Professional Documents
Culture Documents
Operator Manual
Operator Manual
HANDBOOK
Euro 3
GB
The company ASTRA VEICOLI INDUSTRIALI reserves the right to make any modifications to vehicles for technical or commercial rea-
sons at any time; the information, descriptions and illustrations contained in this publication are therefore correct at the time going to
press.
This Use and Maintenance Handbook deals with optional equipment which cannot be present on your vehicle, and alternative equipment
as well (e.g. mechanical and automatic gearbox).
Moreover, the regulations in force in certain countries affect the standard equipment of the vehicle.
This publication could therefore contain information and illustrations not corresponding to the vehicle version provided on a particular mar-
ket.
Reproduction, whether total or partial, of the text and illustrations is strictly forbidden.
HD9 Euro3 I
INTRODUCTION
This Use and Maintenance Handbook is divided into 4 parts, each of which systematically
subdivided according to subject, for quick and easy consulting.
1) Technical specifications: this contains all the characteristic data which should be read
through at least once to acquire a working knowledge of the vehicle.
2) Use of the vehicle and practical hints: this contains information relevant to the main con-
trols and instruments, and the main rules to be followed especially for new vehicles.
3) Maintenance instructions: this section contains the functional instructions for checking
and maintaining the vehicle which must be implemented to ensure satisfying operation,
cost-effective running and long life of the vehicle.
4) Tables and diagrams: contains vehicle scheduled maintenance tables and diagrams.
In this Use and Maintenance Handbook there are texts that are highlighted in a particular
manner:
Failure to heed and/or correctly carry out
procedures, technical information and
precautions given may cause injury.
WARNING
Failure to heed and/or correctly carry out
Standards for use of the AsTronic2 V35 version procedures, technical information and
(recognisable by the pushbutton selector on precautions given may cause damage to
the dashboard in lieu of the selection lever) are the vehicle.
stated in the APPENDIX of this volume.
Procedures, technical information and
precautions which must be highlighted.
After-sales service
For any type of servicing the ASTRA V.I. Dealership is at the complete disposal of the Cus-
tomer. Equipment and skilled staff are available for maintenance or repair jobs. The ASTRA
V.I. Dealership is always willing to offer you hints and advice to ensure you get best perform-
ance from your vehicle.
Spare parts
Any spare parts used for replacements are to be “GENUINE ASTRA SPARES” which can be
obtained from the dealer warehouses and authorised workshops. Remember that a correct
order for spare parts must always include the following details:
– type of vehicle;
– chassis number;
– reference and category numbers, to be found in the Spare Parts Catalogue.
If the items are parts of a main group (engine, cab, axles, power steering, gearbox etc.) indi-
cate also the group version and serial number.
HD9 Euro3 XIII
WARNING
Assembly of accessories, additions and modifications on the vehicle are to be carried out in
conformity with ASTRA directives. The specific document “Directive for conversion and out-
fittings” can be obtained as a guideline from the After Sales Service workshops.
It is reminded that, especially regarding the electrical system. there are several electrical
sockets available (standard or optionals) to simplify electrical operations carried out by the
outfitters.
For any exemption from the directives for the conversion it is necessary to have authorisation
from ASTRA.
It is strictly forbidden to make modifications or connections to the wiring of electronic control
units. In particular the interconnection lines between control units (CAN lines) are never to
be interfered with.
Diagnostics and maintenance operations are to be carried out by skilled personnel using
approved diagnostics equipment.
Ignoring these afore-mentioned prescriptions will annul the contractual warranty .
XIV HD9 Euro3
Technical data
1 2 HD9 Euro3
342BNU001L 356ADT101L
1 ENGINE
Torque converter
ZF WSK 400
ZF WSK 440
HD9ST0044L Hydrodynamic torque converter with freewheel distributor.
Converter exclusion clutch (lock ---up clutch) with automatic engagement.
Gear shift
ZF ECOSPLIT3 16 S 251 OD
Synchronized mechanism with 8 forward gears, divided into a low range group (1÷ 4) and
a high range group (5 ÷ 8), and 1 reverse gear, normal and reduced.
Pneumatic interlocking device to engage gears (servoshift).
Neutral switch to prevent the engine from starting in gear.
Hydrodynamic retarder integrated into the converter
Ratios
Normal Low
1a 13.80 11,55
2a 9.59 8,02
3a 6,81 5,70
4a 4.58 3,84
5a 3.01 2,52
6a 2.09 1,75
7a 1.49 1.24
8a 1.00 0,84
R.G. 13,17 11,03
R.G. = Reverse Gear
HD9 Euro3 1 9
1 AUTOMATIC TRANSMISSION
ALLISON HD 4700
Epicyclical automatic, 7 forward plus reverse.
Hydrodynamic torque converter with free wheeldistributor .
Automatic engage converter lock-up clutch.
Ratios
1st 1:7.63
306ADT001L
2nd 1:3.51
3rd 1:1.91
4th 1:1.43
5th 1:1.00
6th 1:0.74
7th 1:0.64
R.G. 1:4.80
R.G. = Reverse Gear
HD9 Euro3 111
1 TRANSFER DISTRIBUTOR
REAR AXLE
1
Single rear drive axle (Fig. 1)
With double reduction, central by pinion set
and final in wheel hubs with epycicloid gear.
Differential between wheels with pneumatic
lock.
1 DRUM BRAKES
Simplex (Fig. 1)
Wedge ---shaped type with simple effect braking parts.
The adjustment of the brakes is automatic, therefore no intervention is necessary before
the total wear of the brake linings.
Duplex (Fig. 2)
Wedge ---shaped type with dual effect braking parts.
The adjustment of the brakes is automatic, therefore no intervention is necessary before
the total wear of the brake linings.
Systems
2 Service brake: pneumatically operated in two independent sections for non ---towing vehi-
cles, and in three independent sections for towing vehicles.
Parking and emergency brake : pneumatically operated and acts on the rear wheel drums,
through the use of a spring cylinder.
Supplementary parking brake (optional): pneumatically operated: must be engaged with
the engine running.
ABS
Anti ---lock braking system (ABS) with a four channel electronic control unit and four sole-
noid valves that apply the ABS function during braking.
Phonic wheels and sensors on 1st and 2nd axle (2---axle vehicles)
Phonic wheels and sensors on 1st and 3rd axle (3---axle vehicles)
Phonic wheels and sensors on 2nd and 4th axle (4---axle vehicles)
HD9 Euro3 1 15
TYRES
Front: single (*)
Rear: double (**) or single (*)
1 SUSPENSION
Front (Fig. 1):
Longitudinal single leaf springs. Telescopic
duplex hydraulic shock absorbers and roll
bar.
Rear:
2-axle vehicles (Fig. 2):
Longitudinal double leaf springs.
Telescopic duplex hydraulic shock
absorbers and roll bar.
2 3 and 4 axle vehicles (Fig. 3):
Single leaf springs, individual for the two
rocking axles with rocker system.
The torque bars between axle and central
support counteract the axial thrust on accel-
eration and braking.
Anti-roll bar on intermediate axle and on rear
axle (upon request).
345CDT001L
Leaf spring: parabolic or semi-elliptic (upon
request).
Leaf springs: parabolic (standard)
semi ---elliptic (optional).
3
345FDT007L
118 HD9 Euro3
1 STEERING
Vehicles without auxiliary cylinder
Type: 8098 (Fig. 1)
Oil pump driven by engine.
Emergency pump controlled by trans-
mission (if present).
Front wheel steering with quadrilateral kin-
etic motion assembly.
1 ELECTRICAL SYSTEM
Nominal voltage: 24 V
Accumulators (Fig. 1) (n˚ 2):
12 V --- 170 Ah or
12 V --- 220 Ah
Alternator: 28 V --- 90 A
Starter motor
24V --- 4.5 kW (engine F2B)
24V --- 5 kW (engine F3B)
Ground reference: negative pole.
2 CHASSIS (Fig. 1)
Built with rectilinear side members in high
strength “C” section steel, connected by
riveted or bolted cross-members.
Standard fuel tank
Steel, capacity 300 liters with level and
reserve indicator.
Oversize fuel tank
Steel, capacity 600 liters with level and
reserve indicator.
1 20 HD9 Euro3
VEHICLE OUTFITTING
1
Set of keys
D Ignition/door/fuel tank keys.
D Open/close doors remote control (if pre-
sent).
Documentation
D USE AND MAINTENANCE manual.
357ADT001L Vehicle outfitting
D Lifting jack (Fig. 1).
D Jack levers/cab lifting/wheels wrench
2 (Fig. 2).
357ADT002L
HD9 Euro3 121
357ADT003L
357ADT004L
1 22 HD9 Euro3
Night driving
Take special care, reducing speed if necessary, especially on unlit roads.
Keep a greater safety distance than when driving by day: in effect it is more difficult to estimate the speed of an approaching vehicle when
only its lights are visible.
Stop and rest as soon as you feel tired. To continue would only be a hazard to yourself and others.
Use high beams only outside built-up areas an only when you are sure they do not other drivers.
Always dip headlights with oncoming traffic.
Parking
Switch off the engine.
Engage the parking brake.
Engage 1st gear if the vehicle is parked on a slope or reverse gear if the vehicle is facing downwards (manual gearshift vehicles only).
Never leave the key turned to MAR with the engine off to avoid flattening the batteries.
Tyres
Always reduce speed before taking on a tight bend, even if vehicle performance permits.
Avoid sharp acceleration of heavy braking.
Do not drive at constant high speeds for long periods, especially on uneven road surfaces.
Make certain that wheels are correctly balanced and adjusted.
Avoid violent impacts to tyre walls (for example when parking).
Never tamper with tyre inflation valves.
HD9 Euro3 1 27
Do not insert any kind of tool between tyre and wheel rim.
If the rim is damaged, replace it.
If a tyre loses pressure for no apparent reason, replace the wheel and check the faulty tyre.
Tyre pressures, including the spare, must always be as specified.
Tyres that are old (over 6 years) or used should only be used in case of emergency and with due caution.
Do not leave the vehicle parked for long periods on the edge of the kerb or similar irregularities on the road surface.
Regularly check tyre tread depth, changing tyres when depth is less than the legal minimum.
The vehicle mounts ’tubeless’ tyres, meaning without inner tube. Inner tubes must not be fitted to tubeless tyres.
Certain types of tyres are fitted with wear indicators. They must be changed as soon as the indicators become visible on the tread.
Aquaplaning is more likely with worn tyre treads.
Snow chains
The use of snow chains is governed by local law in each country.
Chains should only be fitted to drive wheels.
To prevent tyre damage, do not drive on clear roads with chains fitted. In extreme cases (tunnels, etc....) proceed at low speed and in any
case remove the chains as soon as conditions permit.
Maintain moderate speed with chains mounted, avoiding potholes and driving onto the kerb.
Certain tyres of snow chain require tension adjustment after travelling a short distance.
Economic, ecological driving
Road conditions and driving style have a direct influence on fuel consumption and environmental impact.
Carry out the maintenance operations described below at regular intervals and with care.
Do not demand maximum power from the vehicle with the engine cold.
Do not rev the engine when parked.
Always avoid sharp acceleration and repeated braking/acceleration. Engage a higher gear as soon as conditions permit.
If possible, avoid driving with side windows lowered. Use the air-conditioner/ventilation system to obtain the desired conditions in the cab.
342BNU002L
1 30 HD9 Euro3
1 1 EXTERNAL LIGHTING
Front lights (Fig. 1)
1. High beam
2. Parking light and headlight
3. Front direction indicator
4. Side direction indicator
5. Front clearance light
6. Rotary warning lights (if fitted)
342BNU009L
HD9 Euro3 1 31
228NU205
1 32 HD9 Euro3
307HNU008L
HD9 Euro3 1 33
1 DOORS
342BNU005L
136 HD9 Euro3
342BNU006L
HD9 Euro3 1 39
342BNU007L
1 2
342BNU008L
HD9 Euro3 1 41
341DNU020L
142 HD9 Euro3
285ANU002L
HD9 Euro3 143
284CNU004L
342BNU051L
144 HD9 Euro3
1 SEATS
Fore and aft adjustment
Lift lever (Fig. 1, ref. 1) to have the seat free
to move backwards or forward.
342BNU010L
HD9 Euro3 145
Height adjustment
Lift lever (Fig. 1, ref. 4) to raise the seat; re-
lease the lever after adjustment. Seat height
is memorised automatically.
Lower lever to lower the seat (100 mm max.)
Backrest angle adjustment
Lift lever (Fig.1, ref. 5) and set the backrest to
the desired angle with your back. Release
the lever to block the backrest.
342BNU010L
146 HD9 Euro3
1 SEAT BELTS
The vehicle is equipped with three-point seat
belts and automatic reel (Fig. 1).
D To fasten the belt grip the tab and insert it
into the buckle until it clicks (Fig. 2).
D To release the belt, press the button on the
top of the buckle (Fig. 3).
178NU09
178NU10
HD9 Euro3 1 47
342BNU012L
342BNU013L
HD9 Euro3 149
1 HATCH
To open the hatch (Fig. 1) operate as fol-
lows:
D press the red button;
D turn the handle and push it up (Fig. 1, see
arrow).
To close the hatch (Fig. 2) operate as fol-
lows:
HD9ST0045L D press the red button;
D pull the handle down and turn it (Fig. 2, see
arrow) until it clicks.
2
HD9ST0046L
1 50 HD9 Euro3
1 COMPARTMENTS
Dashboard (Fig. 1)
1. Bottle/can holder
2. Mobile phone holder
3. Items tray (according to outfitting)
4. Gloves compartment
5. Compartment in front of passenger
342BNU015L
HD9 Euro3 1 51
Door (Fig. 1)
1
1. bottle holder
2. pocket
3. pocket
Tunnel (Fig. 2)
1. coin holder
2. loose items tray
Seat (Fig. 3)
1. Compartment (closed with lid)
Act on button and lower lid to open.
Raise lid and press until it clicks to close.
2. items holder
Rear wall (Fig. 4)
1. bottle holder
342BNU016L 2. items compartment
2 3 4
1 ACCESSORIES - DEVICES
Sun blind tabs (Fig. 1, ref. 1)
Grip the front edge of the tab and turn down-
ward.
Bring to position by hand.
Grip handle (Fig. 1, ref. 2)
On passenger side.
Coat hook (Fig. 1, ref. 2)
On both sides of cab.
Cigar lighter (Fig. 2, ref. 1)
Press to activate cigar lighter: a click indi-
cates it is ready for use.
342BNU020L After use return to its seat without pressing.
Ashtray (Fig. 2, ref. 2)
2 On both sides of cab.
Raise lid to open.
Lower lid to close.
12Volt current socket (Fig. 2, ref. 3)
Open cap and insert facility .
After use close cap.
342BNU021L
HD9 Euro3 1 53
1 CONTROLS
Controls on dashboard (Fig. 1)
1. Headlamps geometry adjustment
2. External lights switch
3. Hazard lights
4. Parking brake control
342BNU022L
1 54 HD9 Euro3
HD9ST0094L
HD9 Euro3 155
Controls on floor
Steering wheel position control
Steering wheel position adjustment is pneu-
342BNU024L
matic, and can be regulated by means of the
button on the floor at the base of the steering
column, driver’s side (Fig. 2).
2 Proceed as follows:
D With the button pressed take the wheel in
your hands and bring it to the required
position.
D Once in position, release the button.
357ANU101L
1 56 HD9 Euro3
1 Accelerator
The accelerator is controlled by means of a
pedal on the floor to be operated by the
driver’s right foot (Fig. 1, ref. 1).
Press the pedal to increase the torque output
by the engine proportionally to the position
of the pedal.
Service brake
The service brake is controlled by means of
272NU062X a pedal on the floor to be operated by the
driver’s right foot (Fig. 1, ref. 2).
Press the pedal to obtain a braking effect in
proportion to the exerted pressure.
Clutch
The clutch is controlled by a pedal to be
operated with the driver’s left foot (Fig. 1,
ref. 3).
Press the pedal to release the clutch. Only for
manual trasmission vehicles.
HD9 Euro3 157
342BNU025L
357ANU102L
357ANU201L
158 HD9 Euro3
HD9ST0078L
HD9 Euro3 159
1 Blackout curtain
Each of the two curtains can slide (see arrow)
along the track to completely block the side
window up to the centreline of the wind-
screen.
HD9ST0079L
160 HD9 Euro3
HD9ST0080L
HD9 Euro3 161
357ANU203L
1 62 HD9 Euro3
1 1 EXTERNAL LIGHTING
Front lights (Fig. 1)
1. High beam
2. Parking light and headlight
3. Front direction indicator
4. Side direction indicator
5. Front clearance light
6. Rotary warning lights (if fitted)
357ANU204L
HD9 Euro3 1 63
285ANU053L
1 64 HD9 Euro3
307HNU009L
HD9 Euro3 1 65
1 DOORS
The vehicle has two doors symetrically
placed at each side.
The external door handle (Fig. 1, see arrow)
can be locked from the outside with a key.
To open the door pull down the external
handle.
D to block the lock, turn the key anticlock-
wise (Fig. 1, ref. 1);
D to block the lock, turn the key clockwise
(Fig. 1, ref. 2);
D to open the door, pull handle downward.
When the door is opened the cabin interior
light comes on automatically, along with the
cabin step lights.
357ANU205L
HD9 Euro3 167
357ANU206L
1 68 HD9 Euro3
357ANU207L
HD9 Euro3 1 71
357ANU208L
1 2
357ANU209L
HD9 Euro3 1 73
357ANU210L
1 74 HD9 Euro3
285ANU002L
HD9 Euro3 175
357ANU213L
342BNU051L
176 HD9 Euro3
1 SEATS
Fore and aft adjustment
Lift lever (Fig. 1, ref. 1) to have the seat free
to move backwards or forward.
357ANU214L
HD9 Euro3 177
Height adjustment
Lift lever (Fig. 1, ref. 5) to raise the seat; re-
lease the lever after adjustment. Seat height
is memorised automatically.
Lower lever to lower the seat (100 mm max.)
Backrest angle adjustment
Lift lever (Fig.1, ref. 6) and set the backrest to
the desired angle with your back. Release
the lever to block the backrest.
357ANU214L
178 HD9 Euro3
1 SEAT BELTS
The vehicle is equipped with three-point seat
belts and automatic reel (Fig. 1).
D To fasten the belt grip the tab and insert it
into the buckle until it clicks (Fig. 2).
D To release the belt, press the button on the
top of the buckle (Fig. 3).
178NU09
178NU10
HD9 Euro3 1 79
357ANU216L
357ANU217L
HD9 Euro3 181
1 HATCH
To open the hatch (Fig. 1) operate as fol-
lows:
D press the red button;
D turn the handle and push it up (Fig. 1, see
arrow).
To close the hatch (Fig. 2) operate as fol-
lows:
HD9ST0045L D press the red button;
D pull the handle down and turn it (Fig. 2, see
arrow) until it clicks.
2
HD9ST0046L
1 82 HD9 Euro3
1 COMPARTMENTS
Dashboard (Fig. 1)
1. Bottle/can holder
2. Mobile phone holder
3. Items tray (according to outfitting)
4. Gloves compartment
5. Compartment in front of passenger
357ANU218L
357ANU219L
HD9 Euro3 1 83
Door (Fig. 1)
1
1. bottle holder
2. pocket
3. pocket
Tunnel (Fig. 2)
1. coin holder
2. loose items tray
Seat (Fig. 3)
1. Compartment (closed with lid)
Act on button and lower lid to open.
Raise lid and press until it clicks to close.
2. items holder
Rear wall (Fig. 4)
1. bottle holder
2. items compartment
357ANU220L
2 3 4
1 ACCESSORIES - DEVICES
Sun blind tabs (Fig. 1, ref. 1)
There are three sun blind tabs.
Grip the front edge of the tab and turn down-
ward.
Bring to position by hand.
Grip handle (Fig. 1, ref. 2)
On passenger side.
Coat hook (Fig. 1, ref. 3)
On both sides of cab.
Cigar lighter (Fig. 2, ref. 1)
Press to activate cigar lighter: a click indi-
357ANU223L cates it is ready for use.
After use return to its seat without pressing.
Ashtray (Fig. 2, ref. 2)
2
On both sides of cab.
Raise lid to open.
Lower lid to close.
12Volt current socket (Fig. 2, ref. 3)
Open cap and insert facility .
After use close cap.
357ANU224L
HD9 Euro3 1 85
1 CONTROLS
Controls on dashboard (Fig. 1)
1. Headlamps geometry adjustment
2. External lights switch
3. Hazard lights
4. Parking brake control
357ANU225L
1 86 HD9 Euro3
HD9ST0095L
HD9 Euro3 1 87
Controls on floor
Steering wheel position control
Steering wheel position adjustment is pneu-
357ANU227L
matic, and can be regulated by means of the
button on the floor at the base of the steering
column, driver’s side (Fig. 2).
2 Proceed as follows:
D With the button pressed take the wheel in
your hands and bring it to the required
position.
D Once in position, release the button.
357ANU228L
188 HD9 Euro3
1 Accelerator
The accelerator is controlled by means of a
pedal on the floor to be operated by the driv-
er’s right foot (Fig. 1, ref. 1).
Press the pedal to increase the torque output
by the engine proportionally to the position
of the pedal.
Service brake
The service brake is controlled by means of
272NU062X a pedal on the floor to be operated by the
driver’s right foot (Fig. 1, ref. 2).
Press the pedal to obtain a braking effect in
proportion to the exerted pressure.
Clutch
The clutch is controlled by a pedal to be op-
erated with the driver’s left foot (Fig. 1, ref. 3).
Press the pedal to release the clutch.
HD9 Euro3 189
357ANU229L
357ANU230L
357ANU231L
190 HD9 Euro3
HD9ST0097L
HD9 Euro3 191
1 Blackout curtain
Each of the two curtains can slide (see arrow)
along the track to completely block the side
window up to the centreline of the wind-
screen.
HD9ST0098L
192 HD9 Euro3
HD9ST0100L
HD9 Euro3 193
ALL VEHICLES
INSTRUMENTS
Instrument panel (Fig. 1)
341DNU001L
HD9 Euro3 1 95
285ANU010L
HD9 Euro3 1 97
4 3
285ANU012L
HD9 Euro3 1 99
357ANU233L
C Bolts wrench: system error. Go to the
nearest authorised garage.
2
Automatic transmission warning lights
(Fig. 2)
1. automatic transmission failure warning
light.
2. automatic transmission oil temperature
high warning light.
357ANU239L
1102 HD9 Euro3
1 CONTROL OPERATION
Position and headlight controls (Fig. 1)
The control has three positions:
D position 0: off;
D position 1: first click: position lights on;
D position 2: second click: headlights on.
2
272NU044X
HD9 Euro3 1 105
Horn (Fig. 2)
2 The horn can be sounded by pressing the
272NU045X
indicated points (Fig. 2, ref. 1, 2).
1
2
272NU046X
1 106 HD9 Euro3
272NU048X
272NU049X
HD9 Euro3 1 107
272NU056X
272NU060X
1 108 HD9 Euro3
1 Cruise control
The vehicle is fitted with an engine speed /
vehicle speed control.
285ANU039L
1 110 HD9 Euro3
285ANU022L
HD9 Euro3 1 111
342ANU003L
1112 HD9 Euro3
306ANU002L
HD9 Euro3 1113
1 Distributor-reducer (transfer)
Position knob (Fig. 1):
D Position 0:travelling on road (normal
ratios).
D Position 1, “tortoise” symbol:off-road use
(step-up ratios).
The differentials must be engaged with the vehicle stopped and with the wheels
straight.
If the lock does not disengaged immediately, change direction in order to eliminate any
tension present.
Proceed with caution when lock is engaged. Do not engage the lock on roads that do
not require its use.
In muddy or slippery conditions do not allow the wheels to slip when the differential
lock is not engaged, as this will lead to serious damage to the gearing (a few seconds
are enough).
Do not engage the differential while a wheel is slipping as this will also cause serious
damage to gearing.
After use, always check that the locks are disengaged checking both the warning
lights and the position of the control button.
1 118 HD9 Euro3
The differentials must be engaged with the vehicle stopped and with the wheels
straight.
If the lock does not disengaged immediately, change direction in order to eliminate any
tension present.
Proceed with caution when lock is engaged. Do not engage the lock on roads that do
not require its use.
In muddy or slippery conditions do not allow the wheels to slip when the differential
lock is not engaged, as this will lead to serious damage to the gearing (a few seconds
are enough).
Do not engage the differential while a wheel is slipping as this will also cause serious
damage to gearing.
After use, always check that the locks are disengaged checking both the warning
lights and the position of the control button.
1 120 HD9 Euro3
285ANU025L
HD9 Euro3 1121
Disengage procedure:
D Switch off the engine
D Press the corresponding button.
D Check that corresponding light goes out
on cluster.
1 122 HD9 Euro3
Engage procedure:
D Gear idling, vehicle stationary, engine at
minimum.
Disengage procedure:
D Press the clutch pedal full down.
342ANU008L
D Press the corresponding PTO button
(Fig. 1; Fig. 2).
D Check on cluster that corresponding light
goes out .
D Release the clutch pedal.
HD9 Euro3 1 123
Engage procedure:
D Gearbox in Neutral, vehicle not moving,
engine at minimum.
Disengage procedure:
D Press the relevant PTO button (Fig, 1, 2).
D Check that the cluster indicator light has
gone dark.
Engage procedure:
D Gearbox in Neutral, vehicle not moving,
engine at minimum.
Disengage procedure:
D Press the relevant PTO button (Fig, 1, 2).
D Check that the cluster indicator light has
gone dark.
342ANU008L
HD9 Euro3 1 125
1 TACHOMETRIC SIMULATOR
The tachometric simulator (Fig. 1) permits
correct electronic management of the clus-
ter.
285ANU026L
1126 HD9 Euro3
j cool air
J warm air
342BNU43L
1 128 HD9 Euro3
Symbols
342BNU44L
Ventilation outlets
Foot cooling/outlets
Foot cooling
Foot cooling/windshield
Climate control
Recirculation
HD9 Euro3 1 129
342BNU45L
HD9 Euro3 1 131
342BNU46L
1 132 HD9 Euro3
342BNU47L
HD9 Euro3 1 133
342BNU48L
1 134 HD9 Euro3
357ANU104L
HD9 Euro3 1135
1 2 3 4 5
285ANU043L
1 136 HD9 Euro3
1 Refuelling
Proceed as follows:
D clean the filler area, open the filler cap
(Fig. 1, ref. 1) with the key and refuel with
the specified fuel type;
342BNU001L
D close the filler cap carefully.
1 STARTING ENGINE
2
Tow starting
Proceed as follows:
D lay the cables on the ground ensuring that
the terminals do not touch metal parts or
each other; connect one end of the red
cable (A) to the POSITIVE terminal (Fig. 1,
238NU44
ref. 1) of the flat battery;
D connect the other end of the red cable (A)
to the POSITIVE terminal (Fig. 1, ref. 2) of
the external battery;
D connect one end of the black cable (B) to
the NEGATIVE terminal (Fig. 1, ref. 3) of
the external battery;
D connect the other end of the black terminal
(B) to any point of the chassis of the vehicle
(Fig. 1, ref. 4) to be started which is cer-
tainly connected to earth.
1 146 HD9 Euro3
238NU44
The use of a booster is permitted follow-
ing the use instructions of the said instru-
ment.
COLD START
The following table shows the precautions to be adopted for starting the engine at temperatures lower than 0 ˚C.
Temperature [˚C]
Operations
From 0 to -19 From -19 to -25 Lower than -25
Starting procedure normal with heater with heater
replace with Artic diesel fuel replace with suitable fuel
Fuel wash out the engine and auxil-
add suitable percentage of additive
iary heater feeding circuit
Engine oil no replacement needed replace with suitable type
Engine coolant appropriate percentage of antifreeze
Transmission oil no replacement needed
Power steering steering fluid no replacement needed
Windscreen washer fluid appropriate percentage of antifreeze
Batteries check maximum charge by measuring electrolyte density
1 148 HD9 Euro3
272BNU100
HD9 Euro3 1149
1 STOPPING ENGINE
Stopping from drivers cabin
To stop the engine, proceed as follows:
D bring the engine to idle speed for a few
minutes to reached steady state tempera-
ture and ensure turbocompressor lubrica-
tion;
D turn the ignition switch to STOP (Fig. 1,
272BNU091 ref. 0) and remove the key.
306ANU002L
HD9 Euro3 1 151
1 MANUAL TRANSMISSION
VEHICLES
STARTING THE VEHICLE
1 Before starting the vehicle, make sure that
the tractor brake low pressure warning lights
and trailer brake low pressure warning lights
(if fitted ) are off, and that brake air pressure
has reached 6 bar (Fig. 1). If necessary wait
178NM81 a few minutes for the compressor to charge
the air tanks.
To start the vehicle proceed as follows:
2 D press the clutch pedal (Fig. 2, ref. 3);
272NU062X
1152 HD9 Euro3
285ANU045L
HD9 Euro3 1153
285ANU030L
1154 HD9 Euro3
1 GEARBOX
The operations to control the gearbox are the
same as those on traditional type synchro-
nised gearboxes, i.e. without requiring
doubling of the clutch when changing up
and without intermediate acceleration when
changing down.
The individual gears can be engaged only
when the parts to be mated reach the same
178NU52 speed. It is therefore important to press the
gear lever evenly until the gear is engaged.
2
To avoid damaging the toothing of the
gear, reverse should only be engaged
when the vehicle is stationary.
Splitter control
1
The splitter control which makes it possible
to divide each of the eight gears (and re-
verse) occurs via the pre-selection valve lo-
cated in the control lever and operated by the
pre-selection lever (Fig. 1):
D lever upwards (position A) = > normal
gears
D lever downwards (position B) = > step-up
gears
To control the splitter the lever should be
worked and the clutch pedal fully de-
pressed.
A valve activated by the clutch pedal com-
mands the splitter control cylinder, so that
switching is obtained. To obtain correct
splitter operation, engagement and disen-
gagement movements must not be abrupt.
Engagement of reduced gears is indicated
by the relevant LOW SPLIT warning light
178NU53 (Fig. 2) that switches on.
The use of the splitter is particularly useful in
certain cases, for example:
D to exploit the maximum power of the en-
2 gine when difficulty is experienced when
driving off, overtaking or travelling uphill;
D when travelling in urban areas or when tra-
velling in a queue when you wish to main-
tain the engine at an economical rpm.
341DNU006L
HD9 Euro3 1 157
285ANU027L
1160 HD9 Euro3
285ANU045L
1162 HD9 Euro3
285ANU030L
HD9 Euro3 1163
1 GEARBOX
The controls on these gearboxes are the
same as those on conventional
synchronised gearboxes, that is without
double declutching when passing to higher
gears and without intermediate acceleration
when passing to lower gears.
The gears can be engaged only when the
parts to be coupled have reached the same
178NU52 speed. Therefore it is important to push the
control levers evenly until the gear is
engaged.
2
The reverse gear must be engaged only
when the vehicle is stopped; otherwise it
may cause damage to the teeth of the
switch.
Gearbox command (Fig. 1)
With the downshift gear group engaged
(”turtle” light on, Fig. 2, Ref. 1) and the
341DNU005L
transmission in neutral, the control lever is
positioned in direction 3/4, while with normal
gear engaged (”turtle” light off, Fig 2, ref. 1)
and the transmission in neutral, the lever is
positioned in direction 5/6.
In order to engage gears 1/2 and 7/8, it is
necessary to move the gear shift lever
manually to the left or right respectively,
overcoming the slight resistance of the
positioning springs.
Selections 3/4 and 5/6 are separated by a
click with a stronger spring.
HD9 Euro3 1 165
341DNU006L
HD9 Euro3 1 167
1 STARTING UP
When the engine has been started the
display shows the symbol N (Fig. 1). The
system is in manual mode.
285ANU045L
1174 HD9 Euro3
285ANU030L
HD9 Euro3 1175
147NU10
HD9 Euro3 1177
1 Kick-down function
Pressing the accelerator pedal beyond the
hard limit stop point causes the control sys-
tem to set POWER mode.
Before shifting up, each gear is maintained
up to the corresponding maximum engine
speed, downshifting in case of sharp accel-
eration.
The system remains in automatic mode dur-
147NU11 ing kick-down.
Maintaining the selected gear
In automatic mode, if the current gear has to
be maintained (for example to accelerate be-
fore beginning a climb), press function but-
ton F without moving the lever.
The system shifts to manual mode: no fur-
ther gear shifts are possible except those
made by means of the lever.
To return to automatic mode, press function
button F again without moving the lever.
1178 HD9 Euro3
147NU12
147NU10
HD9 Euro3 1179
1 Shift to neutral
D Press the function key (N) (Fig. 1).
The N symbol appears on the display. Ma-
nual mode is enabled.
1 Reverse gear
147NU09
1182 HD9 Euro3
1 Protection functions
Clutch protection
If the clutch overheats (for example due to
307HNU005L
HD9 Euro3 1185
1 Operation
D Activate emergency mode and start the
engine.
D Press and release the brake.
D Engage the required gear by repeated
operating the gear lever (Fig. 2):
(a) forward (+) to shift up
(b) backward (---) to shift down
147NU04 The gears to be used in LIMP HOME mode
must be selected when the vehicle is sta-
tionary only.
2 Movements of the gear lever while the sy-
stem is travelling will not be taken into ac-
count by the system.
307HNU006L
1186 HD9 Euro3
1 Uphill starting
D If the clutch is engaged by means of the
button (Fig. 1, ref. F) when the brake is
pressed, release the brake pedal briefly in
order to be able to disengage the clutch
with the accelerator again.
Driving downhill
D The clutch will be automatically engaged
when the vehicle is travelling downhill with
147NU04
a gear engaged.
Restoring normal operation (RESET)
D Turn the key to the STOP position and wait
for the indicator to go out.
D Turn the key back to the MAR position.
HD9 Euro3 1187
272NU005MY
1190 HD9 Euro3
Kick-down
The kick down device operation (i.e. depress
accelerator pedal beyond limit stop) enables
the driver to “force” down-shifting when run-
285ANU030L
ning. This device can be used to have higher
vehicle pickup after a moderate slowing
down (i.e. not causing automatic shifting to
a lower gear).
Do not use this device continuously because
it causes rough use of the transmission,
stresses the assembly and leads to higher
fuel consumption.
HD9 Euro3 1193
1 Automatic transmission
1. Safety button to be pressed to allow
selector lever movement.
2. MODE button : to choose a second set-
ting of the automatic transmission con-
trol unit.
PERFORMANCE mode: default set-
ting, button not pressed, LED off.
ECONOMY mode: second setting, but-
ton pressed, LED on.
357ANU236L
1196 HD9 Euro3
1 Drive position
This position must be used for driving the ve-
hicle in the normal conditions.
Automatic transmission control system se-
lects the most suitable gear and controls en-
gagement of converter automatic lock-up
clutch according to engine speed and load.
1 Positions 6, 5, 4 and 3
These positions should be used occasional-
ly when selection should be limited to the first
three gears, cutting out the higher gears and
first gear, due to particular load or road con-
ditions.
Position 2
This position must be used to control vehicle
speed uphill and especially downhill on par-
ticularly steep roads.
Position 1
There transmission does not shift and out-
357ANU236L puts maximum torque to wheels.
1198 HD9 Euro3
1 Fault
The “Check Trans” warning will on the side
panel (Fig. 1, ref. 1) will light up to indicate a
possible automatic transmission fault. The
error code will appear on the display by the
side of the selection lever (Fig. 2, see arrow).
357ANU237L
HD9 Euro3 1199
1 ALL VEHICLES
SPEED PROGRAMMER
Engine idle speed adjustment / memoris-
ing
The speed programmer is a device that acts
on the engine power supply management
system, controlling rotation speed both with
vehicle stationary and in motion, so that cer-
tain conditions are met.
Conditions:
D engine at idle speed;
D engine at temperature over 30 ˚C.
1 202 HD9 Euro3
1 Proceed as follows:
D Action the Cruise Control lever (Fig. 1,
ref. 1) toward the steering wheel
(RESUME) until engine speed reaches the
basic stabilised rate (approx 550 rpm);
D Adjust speed as required using ON +
(Fig. 1, ref. 2) or ON --- (Fig. 1, ref. 3)
(pivoting head key).
1 Conditions:
D engine brake lever/retarder not engaged;
D vehicle moving with gear engaged;
D vehicle speed greater than 20 kph;
D brake pedal not pressed;
D clutch pedal not pressed.
Control Vehicle speed regulation
ON + Increases speed
ON --- Decreases speed
RESUME Selects last set speed
OFF Cancels speed regulation
HD9 Euro3 1 205
1 Enable
Proceed as follows:
1 Changing setting
Proceed as follows:
D after activating the function press ON (+)
(Fig. 1, ref. 2) to increase vehicle speed;
or
D after activating the function press ON (---)
(Fig. 1, ref. 3) to decrease vehicle speed.
Tip Function
Briefly press the ON (+) or ON (---) button to
vary speed by steps of 1 km/h.
Ramp Function
Pressing down the ON (+) or ON (---) buttons
changes speed continually.
HD9 Euro3 1 207
1 Permanent disable
Proceed as follows:
D Engage the Cruise Control lever towards
the dashboard (OFF) (Fig. 1, ref.1).
or
D Operate the brake or engine brake pedal;
or
D Press/turn the accelerator pedal
(demanding a higher speed than set) for
more than 60 seconds.
Temporary disable
Proceed as follows:
D Operate the clutch pedal (if present) the
system shifts to stand-by. After disengag-
ing the clutch the vehicle returns to the
cruising speed set previously.
D Press/turn the accelerator pedal for more
than 60 seconds. As soon as the acceler-
ator is released the function automatically
resumes at the last set value.
1 208 HD9 Euro3
284CNU014L
Use the retarder to reduce vehicle speed
on turns or downhill, to prevent overheat-
ing the brakes.
21 Function warning light (Fig. 3) switches on:
D bringing the ignition switch to MAR (RUN)
for three seconds (test);
D in fixed mode until the retarder performs its
braking action;
D flashing if there is a system fault.
272GNU104
1 210 HD9 Euro3
228NUR53
HD9 Euro3 1 211
272GNU105
1 212 HD9 Euro3
1 VEHICLE PARKING
B Parking brake --- vehicles without trailer
The parking brake (Fig. 1) has two positions:
D position A: engaged, vehicle braked;
D position B: disengaged, vehicle NOT
braked.
A To engage the parking brake bring the lever
to position A.
To disengage the parking brake raise the col-
lar and bring the control lever to position B.
1 SEMI-TRAILER COUPLING
Coupling
Proceed as follows to open the fifth wheel:
D raise the safety lever (Fig. 1, ref. 1);
D move the bolt (Fig. 2, ref. 2) forwards to
release the first stop notch (Fig. 3, see
arrow);
D pull the bolt fully to the second stop notch
JSK38 50_03 (see arrow).
Proceed as follows to couple the semi-trailer:
D immobilise the semi-trailer;
2
The semi-trailer skid plate should be
approx. 5 cm lower than the top of the fifth
wheel.
309FNU005L
1218 HD9 Euro3
1 Check closure
D check that the safety lever (Fig. 1, ref. 1) is
in the lower position;
D the back plate must uniformly rest on the
fifth wheel (see arrow).
Uncoupling
Proceed as follows:
D immobilise the vehicle;
D lower the supporting legs;
D disconnect the pneumatic and electric
connections;
D open the fifth wheel as described above;
D move the tractor forwards.
178NU85
HD9 Euro3 1219
307HNU003L
HD9 Euro3 1221
1 TRAILER COUPLING
4 3
Pneumatic coupling (Fig. 1)
1. Automatic (red)
2. Adjustable (yellow)
SEMI-TRAILER COUPLING
2
Pneumatic coupling (Fig. 2)
1. Automatic (red)
2. Adjustable (yellow)
LADDER
3 Use the specific ladder (Fig. 3, ref. 1) to
access the electric and pneumatic connec-
tions of the tractor.
1 272NU108X
1 224 HD9 Euro3
1 Operating instructions
Proceed as follows:
D release the parking brake spring cylinders
operating as described in the relevant sec-
tion.
If there is suspicion of internal transmis-
sion failures, or when driving long dis-
tances, it is necessary to remove the pro-
peller shaft.
228NUR61
Manual transmission vehicles
D Check that the gears high range is inserted
(5th --- 8th ratio).
D Bring the lever to idle position.
D Start towing keeping MAXIMUM SPEED at
40 KM/H.
It is advised not to exceed a maximum
distance of 200 km.
Automated transmission vehicles
D Insert the gears high range proceeding as
follows:
--- check the gear pneumatic and electrical
supply;
--- move the ignition switch to position 1;
--- check there are no error messages on the
display.
D Select Neutral position.
D Start towing, maintaining a MAXIMUM
SPEED of 25 km/h for a MAXIMUM DIS-
TANCE of 100 km.
Vehicles with automatic Allison transmission
A. 2-axle vehicles
B. 3-axle vehicles
C. 4 axle vehicles
357ANU113L
1 228 HD9 Euro3
228NUR62
1230 HD9 Euro3
1 WHEEL CHANGE
Jacking up the vehicle
To use the jack:
D remove the cab jack (Fig. 1, ref. 1) from its
housing behind the passenger seat by
loosening the retainer screw (Fig. 1, ref. 2)
from the bracket;
D take the rod supplied;
D check, that the hydraulic valve (Fig. 2,
285ANU038L ref. 1) of the jack is rotated clockwise
(hydraulic circuit under pressure);
D position the jack at the raising points
2 specified in the following page;
D insert the rod into the bush (Fig. 3, ref. 2)
and work the pump until lifting the wheel;
D after replacement, SLOWLY turn the jack
control hydraulic valve anticlockwise;
D remove the jack and press the top part of
1 2 jack cylinder with your foot to fit it back into
seat.
Strictly comply with instructions indi-
178NU91 cated on the label attached to the jack to
use it correctly.
The wheels should be changed when the
vehicle is on level ground and unloaded
with the hand brake engaged and chocks
placed against the wheels which remain
on the ground.
HD9 Euro3 1 231
1 4 Changing a wheel
To change a wheel:
D use the wheel brace provided to loosen
the wheel bolts on the wheel to be
changed;
D raise the vehicle until the wheel is off the
ground and set the jack at the following
points:
Figure 1: axle;
272NU006MY 272NU008MY Figure 2: front axle;
Figure 3: intermediate axle;
Figure 4: rear axle.
2
272NU007MY
272NU008MY
1232 HD9 Euro3
309FNU008L
HD9 Euro3 1233
1 DIAGNOSTICS
The odometer display shows errors present
in the vehicle control system memory.
The warning light related to the concerned
system will appear to indicate that errors are
present. The control systems are indicated
by four letters (Fig. 1, see table).
Proceed as follows if one or more warning
lights come on (see table, Fig. 1):
D Turn the ignition switch to MAR;
D Hold the button pressed for at least 5 se-
conds (Fig. 2, ref. 1). The error situation
2 when the request was made will appear on
the display (Fig. 2, detail).
a error sequential number
b total number of errors present
c error code
d ECU type (Fig. 1, see table).
307ANU100L
1236 HD9 Euro3
2 ALLISON connector
For connection with the specific Allison auto-
matic transmission diagnostics tool.
356ANU102L
HD9 Euro3 1 237
Maintenance Instructions
1 238 HD9 Euro3
INTRODUCTION
Properly dispose of replaced material (brake pads, filters, etc.) and materials resulting from maintenance operations and
repairs (material soaked in fuel, oil, powder, etc.) according to the laws in force, diversified from normal waste.
Collect and dispose of used lubricants and fluids, according to the laws in force.
Collect and dispose of used batteries according to the laws in force.
Drain and recharge the air conditioning system using the specific devices, according to the laws in force.
All level checks must be carried out with vehicle parked on flat and handbrake engaged.
Wait a few minutes for the level to stabilise before checking.
Observe scrupulous cleanness of oil and fluid containers when refilling.
Before injecting grease, or checking levels, carefully clean the pressure fittings and the areas around the level and filling
caps.
Use oil and fluid of the same type used before in the various assemblies when topping up.
Never tamper with valves, regulators or other devices, unless specified in the handbook, to prevent damage to vehicle
components and consequent hazards for persons.
Technical information on maintenance (intervals, type and number) is given in TABLES AND DIAGRAMS.
1 240 HD9 Euro3
342BNM001L
HD9 Euro3 1241
Proceed as follows:
D make sure the guard is suitably restrained
to prevent any sudden downward move-
ment;
HD9ST0135L
D remove the guard lock pins from both
sides (Fig. 2, see arrow);
D carefully lower the guard so as not to
damage the wiring of the additional head-
lights.
Reposition the guard by reversing the afore-
said operations.
1 242 HD9 Euro3
272NM002MY
272GNM001
1244 HD9 Euro3
HD9ST0138L
HD9 Euro3 1 245
342BNM004L
1248 HD9 Euro3
1 ENGINE
Changing engine oil
Proceed as follows:
D stop the warm engine and waitfor the cool-
ant temperature to drop to 60 ˚C;
D tilt the cab;
D arrange a suitable sized container and re-
move the dipstick;
178NM10
D clean the cap area, loosen the drain cap
(Fig. 1) and drain all the oil for the time re-
quired;
D clean the drain plug, check that the thread
is in good condition, replace the O-ring
and close it;
HD9 Euro3 1249
156NM11
1250 HD9 Euro3
Proceed as follows:
342BNM005L D stop the warm engine and waitfor the cool-
ant temperature to drop to 60 ˚C;
D loosen the filtering cartridge (Fig. 1, see
2 arrow) using the specific tool and accu-
rately clean the housing;
D fasten the cartridge by hand until the seal
comes into contact with the housing, then
turn by another 3/4 of a turn (Fig. 2).
Proceed as follows:
178NM12 D stop the warm engine and waitfor the cool-
ant temperature to drop to 60 ˚C;
D loosen the filtering cartridge (Fig. 1, see
2 arrow) using the specific tool and accu-
rately clean the housing;
D fasten the cartridge by hand until the seal
comes into contact with the housing, then
turn by another 3/4 of a turn (Fig. 2).
228NM222
228NM223
HD9 Euro3 1253
178NM05
1254 HD9 Euro3
272CNU099
Keep the fuel tank as full as possible. Use
fuels of the specified types supplied by
petroleum companies. Do not use other
than specified fuels.
Use of other than specified fuels can
cause severe engine damage.
1 256 HD9 Euro3
285ANM002L
HD9 Euro3 1257
285ANM003L
HD9 Euro3 1 259
1
178NM119
1260 HD9 Euro3
1 INTAKE SYSTEM
Intake system seal check
Proceed as follows:
D tip the cabin;
D check the intake system seals and con-
nectors (Fig. 1, see arrow).
Turbocompressor lubrication check
Proceed as follows:
D tip the cabin;
D inspect the delivery pipes (Fig. 2, ref. 1)
and return pipes (Fig. 2, ref. 2) to check
absence of leaks or faults that could cause
decreased oil flow to the turbo.
269NM193
HD9 Euro3 1261
Proceed as follows:
D release the retainer springs (Fig. 1, see
arrow) and remove and thoroughly clean
the cover;
174NM26 D extract the primary cartridge (Fig. 2, see
arrow);
D dust removal using compressed air at
2 maximum 3 bar pressure, blowing air from
inside filter element outwards (Fig. 3);
156NM52
1262 HD9 Euro3
178NM88
1264 HD9 Euro3
1 COOLING SYSTEM
Expansion chamber
Version with normal cooling system (Fig. 1).
Version with supplementary cooling system
(Fig. 2).
HD9ST0055L
HD9 Euro3 1265
228NMR01
1 266 HD9 Euro3
antifreeze
156NM61
water
1 MULTIPOWER PTO
Oil level check
Proceed as follows:
D with the engine off remove the dipstick
(Fig. 1, ref. 1) and check that oil level is
between the notches on the dipstick, then
replace it;
D if necessary, top-up the level as shown in
285ANM001L the following paragraph.
1272 HD9 Euro3
1 Oil change
Proceed as follows:
D place a suitable container, clean the area
around the level plug and remove it (Fig. 1,
ref. 1);
D remove the drain plug (Fig. 2, ref. 1) fully
drain off the oil;
D clean the drain plug, check that the thread
is in good condition, replace the O-ring
285ANM002L
and close it;
D fill with the required quantity of fluid as
shown on the cap (Fig. 1, ref. 1);
2 D clean the filler cap, check that the thread is
in good condition, replace the O-ring and
close it;
D test drive then check level again, removing
the screw (Fig. 2, ref. 2) waiting for oil to
stop draining then replacing the screw;
D top-up the level if necessary.
Proceed as follows:
228NMR02
D position a suitable container then remove
the cover (Fig. 2, ref. 1);
D remove the filter (Fig. 2, ref. 2) and recover
the seal (Fig. 2, ref. 3);
D refit the filter following above instructions
in reverse order.
1 274 HD9 Euro3
1 TRANSMISSION
1 Oil change
Proceed as follows:
D place a suitable container, clean the area
around the level plug and remove it (Fig. 1,
ref. 1);
D remove the drain plug (Fig. 2, ref. 1) fully
drain off the oil;
D clean the drain plug, check that the thread
is in good condition, replace the O-ring
228NM227
and close it;
D fill with the specified oil until it flows from
the plug hole (Fig. 1, ref. 1);
2 D clean the level plug, check that the thread
is in good condition, replace the O-ring
and close it;
D carry out a test drive then re-check level at
plug (Fig. 1, ref. 1);
D if necessary, top-up with specified oil until
it flows from the hole, repeat the test drive
and check the level again.
228NM228
1 276 HD9 Euro3
1 GEARBOX
Oil level check
1 Oil change
Version standard
Proceed as follows:
D clean the level/filler cap zone (Fig. 1, ref. 1)
then remove the cap;
D prepare an appropriate container and
remove the drain cap (Fig. 2, ref. 1) ;
D clean the drain cap, check that the thread-
342BMM009L ing is in good condition, replace the seal-
ing ring with a new one and close the drain
cap;
2 D fill with prescribed lubricant through the
level/filler cap (Fig. 1, ref. 1) until it over-
flows;
D clean the level/filler cap, check that the
thread is in good condition, replace the
o-ring and close the cap;
D run a road test, check the level through the
cap (Fig. 1, ref. 1);
D if required, top up oil of the specified type
342BMM011L until it spills out of the hole. Repeat the
road test and check the level again.
1 278 HD9 Euro3
HD9ST0102L
HD9 Euro3 1279
357ANM102L
HD9ST0103L
1280 HD9 Euro3
Proceed as follows:
D prepare an appropriate container;
D unscrew the fastening screws (Fig. 1, ref.
1) and remove the cover (Fig. 1, ref. 2);
D remove the filter (Fig. 1, ref. 3) from the
cover;
When refitting, lubricate the
O-rings (Fig. 1, ref. 4) of the filter.
357ANM104L
1282 HD9 Euro3
1 HYDROMECHANICAL GEARBOX
Oil level check
Perform the check with the vehicle on
level ground, after idling the engine for a
few minutes, with the oil cold (30 ---40 ˚ C),
the vehicle braked and the 8th gear
engaged.
Perform the following:
HD9ST0089L D clean the area around the cap, then open
the level cap (Fig. 1, ref. 1): the lubricant
should leak from the hole;
D if necessary, restore the operating level as
shown in the following paragraph;
D close the level cap.
Check the breather (Fig. 1, see arrow), which
must be clean and running.
1284 HD9 Euro3
2 Oil changing
Perform the following:
D prepare a container of suitable size, clean
the area around the cap and remove the
level cap (Fig. 1, ref. 1);
D remove the drain plugs (Fig. 1, ref. 2) and
completely drain the lubricant;
D clean the drain plugs, ensure that the
thread is in good condition, replace the
O ---ring and close them;
D remove the filler cap (Fig. 1, ref. 3), and
refill with the prescribed lubricant until it
overflows from the hole of the level cap
(Fig. 1, ref. 1);
D start the engine by running it at a min-
imum, with the vehicle braked and in 8th
gear, and add more oil from the hole of the
filler cap (Fig. 1, ref. 3) until it comes out of
the hole of the level cap (Fig. 1, ref. 1);
D clean the filler and level caps, ensure that
HD9ST0088L
the thread is in good condition, replace the
O ---ring and close them without tighten-
ing;
D run the engine for 2 or 3 minutes at
medium speed (about 1200 rpm);
D bring the engine back to minimum, with
the vehicle braked and in 8th gear, re --- -
open the filler cap (Fig. 1, ref. 3) and level
cap (Fig. 1, ref. 1), and add more oil until
it flows from the hole of the level cap (Fig.
1, ref. 1);
D close the level cap and the filler cap.
HD9 Euro3 1285
1 AUTOMATED TRANSMISSION
Checking oil level
1 Changing oil
Version standard
Proceed as follows:
D clean the level/filler cap zone (Fig. 1, ref. 1)
then remove the cap;
D prepare an appropriate container and
remove the drain caps (Fig. 1, ref. 2) and
(Fig. 2, ref. 1) emptying out all the lubric-
357ANM105L ant;
D clean the drain caps, check that the
threading is in good condition, replace the
2 o-ring with a new one and close the drain
caps;
D fill with the specified oil until it flows from
the level/filler cap (Fig. 1, ref. 1);
D clean the cap, check that the threading is
in good condition, replace the O-ring with
a new one and close the cap;
D run a road test, check the level through the
cap (Fig. 1, ref. 1);
357ANM107L D if required, top up oil of the specified type
until it spills out of the hole. Repeat the
road test and check the level again.
1 288 HD9 Euro3
357ANM102L
HD9ST0103L
1290 HD9 Euro3
Proceed as follows:
D prepare an appropriate container;
D unscrew the fastening screws (Fig. 1, ref.
1) and remove the cover (Fig. 1, ref. 2);
D remove the filter (Fig. 1, ref. 3) from the
cover;
When refitting lubricate the
O-rings (Fig. 1, ref. 4) of the filter.
357ANM104L
1292 HD9 Euro3
1 AUTOMATIC TRANSMISSION
Checking oil level
HD9ST0104L
HD9 Euro3 1297
Proceed as follows:
D arrange a container of appropriately
capacity, clean the area around the
flanges and then loosen the fasten screws
274NM1C2 (Fig. 1, ref. 1) and remove the flange (Fig.
1, ref. 2) and the seals (Fig. 1, ref. 3);
D remove the cartridge (Fig. 1, ref. 4);
1 DISTRIBUTOR-TRANSFER (TRANSFER)
--- TYPE I
Oil level check
Proceed as follows:
D clean the area around the level plug and
remove it (Fig. 1, ref. 1): oil should drip
from the hole;
D if necessary, top-up the level as shown in
the following paragraph;
238NM10 D close the level plug.
1 Oil change
Proceed as follows:
D place a suitably sized container, clean the
area around the plugs then remove the
level plug (Fig. 1, ref. 1); and filler cap
(Fig. 1, ref. 2);
D unscrew the plugs (Fig. 2, ref. 1) and fully
drain off the oil;
D clean the drain plug, check that the thread
238NM10 is in good condition, replace the O-ring
and close it;
D prepare 6.5 litres of fresh oil;
D fill through the filler cap (Fig. 1, ref. 2) until
2 oil flows from the level plug (Fig. 1, ref. 1);
D clean the filler cap and level plug, check
that the thread is in good condition,
replace the O-rings and close them;
D drive the vehicle for a few minutes to allow
oil to reach all transfer components, then
stop and wait ten minutes for the oil to
settle;
D remove the level plug (Fig. 1, ref. 1): oil
238NM11 should flow from the hole. If not, top up
level exclusively through the cap (Fig. 1,
ref. 2) until oil flows from the level plug
(Fig. 1, ref. 1);
D close both the level plug and filler cap.
1302 HD9 Euro3
1 DISTRIBUTOR-TRANSFER (TRANSFER)
--- TYPE II
Checking oil level
Proceed as follows:
D Clean the area around the filler/level plug
then open it (Fig. 1, ref. 1): oil should arrive
at the edge of the hole;
D Top up with the specified lubricant, if
necessary, through the same hole;
D Close the plug;
D Check that the breather (Fig. 1, see arrow)
is perfectly clean and functional.
272CNU101
HD9 Euro3 1303
1 Changing oil
Proceed as follows:
D Place a suitably sized container, clean the
area around the plug then remove the level
plug (Fig. 1, ref. 1);
D Remove the drain plug (Fig. 1, ref. 2) and
fully drain the oil;
D Clean the drain plug, check that the thread
is in good condition, replace the o-ring and
close it.
D Fill with the specified oil until it flows from
the plug hole (Fig. 1, ref. 1);
D Clean the level plug, check that the thread
is in good condition, replace the o-ring and
close it;
D Carry out a test drive then re-check level at
plug (Fig. 1, ref. 1);
D If required, top up with oil of the specified
type, repeat the road test and check the
level again.
272CNU101
1304 HD9 Euro3
1 SPLITTER-REDUCER (TRANSFER
CASE) --- TYPE III
Checking oil level
Proceed as follows:
D clean the cap area and open the level cap
(Fig. 1, ref. 3): the lubricant must reach the
edge of the hole;
D top up, if required, with oil of specified type
through the same hole;
D close the cap;
D check the breather (Fig. 1, see arrow): it
must be perfectly clean and functioning.
307HNM001L
HD9 Euro3 1 305
1 TRANSMISSION SHAFTS
Greasing
Proceed as follows:
D clean the joint concerned;
D Inject grease into the universal joint grease
nipples (Fig. 1, see arrow) each trans-
mission shaft has two or three greasing
points.
178NM46
Inject grease until it seeps from the
grease nipples to ensure efficient lubrica-
tion
A hand pump must be used for greasing,
and never a high pressure grease gun.
HD9 Euro3 1307
1 AXLES
Front axle
Check differential oil level
Proceed as follows:
D clean the area around the level plug and
remove it (Fig. 1, ref. 1): oil should drip
from the hole;
228NM230
D if necessary, top-up the level as shown in
the following paragraph;
D close the level plug.
Check that the breather (Fig. 1, see arrow) is
perfectly clean and functioning.
Differential oil change
Proceed as follows:
D place a suitable container, clean the area
around the level plug (Fig. 1, ref. 1) and
remove it; (Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) fully
drain off the oil;
D clean the drain plug, check that the thread
is in good condition, replace the O-ring
and close it;
D fill with the specified oil until it flows from
the plug hole (Fig. 1, ref. 1);
D clean the level plug, check that the thread
is in good condition, replace the O-ring
and close it;
D carry out a test drive then re-check level at
plug (Fig. 1, ref. 1);
D if necessary, top-up with specified oil until
it flows from the hole, repeat the test drive
and check the level again.
1 308 HD9 Euro3
Proceed as follows:
D turn the plug (Fig. 1, ref. 1) such that the
reference mark is horizontal;
D clean the plug zone and open the plug
178NM50 (Fig. 1, ref. 1): oil should drip from the hole;
D if necessary, top-up the level as shown in
the following paragraph;
D close the level plug.
HD9 Euro3 1309
Proceed as follows:
D turn any of the screws (Fig. 1, ref. 2) in the
lowest position, until the cap is situated
aloft;
178NM50 D clean the area around the cap, then open
it (Fig. 1, ref. 1);
D place a suitably sized container, clean the
area around the level plug (Fig. 1, ref. 2)
and remove it fully draining off the oil;
D tighten the screw;
D position cap hole (Fig. 1, ref. 1) in horizon-
tal position;
D fill up with new oil until it overflows from
hole (Fig. 1, ref. 1);
D clean the drain plug, check that the thread
is in good condition, replace the O-ring
and close it;
D repeat operation for the other hub;
D carry out a test drive, then re-check the
level at plug (Fig. 1, ref. 1);
D if necessary, top-up with specified oil until
it flows from the hole, repeat the test drive
and check the level again.
1310 HD9 Euro3
Proceed as follows:
D adjust the cap (Fig. 1, ref. 1) so that it is
arranged in horizontal position;
D clean the cap area and open the level cap
276NM019T (Fig. 1, ref. 1): the lubricant must flow out
of the hole;
D top up the level as shown in the following
paragraph, if required;
D close the filler cap.
1312 HD9 Euro3
Proceed as follows:
D take any of the screws (Fig. 1, ref. 2) to the
lowest position, so that the cap (Fig. 1, ref.
1) is facing upwards;
276NM019T D clean the cap area and open the cap (Fig.
1, ref. 1);
D arrange a suitably sized container, clean
the screw area and remove it (Fig. 1, ref. 2)
and drain the lubricant completely;
D tighten the screw;
D adjust the cap (Fig. 1, ref. 1) so that it is
arranged in horizontal position;
D fill until oil spills out the of the hole on the
cap (Fig. 1, ref. 1);
D clean the cap, check that the threading is
in good condition, replace the o-ring and
close it;
D repeat the procedure on the other hub;
D run a road test, check the cap level (Fig. 1,
ref. 1);
D if required, top up oil of the specified type
until it spills out of the hole. Repeat the
road test and check the level again.
HD9 Euro3 1313
1 Changing oil
Proceed as follows:
D on either of the hubs, turn any of the
screws (Fig. 2, ref. 1) in the lowest position;
D position a container with adequate capac-
ity, clean the zone around the plugs and
then remove the level plug (Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) and
(Fig. 3, ref. 1) and both the screws (Fig. 2,
228NM232
ref. 1) and completely drain off the oil, then
refasten the screws;
D clean the drain plugs, check that the
2 thread is in good condition, replace the
o-rings and close them;
D fill with the specified oil until it flows from
the plug hole (Fig. 1, ref. 1);
228NM233 1
1 316 HD9 Euro3
1 Rear axle
Oil level check
Proceed as follows:
D clean the area around the level plug and
remove it (Fig. 1, ref. 1): oil should drip
from the hole;
D if necessary, top-up the level as shown in
the following paragraph;
228NMR09 D close the level plug.
Check that the breather (Fig. 1, see arrow) is
perfectly clean and functioning.
HD9 Euro3 1317
1 Changing oil
Proceed as follows:
D on either of the hubs, turn any of the
screws (Fig. 2, ref. 1) to the lowest position;
D position a container with adequate capac-
ity, clean the zone around the plugs and
then remove the level plug (Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) and
both the screws (Fig. 2, ref. 1) and fully
228NMR09
drain off the oil, then refasten the screws;
D clean the drain plug, check that the thread
is in good condition, replace the o-ring and
2 refit the plug.
D fill with the specified oil until it flows from
the plug hole (Fig. 1, ref.; 1);
1 SUSPENSIONS
Leaf spring pins greasing
Fig. 1: Support pin
Fig. 2: Support plate
Proceed as follows:
D clean the relevant union;
D inject grease in the pressure unions of leaf
342BNM012L spring joints (see arrow).
342BNM013L
HD9 Euro3 1319
342BNM015L
342BNM016L
1320 HD9 Euro3
1 STEERING SYSTEM
Oil level check
Proceed as follows:
D park the vehicle with the engine off and
wheels straight;
D clean the area around the plug, then
unscrew the plug and check that the reser-
voir oil level is between the two notches
228NM236 (Fig. 3) on the dipstick;
D if necessary top-up the level and close the
plug.
3
228NM237
HD9 Euro3 1321
178NM60
1 326 HD9 Euro3
272NM005X
HD9 Euro3 1327
228NMR11
1328 HD9 Euro3
Proceed as follows:
D set the wheels so that they are pointing forwards;
D check that the distances A and B measured along the centreline of the rims at the same
height from the ground, correspond to the specified values.
Fore-carriage Measurement
1st axle B = A --- (1 / 3 mm)
2nd axle B=A
C D E
1 2
1 2
1 330 HD9 Euro3
1 BRAKING SYSTEM
Shoe-drum play check
Inflating tyres
Proceed as follows:
D remove the protective cap and connect
the inflation device fitting to the valve
(Fig. 1, see arrow);
D take to specified pressure;
D disconnect the fitting and close the protec-
tive cap.
HD9 Euro3 1335
1 Greasing
Proceed as follows:
D tip the cab;
D grease the mechanism of both cab stop
hooks (Fig. 1, ref. 1);
D grease the telescopic manual trans-
mission control rod (Fig. 1, ref. 2).
357ANM001L
HD9 Euro3 1 337
1 TOWING SYSTEMS
Greasing the fifth wheel
Fig. 1: fixed fifth wheel
Fig. 2: pivoting fifth wheel
Proceed as follows:
D release the semi-trailer from the tractor;
D clean the surface of the fifth wheel plate
307FNM002L and the semi-trailer hitching plate;
D apply plenty of grease the fifth wheel plate,
the locking mechanism for the fifth wheel,
2 the coupling pin and semi-trailer attach-
ment plate;
D the rubber buffers require no mainten-
ance;
D clean the concerned fitting;
D inject grease in the pressure fittings of the
fifth wheel (see arrow).
307FNM003L
Inject lubricant until it pours out of the
lubricated points to ensure efficient
lubrication.
Use a manual grease dispenser only.
Never use a high pressure grease dis-
penser.
1 AIR CONDITIONER
Air-conditioner system maintenance
Proceed as follows:
D open the radiator grill;
D remove the cover (Fig. 1, see arrow) and
replace dust filter;
D inspect and clean the condenser with
compressed air (max 5 bar).
342BNM018L
1340 HD9 Euro3
11 SUPPLEMENTARY HEATER
Replacing the supplementary heater fuel
filter
Proceed as follows:
D arrange a container of appropriate capac-
ity and clean the filter area;
D unscrew the cup (Fig. 1, see arrow) using
the wrench if necessary, and remove it
357ANM108L from its seat;
D replace the filter cartridge;
1 BODYWORK
Replacing front windscreen wiper blade
(Fig. 1)
Proceed as follows:
D lift the arm and blade;
D push the blade backwards, disengaging it
from the stop and removing it;
D fit the correct adapter on the new blade
357ANM109L and approach the blade to the clip to
fasten it in the adapter;
D pull the blade fastening the adapter clip.
2
Observe the specifications provided by
Temperature Product Water
the supplier.
---35 ˚C 1 0
---20 ˚C 1 1 Windscreen washer reservoir
---10 ˚C 1 2 You are advised to use a specific antifreeze
0 ˚C 1 6 product mixed with water as shown in the
summer 1 10 table (Fig. 2).
178NM80 Proceed as follows:
D open the radiator grill;
D unscrew the plug (Fig. 3, see arrow) and fill
3 until completely full;
D replace the cap and close the grill.
342BNM004L
HD9 Euro3 1343
Bodywork maintenance
Periodically wash the vehicle with neutral detergent and water to remove any corrosive ag-
ents (salt, sand, etc.).
Dry accurately with compressed air to fully eliminate any stagnating water.
Do not use products containing aromatic solvents, methanol or hydrocarbons for cleaning
paintwork.
Do not wash inside the cab with a jet of water or steam.
Cleaning plastic parts
Plastic parts should be cleaned using the same procedure as for normal washing.
For any remaining traces of dirt use specific products, carefully following the manufacturer’s
recommendations.
Do not use products containing aromatic solvents, methanol or hydrocarbons for ceaning
paintwork.
Fabric panels cleaning
1 LIGHTING SYSTEM
Headlight/front sidelight bulb replace-
ment
Proceed as follows:
D unhook the guard grill by rotating it toward
the outside (Fig. 1, see arrow);
D unscrew the screws (Fig. 2, see arrow) on
the inside of the fenders and rotate the
228NMR21 complete headlight group toward the out-
side;
D remove the corresponding cover (Fig. 3):
2 1. headlight
2. side light
3. high beams
D disconnect the electrical connector;
D release the bulb retaining spring and
remove the halogen bulb
or
D remove the sidelight bulb;
228NMR22 Never touch a halogen bulb with fingers,
to avoid damage.
228NMR23
HD9 Euro3 1 345
1 Headlight alignment
After dismantling the headlights or following
crash damage, the headlights have to be
realigned.
It is advisable to use specific equipment for
this operation.
However, a sufficiently correct alignment can
be achieved proceeding as follows:
D park the unladen vehicle, with tyres at cor-
178NM103
rect pressure, on flat ground nearly up
against a light coloured wall;
D mark two crosses on the wall, correspon-
2 ding to the two headlights (Fig. 1);
D back the vehicle up 10 m and shine the
headlights (Fig. 1) on the wall. The dis-
tance between the crosses and reference
points P-P must be equal to the percen-
tage of the distance between the vehicle
and the wall indicated on the specific plate
(Fig. 2);
D if necessary, use the adjuster screws
238NM51 (Fig. 3):
1. vertical adjustment
2. horizontal adjustment
3
For vehicles fitted with adjustable head-
lights, turn the adjuster knob to position
0.
228NMR24
1 346 HD9 Euro3
1 2
228NMR27 228NMR28
1 1
Front clearance light bulb replacement
Proceed as follows:
D remove the fastening screws and remove
the complete light (Fig. 1, ref. 1);
D for replacement, follow the removal
instructions in reverse order.
Rotary warning light bulb replacement
Proceed as follows:
228NMR29
D remove the screws and the cover (Fig. 2,
ref. 1);
D replace the bulb;
2
D for replacement, follow the removal
instructions in reverse order.
Ceiling light bulb replacement
Proceed as follows:
D insert a screwdriver between the light fit-
ting and cabin interior lining (Fig. 3, ref. 1);
lever off the fitting and replace the bulb.
228NMR30 D for replacement, follow the removal
instructions in reverse order.
Replacing cab step light
3 Proceed as follows:
D press and turn the bulb anti-clockwise
(Fig. 3, ref. 2).
D For replacement, follow the removal
instructions in reverse order.
228NMR31
HD9 Euro3 1349
List of bulbs
Lights:
--- main beam and dipped beam light Double filament halogen 75/70
--- position Round 4
Front direction indicator Round 21
Side direction indicator Round 21
Rear lights:
--- position/brake (stop) Round double filament 5/21
--- turn Round 21
--- reverse Round 21
--- rear foglight Round 21
Number plate light Round 10
Overall light Round 5
Rotating light Round 21
Rear light Round 21
Cabin ceiling light Round/cylindrical 5/5
Instrument panel/warning lights All glass 1.2
Warning lights All glass 1.2
1 350 HD9 Euro3
1 ELECTRICAL SYSTEM
Precautions
Make absolutely sure that the electrical
power is disconnected before working di-
rectly or indirectly on electrical system parts
by operating the battery disconnect switch
(Fig. 1).
A: power off
B: power on
272CNU093
The vehicle electrical system should work
even if the fitted battery is flat.
In order to avoid incorrect interventions
which may irreversibly damage the elec-
tronic control units installed on board the ve-
hicle the following recommendations should
be followed:
D when work on the chassis requires arc
welding the connector should be removed
from the control units: when welding is to
be carried out near the control units,
remove the units;
D after a service operation requiring battery
disconnection, make sure that the ter-
minals are well connected;
D never use a battery charger to start the
engine;
D disconnect the batteries to recharge them;
D do not disconnect or connect the con-
nectors to the electronic control unit when
the engine is running or control units are
powered;
D do not disconnect the batteries when the
engine is running;
D remove the electronic control units in the
event of operations at temperatures
exceeding 80˚C (oven painting, etc.).
HD9 Euro3 1 351
Proceed as follows:
D lay the cables on the ground ensuring that
the terminals do not touch metal parts or
each other. Connect the red cable (Fig. 1,
ref. a) to the POSITIVE terminal of the flat
battery;
D connect the black cable (Fig. 1, ref. b) to
the NEGATIVE terminal of the flat battery;
D set the recharge time and current. Start re-
charging.
1354 HD9 Euro3
Proceed as follows:
D cut---out electric power supply acting on
the battery master switch;
D remove the battery compartment cover
(Fig. 1):
D disconnect the battery as follows:
--- disconnect the negative terminal;
--- disconnect the positive terminal.
D remove the flat batteries;
D thoroughly clean the battery compart-
ment, removing oxides and grime;
D install the new batteries;
D connect the battery leads as follows:
--- connect the positive terminal;
--- connect the negative terminal.
D smear pure Vaseline on the terminals;
D replace the battery compartment cover.
D activate electric power supply.
HD9 Euro3 1355
Fuse replacement
Proceed as follows:
342BNM021L D disconnect the batteries from the battery
master switch;
D remove the compartment lid;
3 D remove the blown fuse from its housing;
D fit a new fuse WITH THE SAME AMPERES
as the blown fuse;
D refit the compartment lid;
342BNM022L
1356 HD9 Euro3
342BNM023L
HD9 Euro3 1 357
FUSES
Fuse holder (70005)
RELAYS
CODE
REF. DESCRIPTION
COMPONENT
001 Relay for climate control 25332
002 Resistor holder for PTO parameter setting 61125
003 Synchro protection engagement relay 25611
004 Power steering failure warning light control relay 25868
005 Horn relay 25805
006 Lights on relay 25806
007 Flywheel PTO engagement enable relay 25701
008 PTO1 engagement relay 25704
009 PTO2 engagement relay 25897
010 PTO3 engagement relay 25898
011 PTO1 parameter setting recall relay (outfitters)
012 PTO2 parameter setting recall relay (outfitters)
013 PTO3 parameter setting recall relay (outfitters)
014 SET adjustment relay +( outfitters) (outfitters)
015 SET adjustment relay --- ( outfitters) (outfitters)
016 PTO engaged confirmation relay (outfitters)
017 Idle gear confirmation relay (outfitters)
018 External cruise activation relay (outfitters)
019 Reverse light relay for vehicle with automatic or automated transmission 25030
HD9 Euro3 1 361
RELAYS
CODE
REF. DESCRIPTION
COMPONENT
A Diodes holder EV PTO outfitter wiring (outfitters)
B Vehicle doors open locking relay 25500
C --- ---
D --- ---
E --- ---
F Terminal 15a/50A relay 25213A
G Window washer level delay relay 25907
H 40A engeine start relay 25200
I Fuel pre-filter heating relay 25825
L Terminal 15b/50A relay 25213B
1 362 HD9 Euro3
HD9STO106L
HD9ST0075L
272NM009X
There is a flying fuse holder near to the batteries, which contains a 20A fuse.
HD9 Euro3 1 365
INTRODUCTION
Scheduled maintenance intervals refer to normal operating conditions. They may vary according to the type of use, road
and environmental conditions.
If in doubt or faults not possible to correct with normal maintenance, contact the Dealer.
1368 HD9 Euro3
342BTB007L
HD9 Euro3 1 369
1 semi-trailer fifth wheel/tow hook greaser 18 oil/power take off oil filter
2 cardan joint greaser 19 transmission oil
3 not used 20 transmission oil filter
4 leaf spring articulation greaser 21 transfer oil (only 4x4 version)
5 stub axle greaser 22 front axle final reductions oil (only 4x4 version)
6 not used 23 front axle oil (only 4x4 version)
7 not used 24 not used
8 VGT actuator grease application procedure 25 not used
9 engine oil vapour filter 26 not used
10 engine oil 27 rear axle and final reductions oil
11 engine oil filters 28 power steeling oil
12 VGT filter 29 power steeling filter
13 clutch control system oil 30 not used
14 fuel filters 31 air conditioning fluid
15 main/secondary air cleaner 32 air cleaner of air conditioning
16 engine coolant 33 compressed air drier filter
17 not used 34 not used
35 cabin tilting oil
342BTB006L
HD9 Euro3 1 371
342BTD005L
HD9 Euro3 1 373
1 semi-trailer fifth wheel/tow hook greaser 18 oil/power take off oil filter
2 cardan joint greaser 19 transmission oil
3 rear carriage articulation greaser 20 transmission oil filter
4 leaf spring articulation greaser 21 transfer oil (only 8x6 and 8x8 version)
5 stub axle greaser 22 front axle final reductions oil (only 8x6 and 8x8
6 steering linkages greaser (only 4-axle vehicles) version)
7. not used 23 front axle oil (only 8x6 and 8x8 version)
8 VGT actuator grease application procedure 24 second axle final reductions oil (8x8 only)
9 engine oil vapour filter 25 second axle oil (8x8 only)
10. engine oil 26 intermediate axle and transfer case oil
11 engine oil filters 27 rear axle and final reductions oil
12 VGT filter 28 power steeling oil
13 clutch control system oil 29 power steeling filter
14. fuel filters 30 not used
15 main/secondary air cleaner 31 air conditioning fluid
16 engine coolant 32 air cleaner of air conditioning
17 not used 33 compressed air drier filter
34 not used
35 cabin tilting oil
SERVICE SCHEDULE
Checking, adjusting and cleaning operations
hours
OPERATION day year
400 800 1600
Check engine oil level X
Check engine coolant level X
Check service brake and parking brake X
Check external lights, dashboard warning lights and windscreen wiper X
Windscreen washer fluid level check X
Check trailer pintle /semi-trailer fifth wheel condition X
Bleed compressed air tank X
Check tyre pressure/conditions X
Fuel filter check/water drain (1) X
Check tightness of wheel fasteners (2) X
Turbocompressor intake/lubrication system seal check X
Check clutch control oil level X
Check gearbox oil level X
Check transfer oil level X
Check transfer case oil level X
Check axle oil level X
Pedal distributors check X
Tow hook/thrust washer functioning check X
Check compressed oil dryer function/if necessary bleed off condensation from
X
tank(s)/visual inspection of tanks
Battery maintenance (unsealed batteries) X
(1) or when respective warning light comes
(2) after 20-40 km and again after 100 km when the vehicle is new or after changing the wheel.
The table indicates the time interval
between two consecutive operations.
HD9 Euro3 1 375
(1) with a NEW vehicle, change engine oil the first time after 800 hours of operation
(2) or when respective warning light comes on
(3) or after every three main filter replacements
342BTB001L
HD9 Euro3 1 379
LOCATION OF COMPONENTS
Engine F3B
Key (see diagram on previous page)
HD9ST0064L
1380 HD9 Euro3
LOCATION OF COMPONENTS
Engine F2B
342BTB002L
HD9 Euro3 1 381
LOCATION OF COMPONENTS
Engine F2B
Key (see diagram on previous page)
LOCATION OF COMPONENTS
Manual transmission
HD9ST0107L
HD9 Euro3 1 383
LOCATION OF COMPONENTS
Manual transmission
Key (see diagram on previous page)
LOCATION OF COMPONENTS
Automated/automatic transmission
357ATB201L
HD9 Euro3 1 385
LOCATION OF COMPONENTS
Automated/automatic transmission
Key (see diagram on previous page)
LOCATION OF COMPONENTS
Multipower/NMV 221 power take off
272CNM005
HD9 Euro3 1 387
LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
Drive-line
272CNM007
HD9 Euro3 1 389
LOCATION OF COMPONENTS
Drive-line
Key (see diagram on previous page)
21 reducer-distributor oil
22 final transfer case oil of 1st front axle
23 1st front axle oil
24 final transfer case oil of 2nd front axle
25 2nd front axle oil
26 intermediate axle and final transfer case oil
27 rear axle and final transfer case oil
1390 HD9 Euro3
LOCATION OF COMPONENTS
Greasing transmission shafts
272CNM008
HD9 Euro3 1 391
LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
Suspension geasing
272CNM009
HD9 Euro3 1 393
LOCATION OF COMPONENTS
Suspension geasing
Key (see diagram on previous page)
3 rear carriage articulation greaser
4 leaf spring joint greaser
1394 HD9 Euro3
LOCATION OF COMPONENTS
Steering linkages, semi-trailer fifth wheel, tow hook greasing
272CNM010
HD9 Euro3 1 395
LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
Systems
HD9ST0108L
HD9 Euro3 1 397
LOCATION OF COMPONENTS
Systems
Key (see figure on previous page)
28 power steering oil
29 power steering oil filter
31 air conditioner system fluid
32 air conditioner filter
33 compressed air dryer filter
35 cab tipper oil
36 oil/oil filter supplementary fan system
1 398 HD9 Euro3
CAPACITY
PARTS TO SUPPLY SPECIFICATIONS
Iitres kg
Additional fan hydraulic circuit
--- TUTELA GI/A D ---21105 12 --- ATF DEXRON II
HD9 Euro3 1 399
TIGHTENING TORQUES
Tightening
Wrench
Fig. Assembly Ref. Function Type torque
(mm)
(Nm)
1 Motor F3B A Filling Screw cap --- ---
B Level Extractable dipstick --- ---
C Draining Screw TE M14x1,5 Wrench 22 TBD
D Oil filter Screw cartridge For filters ---
2 Motor F2B A Filling Screw cap --- ---
B Level Extractable dipstick --- ---
C Draining Screw TE M14x1,5 Wrench 22 TBD
D Oil filter Screw cartridge For filters ---
3 Multipower power take-off A Filling and level Extractable dipstick --- ---
C Draining Screw TCEI M22x1,5 Hex key 12 TBD
D Oil filter cover Screw TCEI M42 Hex key 24 TBD
4 Power take-off A Filling and level see transmission --- ---
C Draining see transmission --- ---
D Oil filter cover Screw TE M8x1,25 Wrench 13 2025
HD9 Euro3 1 401
1 2
3 4
HD9ST0141L
1 402 HD9 Euro3
TIGHTENING TORQUES
Tightening
Wrench
Fig. Assembly Ref. Function Type torque
(mm)
(Nm)
1 ZF manual transmission A Filling and level Screw TE M14x1,5 Wrench 22 54 ÷ 66
(ECOSPLIT 4) C Draining Screw TE M14x1,5 Wrench 22 54 ÷ 66
E Radiator couplings Nut M22x1,5 Fixed 32 ---
2 ZF automated A Filling and level Screw TE M14x1,5 Wrench 22 54 ÷ 66
transmission C Draining Screw TE M14x1,5 Wrench 22 54 ÷ 66
(ASTRONIC 2) E Radiator couplings Nut M22x1,5 Fixed 32 ---
3 Retarder ZF A Filling and level see transmission --- ---
(INTARDER 3) C Draining Screw TE M14x1,5 Wrench 22 54 ÷ 66
D Oil filter cover Screw TE M8x1,25 Wrench 13 20 ÷ 25
F Heat exchanger couplings Nut Fixed 50 ---
HD9 Euro3 1 403
1 2
HD9ST0142L
1 404 HD9 Euro3
TIGHTENING TORQUES
Tightening
Wrench
Fig. Assembly Ref. Function Type torque
(mm)
(Nm)
1 ALLISON automatic A Filling and level Screw cap --- ---
transmission C Draining Screw Panel 10 25 ÷ 32
(4500/4700) D Oil filter cover Screw TBD 51 ÷ 61
E Radiator couplings Nut M22x1,5 Fixed 32 ---
F Heat exchanger couplings Nut Fixed 50 ---
2 ZF hydromechanical A Filling Screw TE TBD TBD
Transmission B Level Screw TE Wrench 26 TBD
(ECOSPLIT 3 + WSK) C Draining Screw TE Wrench 26 TBD
D Oil filter cover Nut M8x1,25 Wrench 13 20 ÷ 25
E WSK draining Screw TE M8x1,25 Wrench 13 20 ÷ 25
HD9 Euro3 1 405
1 2
HD9ST0143L
1 406 HD9 Euro3
TIGHTENING TORQUES
Tightening
Wrench
Fig. Assembly Ref. Function Type torque
(mm)
(Nm)
1 Transfer box STEYR A Filling and level Screw TE M12X1,5 Wrench 19 TBD
(VG 2700) C Draining Screw TCEI M20X1,5 Hex key 10 TBD
2 Transfer box IVECO A Filling Screw TE M22x1,5 Wrench 19 63 ÷ 77
(TC 2200) B Level Screw TE M22x1,5 Wrench 19 63 ÷ 77
C Draining Screw TCEI M27x2 Hex key 12 50 ÷ 60
3 Transfer box STEYR A Filling Screw TE M12X1,5 Wrench 19 TBD
(VG 2000) B Level Screw TE M12X1,5 Wrench 19 TBD
C Draining Screw TCEI M20X1,5 Hex key 10 TBD
HD9 Euro3 1 407
1 2
HD9ST0144L
1 408 HD9 Euro3
TIGHTENING TORQUES
Tightening
Wrench
Fig. Assembly Ref. Function Type torque
(mm)
(Nm)
1 I front axle IVECO A Rear axle filling and level Screw TE M14x1,5 Wrench 17 60 ÷ 70
B Rear axle draining Screw TCEI M14x1,5 Hex key 12 60 ÷ 70
C Hub filling and level Screw TE M22x1,5 Wrench 22 45 ÷ 55
D Hub draining Screw TE M10x1,5 Wrench 17 45 ÷ 55
2 II front axle IVECO A Rear axle filling and level Screw TE M14x1,5 Wrench 17 60 ÷ 70
B Rear axle draining Screw TCEI M14x1,5 Hex key 12 60 ÷ 70
C Hub filling and level Screw TE M22x1,5 Wrench 22 45 ÷ 55
D Hub draining Screw TE M10x1,5 Wrench 17 45 ÷ 55
F Transfer box draining Screw TE Wrench 22 TBD
3 Rear intermediate A Rear axle filling and level Screw TE M14x1,5 Wrench 17 60 ÷ 70
axle IVECO B Rear axle draining Screw TCEI M14x1,5 Hex key 12 60 ÷ 70
D Hub draining Screw TE M10x1,5 Wrench 17 45 ÷ 55
F Transfer box draining Screw TE Wrench 19 TBD
4 Rear axle IVECO A Rear axle filling and level Screw TE M14x1,5 Wrench 17 60 ÷ 70
B Rear axle draining Screw TCEI M14x1,5 Hex key 12 60 ÷ 70
D Hub draining Screw TE M10x1,5 Wrench 17 45 ÷ 55
HD9 Euro3 1 409
1 2
3 4
HD9ST0145L
1 410 HD9 Euro3
TIGHTENING TORQUES
Tightening
Wrench
Fig. Assembly Ref. Function Type torque
(mm)
(Nm)
1 I front axle KESSLER A Rear axle filling and level Screw TE M30x1,5 Wrench 24 150 ÷ 170
B Rear axle draining Screw TCEI M16x1,5 Hex key 8 54 ÷ 66
C Hub filling and level Screw TCEI M24x1,5 Hex key 12 110 ÷ 130
D Hub draining Screw TCEI M16x1,5 Hex key 8 54 ÷ 66
HD9 Euro3 1 411
HD9ST0146L
1 412 HD9 Euro3
Appendix
1 414 HD9 Euro3
WARNING
This appendix contains the use standards of the AsTronic2 V35 version (recognisable by the pushbutton selector on the dashboard in lieu
of the selection lever).
Consult the use standards in this volume for all details not included in this APPENDIX.
1 416 HD9 Euro3
342BNU051L
3
Automated transmission control
3 Selection of the different operating modes is
done through a pushbutton selector (Fig. 3).
1 418 HD9 Euro3
342BNU051L
ALL VEHICLES
INSTRUMENTS
Instrument panel (Fig. 1)
342BNU026L
HD9 Euro3 1 421
357ANU001L
342BNU027L
HD9 Euro3 1423
272GNU007
HD9 Euro3 1 425
1 DISPLAY STRUCTURE
The display is divided into four sections
(A,B,C,D). Each section contains specific
A B C information.
Section A
D Batteries power supply voltage (default)
D Tractor ABS failure
D Power steering 1 circuit failure
D Power steering 2 circuit failure
D Trailer braking system pressure low
D Trailer ABS failure
D Doors open
D Front/rear brakes wear
D Second speed limit engagement
D
D ASR deactivation
D ABS off-road engagement
357ANU002L
D Programmed maintenance time-out
D Cruise control engagement
D Engine cooling liquid level low
D Window washer liquid level low
D Container tipped
Section B
D Logo and outside temperature (default)
D Generic fault
D Serious fault
HD9 Euro3 1 427
1 DISPLAY STRUCTURE
Section C
A B C D Running condition indicator
Section D
D Date - Time - Station/track time (default)
D Steering system failure
D Scheduled maintenance due in 50 hours
D PTO (n˚): rpm
D Headlights geometry adjustment
D Mirrors selection for handling
D Menu
D Front/rear axles braking system pressure
D Engine/transmission oil temperature
D
357ANU002L
1 428 HD9 Euro3
2 Mode symbol
The following cases may occur for the modes below (Fig. 3)
a. automatic mode
b. manual mode
The number of horizontal lines stands for the gears that can be shifted in the current
condition: e.g: three lines = 3 speeds
3 c. manoeuvre mode at low speed
HD9 Euro3 1 431
1 Display operation
Turn the switch to the MAR position: main
systems and their state will appear on the
display.
Display controls
On the steering wheel there are the keys for
the selection and management of certain
functions
1. MENU/OK Key
2. PAGE Key
3. ESCAPE Key
4. Key Y Key B
5. Key + ( ) Key - ( )
272GNU013
HD9 Euro3 1 433
3
S RADIO
S CD
5
2
3 3
S RADIO
1 S VEHICLE DATA
S TRIP 1
S TRIP 2
S CHECK
S LANGUAGE
S PASSWORD
S DISPLAY
2
2 2 2 S BUZZER
S LIGHTS
272GNU200
1 KEY ON (CHECK)
When the key is turned to MAR, the display
shows the following data:
D Time.
D Date.
1 VEHICLE MOTION
When the vehicle is running, the following
data is shown on the display:
D Battery voltage;
D External temperature;
D Transmission conditions;
D Date / PTO engaged and engine speed;
D Time;
357ANU002L
D Radio station / CD track (if there is sound
system with controls on steering wheel).
1436 HD9 Euro3
357ANU008L
357ANU009L
HD9 Euro3 1 437
357ANU009L
1 438 HD9 Euro3
357ANU011L
357ANU012L
HD9 Euro3 1 439
357ANU010L
If the indicator shows a high temperature
value, the page remains until the user
presses key 3 (ESCAPE) or 2, (PAGE) on
2 the steering wheel. The “engine oil tem-
perature high” warning light on the
cluster switches on.
357ANU012L
1 440 HD9 Euro3
2
The sound system can be switched on by
pressing the ON/OFF key on the front panel,
or by pressing key 5 ( ) on the steering
wheel.
When key 5 ( ) is pressed on the steering
wheel, the “RADIO - CD PLAYER” page is
displayed (Fig. 2)
357ANU005L Press key 4 (Y / B) on the steering wheel to
select the RADIO/CD function (the window of
the selected function lights up in yellow).
3 Press key 1 on the steering wheel to confirm
the selected function.
357ANU005L
357ANU016L
1 442 HD9 Euro3
1 DIALOGUE MENU
When key 1 (MENU/OK) on the steering
wheel is pressed, the “DIALOGUE MENU”
page is displayed.
Press key 4 (Y / B) on steering wheel to
select (Fig. 1) required function from those
available:
D SOUND SYSTEM
357ANU017L D VEHICLE DATA
D TRIP 1
D TRIP 2
D CHECK
D LANGUAGE
D PASSWORD
D DISPLAY
D BUZZER
D LIGHTS
357ANU020L
1 444 HD9 Euro3
1 SOUND SYSTEM
When key 1 (MENU/OK) is pressed on the
steering wheel, the “DIALOGUE MENU”
page is displayed.
Press key 4 (Y / B) on the steering wheel to
select the SOUND SYSTEM function (Fig. 1)
(the window of the selected function lights up
in yellow)
Press key 1 (MENU/OK) on the steering
357ANU020L wheel to have access to the RADIO/CD
menu (Fig. 2).
357ANU005L
1 446 HD9 Euro3
1 VEHICLE DATA
When key 1 (MENU/OK) is pressed on the
steering wheel the “DIALOGUE MENU” is
displayed.
Press key 4 (Y / B) on the steering wheel to
select the VEHICLE DATA function (the win-
dow of the selected function lights up in yel-
low)
Press key 1 (MENU/OK) on the steering
357ANU021L wheel to have access to the VEHICLE DATA
menu (Fig. 1, 2, 3).
Press key 4 (Y / B) on the steering wheel to
2 scroll all the vehicle data:
D TOTAL DISTANCE km
D AVERAGE SPEED km/lh
D AVERAGE CONSUMPTION Al/100km
D AVERAGE CONSUMPTION Bl/100km
D TOTAL HOURS h : min
D VEHICLE TIME IN IDLE h : min
357ANU022L D VEHICLE RUNNING TIME h : min
D TIME IN PTO 1 h : min
D TIME IN PTO 2 h : min
3 D TIME IN PTO 3 h : min
D NEXT MAINTENANCE h : min
Press key 1 (MENU/OK) on the steering
wheel to return to the “DIALOGUE MENU”
page.
1 TRIP 1
Press key 1 (MENU/OK) on the steering
wheel to view the “DIALOGUE MENU”.
Press key 4 (Y / B) on the steering wheel to
select TRIP 1 function (the window of the
selected function lights up in yellow)
Press key 1 (MENU/OK) on the steering
wheel to access the TRIP 1 menu (Fig. 1).
Press key 4 (Y / B) on the steering wheel to
357ANU024L scroll all the vehicle data:
D TOTAL DISTANCE km
D AVERAGE SPEED km/h
2 D AVERAGE CONSUMPTION Al/100km
D AVERAGE CONSUMPTION Bl/100km
D TOTAL HOURS h : min
D VEHICLE TIME IN IDLE h : min
D VEHICLE RUNNING TIME h : min
D TIME IN PTO 1 h : min
D TIME IN PTO 2 h : min
357ANU025L D TIME IN PTO 3 h : min
HD9 Euro3 1449
357ANU025L
1450 HD9 Euro3
1 TRIP 2
1 CHECK
Press key 1 (MENU/OK) on the steering
wheel to view the “DIALOGUE MENU”.
Press key 4 (Y / B) on the steering wheel to
select the CHECK function (the window of
the selected function lights up in yellow)
Press key 1 (MENU/OK) on the steering
wheel to access the CHECK page that dis-
plays the faults concerning the control units
357ANU028L installed on the vehicle (Fig. 1, 2).
Press key 4 (Y / B) on the steering wheel to
scroll the control units and any faults.
2 The information is set out in three columns:
357ANU029L
HD9 Euro3 1453
Indicates the control Displays the fault code of Indication regarding the
the failure failure mode
357ANU029L
272GNU044
1454 HD9 Euro3
1 LANGUAGE
Press key 1 (MENU/OK) on the steering
wheel to view the “DIALOGUE MENU”.
Press key 4 (Y / B) on the steering wheel to
select the LANGUAGE function (the window
of the selected function lights up in yellow)
Press key 1 (MENU/OK) on the steering
wheel to access the “LANGUAGE” page to
change the languages of the pages (Fig. 1,
357ANU023L 2).
Press key 4 (Y / B) on the steering wheel to
select the required language (the window of
2 the selected function lights up in yellow).
The following languages can be selected:
D ITALIAN
D ENGLISH
D GERMAN
D FRENCH
D SPANISH
Press key 5 ( ) on the steering wheel to con-
357ANU033L
firm the selected language (the window of
the selected language lights up in green).
Press key 1 (MENU/OK) on the steering
wheel to return to “DIALOGUE MENU”.
1 PASSWORD
357ANU035L
1456 HD9 Euro3
357ANU037L
1 458 HD9 Euro3
357ANU036L
357ANU037L
HD9 Euro3 1 459
1 DISPLAY
Press key 1 (MENU/OK) on the steering
wheel to view the “DIALOGUE MENU”.
Press key 4 (Y / B) on the steering wheel to
select the DISPLAY function (the window of
the selected function lights up in yellow)
Press key 1 (MENU/OK) on the steering
wheel to access the “DISPLAY” page to
change the colour and pattern of the display
357ANU038L background (Fig. 1, 2).
The following backgrounds can be selected:
D BACKGROUND 1 (blue)
2 D BACKGROUND 2 (grey)
D BACKGROUND 3 (red)
D BACKGROUND 4 (yellow)
D BACKGROUND 5 (green)
Press key 4 (Y / B) on the steering wheel to
select the background (the window of the
selected function lights up in yellow and the
display background changes, giving a pre-
357ANU039L view).
To confirm the background selected, press 5
( ) on the steering wheel.
Press key 1 (MENU/OK) on the steering
wheel to return to the “DIALOGUE MENU”.
1 BUZZER
Press key 1 (MENU/OK) on the steering
wheel to view the “DIALOGUE MENU”.
Press key 4 (Y / B) on the steering wheel to
select the BUZZER function (the window of
the selected function lights up in yellow)
Press key 1 (MENU/OK) on the steering
wheel to access the “BUZZER” page to
change the volume of the warning beep
357ANU040L (Fig. 1).
Press key 5 (+ / -) on the steering wheel to
adjust the volume (at each impulse of the key
5 (+ / -) a preview is given of the buzzer
sound level)
Press key 1 (MENU/OK) on the steering
wheel to confirm the chosen sound level and
return to the “DIALOGUE MENU”.
1 LIGHTS
357ANU042L
1464 HD9 Euro3
357ANU043L
357ANU044L
HD9 Euro3 1 465
272GNU062
Pressing key 3 (ESCAPE) on the steering
wheel or not pressing any key on the
steering wheel for 30 seconds, the
2 “VEHICLE MOTION” page returns.
357ANU043L
357ANU044L
1 466 HD9 Euro3
1 Scheduled maintenance
50 hours before the scheduled maintenance
time expires, the message “SCHEDULED
MAINTENANCE DUE IN 50 HOURS” (Fig. 1)
is displayed together with a single beep of
the buzzer.
357ANU046L
HD9 Euro3 1467
357ANU046L
1468 HD9 Euro3
357ANU050L
HD9 Euro3 1471
1 Immobiliser fault
Proceed as follows at key-on if problems to
the electronic key occur and the correct code
cannot be sent to the immobiliser.
D Wait for the warning light check up pro-
cedure to be completed;
D Wait for the “IMMOBILIZER CODE” mess-
age to appear (Fig. 1);
D Proceed with the releasing operation.
1 PTO Engagement
When a PTO is engaged, information con-
cerning the number of the PTO and the rpm
(PTO X: XXXX rpm) is shown instead of DATE
on the “VEHICLE MOTION” page (Fig. 1).
Back camera
The back camera is automatically activated
357ANU051L when reverse gear is selected. The image
coming from the back camera is shown full--
screen on the display.
1 CONTROL OPERATION
Position and headlight controls (Fig. 1)
The control has three positions:
D position 0: off;
D position 1: first click: position lights on;
D position 2: second click: headlights on.
2
272NU044X
1 474 HD9 Euro3
Horn (Fig. 2)
2 The horn can be sounded by pressing the
272NU045X indicated points (Fig. 2, ref. 1, 2).
1
2
272NU046X
HD9 Euro3 1 475
272NU048X
272NU049X
1 476 HD9 Euro3
272NU060X
HD9 Euro3 1 477
1 Cruise control
The vehicle is fitted with an engine speed /
vehicle speed control.
285ANU039L
HD9 Euro3 1 479
285ANU022L
1 480 HD9 Euro3
Work light
342ANU001L
Press the button (Fig. 2) to switch the work
light on.
The warning light (Fig. 2, ref. 1) indicates
2 that the work light is on.
Press the button again to switch the work
light off.
Rear fog light
342ANU003L
HD9 Euro3 1481
306ANU002L
1482 HD9 Euro3
1 Immobilizer
To increase protection against attempted
theft, the vehicle is fitted with an electronic
engine disable system. The ignition keys
(Fig. 1) have an electronic device that trans-
mits a coded signal to the immobilizer con-
trol unit.
272CNU043
HD9 Euro3 1 487
1 Code Card
A Code Card is supplied with the keys
(Fig. 1), bearing the following information:
a the electronic code to use for starting
(Fig. 2, ref. 1);
b the mechanical code of the keys them-
selves (Fig. 2, ref. 2).
1 Emergency start
This function allows the vehicle to be started
without recognisable key or immobilizer sys-
tem fault. Starting is possible after entering
the Electronic Code (on the Code Card) by
means an appropriate procedure to be car-
ried out using the accelerator pedal (Fig. 2,
ref.1).
272NU058X
1 490 HD9 Euro3
1 STARTING ENGINE
306ANU002L
HD9 Euro3 1491
272GNU014
HD9ST0016MR
HD9 Euro3 1493
2
Tow starting
The engine cannot be started by towing.
178NU47
HD9 Euro3 1 495
1 AUTOMATED TRANSMISSION
(ASTRONIC) Type II
The ZF AsTronicselection system isacombi-
nation of an electro-pneumatic engagement
transmission with an automated clutch.
Selection of the different operating modes is
done through a pushbutton selector (Fig. 2
HD9ST0018L
ref. 1).
1. automatic/manual switch (button D)
2. idle switch (button N)
2 3. reverse switch (button R)
The desired mode is engaged/disengaged
each time the button is pressed.
In addition, the steering column contains a
lever (Fig. 2) that allows manual gear shif-
ting.
D Briefly pulling the lever (+1) upshifts gears
by one speed.
HD9ST0019L D Pulling and holding the lever (+2) upshifts
two speeds.
D Briefly pushing the lever (---1) downshifts
gears by one speed.
D Pulling and holding the lever (---2) down-
shifts two speeds.
1 496 HD9 Euro3
21 STARTING UP
When the engine has been started the
display shows the symbol N (Fig. 1). The
system is in manual mode.
HD9ST0021L
HD9 Euro3 1 497
272NU005MY
1498 HD9 Euro3
HD9ST0025L
HD9 Euro3 1 499
357ANU115L
HD9 Euro3 1501
357ANU116L
Do not exceed maximum engine speed,
especially downhill.
Never travel with the transmission in Neu-
tral.
2 Avoid using the auxiliary brakes (engine
brake, intarder) on long downhill
stretches to prevent overheating the ser-
vice brakes.
Never use the parking brake (expect in an
emergency) when travelling.
357ANU008L
1 502 HD9 Euro3
11 Kick-down function
Pressing the accelerator pedal beyond the
hard limit stop point causes the control sys-
tem to set POWER mode.
Before shifting up, each gear is maintained
up to the corresponding maximum engine
speed, downshifting in case of sharp accel-
eration.
The system remains in automatic mode dur-
HD9ST0022L ing kick-down.
Maintaining the selected gear
In automatic mode, press the D pushbutton
(Fig. 1) without engaging the lever to main-
tain selected gear (e.g.: to accelerate uphill).
The system shifts to manual mode: no fur-
ther gear shifts are possible except those
made by means of the lever.
To resume automatic gear shifting press the
D pushbutton again (Fig. 1) without enga-
ging the lever.
1504 HD9 Euro3
1 Shift to neutral
Proceed as follows:
D Press button N (Fig. 1).
The 00 symbol (Fig. 1) appears on the dis-
play. Manual mode is enabled.
1 Reverse gear
Reverse gear is only available in manual
mode.
The system is equipped with two reverse
gears:
R1 = slow reverse
R2 = fast reverse
Engaging reverse
HD9ST0032L Proceed as follows:
D stop the vehicle completely;
HD9ST0034L
HD9 Euro3 1 507
1 Manoeuvring
To manoeuvre at low speeds (e.g. for hitching
a trailer or semi---trailer) a manoeuvre
condition is featured.
The following are available for manoeuvring
operations:
D first gear forward;
D low reverse.
Perform the following:
HD9ST0035L
D fully stop the vehicle;
D press and HOLD DOWN the button (D)
(Fig. 1) for forward rolling manoeuvres;
2 D press and HOLD DOWN the button (R)
(Fig. 1) for reverse rolling manoeuvres.
The display shows the manoeuvre condi-
tions (Fig. 2).
Do the following to exit the manoeuvre con-
ditions:
D press the button (D);
or
HD9ST0036L
D press the button (R).
In manoeuvring mode, the vehicle (the acce-
lerator pedal) is more sensitive and the
clutch action is not as normal. The engine
torque is reduced.
During manoeuvres, the clutch is subject to
greater stress. “CL” appears on the display
if the clutch is overloaded.
HD9 Euro3 1 509
1 Protection functions
Clutch protection
If the clutch overheats (for example due to
many consecutive starts at short intervals, or
with low speed gear selected for too long)
the CL symbol appears on the display and
an alarm will sound.
In this situation the driver must perform a ma-
noeuvre that eliminates the overload (for
example accelerating the vehicle to engage
the clutch, stopping the vehicle or start-out
selecting a low gear).
1 SPEED PROGRAMMER
The speed programmer is a device that acts
on the engine power supply management
system, controlling rotation speed both with
vehicle stationary and in motion, so that cer-
tain conditions are met.
HD9ST0037L Engine idle speed adjustment / memorising
HD9ST0037L
The system allows adjustment of minimum
speed in order to reduce/eliminate
unpleasant cab vibrations.
Conditions:
1 Proceed as follows:
D press (RESUME) the Cruise Control but-
ton (Fig.1, ref.1) until engine speed rea-
ches the set base value (approx. 550 rpm).
D Adjust speed as required using ON +
(Fig. 1, ref. 2) or ON --- (Fig. 1, ref. 3)
(pivoting head key).
HD9ST0037L
Each touch of the ON key increases or
HD9ST0037L decreases engine speed by circa 20 rpm.
Engine idle speed must be between the
following values:
D minimum value: 550 rpm
D maximum value: 750 rpm
Adjust idle speed according to needs
(noise, vibration, etc.).
1 Conditions:
D engine brake lever/retarder not engaged;
D vehicle moving with gear engaged;
D vehicle speed greater than 20 kph;
D brake pedal not pressed;
D clutch pedal not pressed.
1 Enable
Proceed as follows:
357ANU053L
HD9 Euro3 1515
1 Changing setting
Proceed as follows:
D after activating the function press ON (+)
(Fig. 1, ref. 2) to increase vehicle speed;
or
D after activating the function press ON (---)
HD9ST0037L (Fig. 1, ref. 3) to decrease vehicle speed.
Ramp Function
Holding the pivoting ON button (+) pressed
(Fig. 1, ref. 2) or (---) (Fig. 1, ref. 3) increases
speed continuously.
1 Permanent disable
Proceed as follows:
D press (OFF) the Cruise Control pushbut-
ton (Fig. 1, ref. 1);
or
D Operate the brake or engine brake pedal;
HD9ST0037L
or
D Press/turn the accelerator pedal
HD9ST0037L
(demanding a higher speed than set) for
more than 60 seconds.
The set speed disappears from section “A” of
2 the display (Fig. 2).
Temporary disable
Proceed as follows:
D Operate the clutch pedal (if present) the
system shifts to stand-by. After disengag-
ing the clutch the vehicle returns to the
cruising speed set previously.
D Press/turn the accelerator pedal for more
than 60 seconds. As soon as the acceler-
ator is released the function automatically
357ANU054L resumes at the last set value.
The speed set in section “A” of the display
(Fig. 1, ref. 1) appears shaded.
1518 HD9 Euro3
1 DIAGNOSTICS
Press key 1 (MENU/OK) on the steering
wheel to display the “DIALOGUE MENU”.
Press key 4 (Y/B) on the steering wheel to
select the CHECK function (the window of
the selected function lights up in yellow).
Press key 1 (MENU/OK) on the steering
wheel to access the CHECK page that dis-
plays the faults regarding the vehicle control
357ANU028L units (Fig. 1, 2).
Press key 4 (Y/B) on the steering wheel to
scroll the control units and any faults.
2 Press key 1 (MENU/OK) on the steering
wheel to return to “DIALOGUE MENU”.
357ANU029L
1520 HD9 Euro3
357ANU029L
HD9 Euro3 1521
2
ECU DTC FMI
Displays the relevant fault
Indicates the control unit Indicates the type of fault
code
357ANU029L
1522 HD9 Euro3
342BNM023L
1 524 HD9 Euro3
FUSES
Fuse holder (70005)
RELAYS
CODE
REF. DESCRIPTION
COMPONENT
001 Relay for climate control 25332
002 Emergency engine stop relay 25205
003 Automatic transmission reverse light relay 25030
004 Second speed limit request relay ---
005 Horn relay 25805
006 Lights on relay 25806
007 Flywheel PTO engagement enable relay 25701
008 PTO diodes holder 61000
009 PTO1 engagement relay 25704
010 PTO2 engagement relay 25897
011 PTO3 engagement relay 25898
012 Engine starter relay (outfitters)
013 Engine stop relay (outfitters)
014 SET adjustment relay +( outfitters) (outfitters)
015 SET adjustment relay --- ( outfitters) (outfitters)
016 PTO engaged confirmation relay (outfitters)
017 Idle gear confirmation relay (outfitters)
018 External cruise activation relay (outfitters)
019 PTO engagement relay with vehicle stationary (outfitters)
1 528 HD9 Euro3
RELAYS
CODE
REF. DESCRIPTION
COMPONENT
A --- ---
B Vehicle lock relay with doors open 25500
C --- ---
D --- ---
E Power steering 2 fault warning light relay 25868
F PTO solenoid valves diodes holder (outfitters)
G Terminal 15a/50A relay 25,213A
H 40A engeine start relay 25200
I Fuel pre-filter heating relay 25825
L Terminal 15b/50A relay 25213B
HD9 Euro3 1 529
HD9ST0109L