as this may crack Rear cluster lamps n Unscrew the lamp cover n Push the defective bulb into socket twist counterclockwise and remove License plate light n Unscrew the lamp cover n Push the defective bulb into socket twist counterclockwise and remove n Fit a new bulb push it and turn clockwise n Install and screw the cover T...

Page 90: ...side positioning lights Side positioning lights n Unscrew the light cover n Push the defective bulb into socket twist counterclockwise and remove n Fit a new bulb push it and turn clockwise n Install and screw the cover Tighten the cover carefully as this may crack FN0930 Dome light n Use a small screwdriver to pull cover out of the light housing you can see two slots to insert the screwdriver in ...

Page 91: ...ion lamps RH outl lamps instrument cluster illumination F20 10A RH pos lamps LH outl lamps switches illumination F21 10A LH low beam F22 10A RH low beam RH headlamp level motor F23 10A LH high beam F24 10A RH high beam F25 10A LH front fog lamp F26 10A RH front fog lamp F27 10A rear fog lamp F28 10A engine starter F29 10A fuel heating F30 10A air heating F31 30A engine control unit F32 20A SCR dos...

Page 92: ...R20 heated mirror timer R21 relay start R22 relay starter lockout R23 ground relay R24 heated fuel relay R26 trailer indicators Replacing a fuse n The fuse box is situated under the glove box in the instrument board n Fuses are accessible after removal of the glove box bottom which wil be released by turning two rotary holders sense of turning is illustrated on the cover n The individual electric ...

Page 93: ...rted only by connecting it to the battery of some other vehicle with the same nominal voltage n Only approved jumper cables of sufficient cross section may be used n Do not use cables with insulated clamps only Warning Thebatteryoftheothervehiclemust have the nominal voltage of 24V n When starting the engine of the vehicle whose battery is used to start must run Connecting procedure 1 Connect one ...

Page 94: ...e engine in accordance with Chapter Starting the engine n After the engine starts to run remove jumper cables in reverse order n When using the jumper cables to start the vehicle the auto radio must be turned off because this may be damaged n Non insulated parts of cable clamps mustnot toucheach other Thejumper cable connected tothe positiveterminalofthebatterymust notcome in contact with the vehi...

Page 95: ...ion CUMMINS ISBe4 160 ISBe4 185 Number of cylinders valves 4 16 4 16 Cylinders bore 104 mm 104 mm Pistons stroke 132 mm 132 mm Displacement 4 500 cm3 4 500 cm3 Compression ratio 17 3 17 3 Maximum output 117 kW 2 500 rpm 136 kW 2 500 rpm Maximum torque 602 Nm 1 200 1 600 rpm 700 Nm 1 200 1 600 rpm Injection system CommonRail Bosch CommonRail Bosch electronic control unit electronic control unit ...

Page 96: ...pension n fluid shock absorbers with lower stop n rubber upper stop for the version with pneumatic suspension in the bel Engine cooling system n fluid n overpressure type with the forced coolant circulation by means of the centrifugal pump n cooling circuit is fitted with two flap thermostat and expansion tank Air filter dry filter cartridge Clutch n dry n one disc n with asbestos free lining n wi...

Page 97: ...brake valve situated near to driver behind the gear shift lever n the air pressure drop in the chamber of spring loaded cylinders to the value at which the spring loaded brake is activated is indicated to a driver by the respective indicator light Service brake system n dual circuit n pneumatic n with brake pressure control of the rear axle wheels adjusted values of the load sensing valve are stat...

Page 98: ...120 Axle base mm K 2950 1415 5590 2280 1849 1845 1736 1740 N 3400 1415 1365 6040 5990 2730 L 3900 1670 1620 6795 6745 3230 E 4500 2070 2020 7795 7745 3830 S 5100 2470 2420 8795 8745 4430 G 5600 2520 9345 4930 The tolerance 1 holds for the dimensions if not stated otherwise wheelbase K only for versions D60 D90 wheelbase G only for versions D110 D120 ...

Page 99: ...2270 D85 90 2110 2150 2190 2230 2270 D100 2160 2200 2240 2280 D110 120 2230 2270 2310 2350 2390 Portion of the chassis c w cab service weight to rear axle D60 75 1160 1170 1180 1190 1200 D80 1160 1160 1170 1180 1190 D85 90 1210 1220 1230 1240 1240 D100 1230 1240 1250 1250 D110 120 1280 1290 1300 1310 1330 Carrying capacity of chassis cabin c w crew D60 75 2740 4240 2690 4190 2640 4140 2590 4090 25...

Page 100: ...eight1 D60 5990 D65 6490 D70 6990 D75 7490 D80 7990 D85 8490 D90 9000 D100 9990 D110 10990 D120 11990 The maximum allowable front axle load D60 90 3400 D100 3500 D110 4000 D120 4200 The maximum allowable rear axle load D60 4100 D65 4450 D70 4800 D75 80 5200 D85 5800 D90 6200 D100 6600 D110 7400 D120 8200 The table is continued on the next page ...

Page 101: ...6 0 8 0 D 8 5 9 0 D 1 0 0 D 1 1 0 1 2 0 1 0 0 0 0 2 M a x im u m p e r m it te d w e ig h t o f c e n t r a l a x le t ra il e r w i th t ra il e r c o u p l in g fi x e d a t fr a m e r e a r e n d c r o s s m e m b e r D 6 0 8 0 D 8 5 9 0 D 1 0 0 D 1 1 0 1 2 0 6 5 0 0 M a x a l lo w a b l e v e h i c l e c o m b i n a ti o n t ru c k tr a il e r w e i g h t D 6 0 8 0 D 8 5 9 0 D 1 0 0 D 1 1 0 1 ...

Page 102: ... a re w h e e l ty p e v e rs io n K N L E S G D 1 1 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 8 0 0 2 4 5 7 0 R 1 7 5 fr o n t r e a r s p a re w h e e l ty p e v e rs io n K N L E S G D 1 2 0 7 5 0 8 0 0 8 0 0 7 5 0 8 0 0 8 0 0 7 5 0 8 0 0 8 0 0 7 5 0 8 0 0 8 0 0 7 5 0 8 0 0 8 0 0 2 6 5 7 0 R 1 7 5 fr o n t r e a r s p a re w h e e l ty p e v e rs io n...

Page 103: ... 3 73 I 4 10 I 4 56 I 3 73 I 4 10 I 4 56 Disc dimension 17 5 19 5 17 5 19 5 Max theoretical speed km h 121 110 99 131 119 107 121 110 99 131 119 107 D60 75 56 9 64 9 76 3 71 3 83 1 101 5 D80 52 2 59 2 69 1 64 7 74 8 89 5 D85 90 44 9 50 5 58 2 54 9 62 5 73 2 D100 39 5 44 3 50 7 48 0 54 2 62 7 Max theoretical climbing ability D110 120 32 0 35 7 40 4 32 7 37 0 38 4 43 0 49 1 35 2 39 3 44 7 ...

Page 104: ... 200 l Minimum fuel reserve 16 l AdBlue tank capacity 30 l usable capacity is 23 l Rear axle 5 14 differential 4 l wheel body 0 25 l Rear axle 8 20 differential 8 l wheel body 0 25 l Monoblock power steering 1 7 l Windshield washer tank 7 5 l Hydraulic circuit for clutch release 0 5 l Hydraulic circuit for cabin tilting 0 65 l Operation fillings ...

Page 105: ... o d u c t io n m a n u f a c t u r i n g p l a n t VIN Vehicle Identification Number n The vehicle is marked with the VIN number in accordance with the unified international vehicle marking n The VIN number is stamped on the web of the right frame longitudinal beam ahead of the shock absorber holder of the front axle The manufacturer s plate VIN is situa ted also on the right door jamb above the ...

Page 106: ...ressures G n warning batteries circuit breaker H On the cabin right side in the rear information about cabin tilting I On the right door jamb above the door lock n homologation A n homologation B n automatic brake pressure control C n VIN D n headlamps adjustment E n cabin F FN1053 FN1040m FN1030m ...

Page 107: ...51 Combined lever switch 12 Controllers 14 Cooling system 48 Cruise control 16 Cup holder 31 D Diagnostic socket 17 Digital clock 30 Doors 6 Draining the fuel filter 46 Draining the condensate from air tanks 55 64 During driving 40 E Electronic vehicle height adjustment ECAS 63 Electrical equipment 67 Electrically actuated windows 7 Engine 42 Engine brake 13 F Fuel 46 Fuel tank 46 Fuse box 91 G Ge...

Page 108: ...e 96 Weights and axle load 99 Tools and equipment 33 Towing vehicle recovery 80 Transport of loads 62 Troubleshooting Brakes 78 Electrical equipments 77 Engine 73 Monoblock hydraulic power steering 78 Turbocharger 45 Tyres and wheels 61 U Use of jumper cables to start the engine 93 Avia Ashok Leyland Motor s r o Beranových140 199 03 Praha Letňany Version 5b Aj 3 2008 D60 65 70 75 80 85 90 100 110 ...

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