OPERATOR'S MANUAL

Mercedes-Benz Axor 2523R, 2528R, 2528RMC, 2528C, 2528CX, 2528CH

Trucks you can trust

CUSTOMER INFORMATION
OWNER’S NAME & ADDRESS

TEL.NO.

BATTERY
REGISTRATION DATE OF
MODEL VIN ENGINE NO. KEY NO.
NO DELIVERY MAKE SERIAL NO.

SELLING DEALER CODE :

DEALER ADDRESS/STAMP
 INTRODUCTION
Dear Customer,
Congratulations on being a proud owner of a Mercedes-Benz truck!
We welcome you to a whole new driving experience!
This Operator’s Manual has been prepared to acquaint you with the operation and maintenance of your new
Mercedes-Benz truck. Please read this manual carefully, before operating your vehicle. Care has been taken to
include as much useful information as possible. The more you know and understand about your vehicle, the greater
safety and pleasure you will derive from driving it. Every effort has been made to ensure that the details provided in
this manual are accurate. We or our authorised dealer will not in any circumstance be held responsible for any
inaccuracy or consequence thereof.
In accordance with our policy for continuous product improvement, we reserve the right to change the procedures,
illustrations, specifications, dimensions or design as referred to in this manual at any time, without prior notice. All
information, procedures, illustrations contained in this manual are based on the latest products available during
publication. We strongly recommend you to keep this manual as part of the vehicle at all times for handy reference.
We strongly recommend use of genuine parts, service and repairs from only authorised Mercedes-Benz dealer /
service centres.
We wish you safe and pleasant driving.
DELIVERY CHECK LIST DELIVERY CHECK LIST
: _________ 1. VIN Number : _________
1. VIN Number
: _________ 2. Delivery date : _________
2. Delivery date
: _________ 3. Selling Dealer : _________
3. Selling Dealer

GENERAL KITS TOOL LIST GENERAL KITS TOOL LIST

Spare bulb set Tool bag Spare bulb set Tool bag
Warning triangle Ring spanner (24 - 27 mm) Warning triangle Ring spanner (24 - 27 mm)
500 gm Hammer 500 gm Hammer

py
mb
8 Inch Combination Pliers DOCUMENTS 8 Inch Combination Pliers
DOCUMENTS
h Adjustable
8 Inch Adj
djusta
just Spanner Operator’s Manual 8 Inch Adjustable Spanner

o
Operator’s Manual

y
Tow bar
Tow ba
ar / Tommy
T bar and Jack rod Battery warranty card Tow bar / Tommy bar and Jack rod

C
Battery warranty card
KEY’S SET
r
8mm m Screwdriver
S
KEY’S SET
op 8mm
8 Screwdriver

e
W
Wheel spanner 24 / 32 mm Wheel
Wh
Wh spanner 24 / 32 mm

C
Ignition Key (3 Nos.) Ignition Key (3 Nos.) Double end spanner 8 / 9 mm
r
Double end spanner 8 / 9 mm

om
s.)
Co-driver storage key (3 Nos.) s.)
Co-driver storage key (3 Nos.)

le
Double end spanner 10 / 11 mm Double end spanner 10 / 11 mm
OTHERS
t OTHERS
a
Double end spanner 12 / 14 mm

us
Double end spanner 12 / 14 mm

e
First aid kit Double end spanner 13 / 15 mm First aid kit Double end spanner 13 / 15 mm

C D
Wheel chock Double end spanner 16 / 18 mm Wheel chock Double end spanner 16 / 18 mm
Spare wheel tyre
yre Double end spanner 21 / 23 mm Spare wheel tyre Double end spanner 21 / 23 mm
Screwdriver / Torx T20 Screwdriver / Torx T20
Screwdriver / Torx T30 Screwdriver / Torx T30

Works Manager Name: ________ Customer Sign: __________ Works Manager Name: ________ Customer Sign: __________

Dealer’s Stamp & Sign: ________ Dealer’s Stamp & Sign: ________
 CONTENTS
1. GENERAL ..................................................... 1-1 5. INSTRUMENT AND CONTROLS ..........5-1
Safety Tips..........................................................1-1 Instrument Cluster ........................................... 5-1
Do’s and Don’ts .................................................1-1 Instrument Cluster and Warning Indicators 5-2
Care for Environment .......................................1-5 Switch Controls............................................... 5-10
Optional Fitment ..............................................1-6
6. ELECTRICALS ............................................6-1
Genuine Parts ...................................................1-7
Lighting ............................................................. 6-1
2. PRODUCT INFORMATION .................... 2-1 Removal and Installation ................................ 6-2
Vehicle Identification .......................................2-1 Fuse and Relay Box ......................................... 6-4
Aggregate Identification .................................2-1 Components Location ..................................... 6-8

3. TECHNICAL DATA ................................... 3-1 7. BRAKE SYSTEM ........................................7-1

Technical Specification ...................................3-1 Spring Brake Actuator .................................... 7-1
Vehicle Dimensions .........................................3-5 Service Brake .................................................... 7-1
Engine / Exhaust Brake System ..................... 7-1
4. FEATURES OF CABIN ............................. 4-1 Automatic Slack Adjuster ............................... 7-2
Cabin Styling ....................................................4-1
Cabin Interiors ..................................................4-6 8. WHEELS AND TYRES ...............................8-1
Storage Information ....................................... 4-10 Tyre and Wheel Information ........................... 8-1
HVAC Controls (Applicable for Changing a Deflated Wheel ........................... 8-2
AC Models)....................................................... 4-12 Spare Wheel Operation ................................... 8-5
Tyre Rotation Procedure.................................. 8-6
9. MISCELLANEOUS INFORMATION ...... 9-1 13. LUBRICANT SPECIFICATION ..........13-1
Warning Triangles ............................................9-1 Lubricant Specification .................................. 13-1
Tail Lamp Mounting .........................................9-2 Chassis Lubrication Points ........................... 13-7
Bulb Specification ............................................9-3
14.MAINTENANCE & LUBRICATION ......14-1
10. DRIVING AND OPERATION .............. 10-1 Maintenance Chart - 2523R & 2528R.............14-1
Seat and Seat Belts ....................................... 10-1 Maintenance Chart - 2523C, 2528CH,
Check Before Driving .....................................10-3 2528CX & 2528RMC .................................... 14-17
Engine Starting and Stopping ...................... 10-4 Air Intake System ......................................... 14-34
Gear Shifting ................................................... 10-7 Cooling System ............................................. 14-36
Driving Controls .............................................10-7 Fuel System ................................................... 14-36
Ready Mix Concrete (RMC) .......................... 10-9 Water Separator ............................................ 14-37
Tipping System Layout (2528C, 2528CH Engine Oil Inspection .................................. 14-37
& 2528CX) .....................................................10-11 Refrigerant Gas ............................................ 14-39
Tipping Oil Level Check ..............................10-12 Clutch Fluid ................................................... 14-39
Tipping Operation ........................................10-12 Power Steering Fluid ................................... 14-39
AdBlue System Layout ................................10-15 Windscreen Washer Fluid ........................... 14-40
AdBlue Level Check .....................................10-16 Battery Maintenance ................................... 14-40
On Road Conditions .....................................10-17 Fan Belt ......................................................... 14-41
Cab Tilting .....................................................10-17 Vehicle Storage ............................................ 14-41
In Case of Emergency ..................................10-19 Maintenance Records ................................. 14-42
11. BODY BUILDING GUIDELINES ......... 11-1 Service Records ........................................... 14-45

12. ADBLUE AND SCR SYSTEM ............. 12-1 15.TROUBLESHOOTING CHART ............15-1
RECOMMENDATION
Use DIESEL fuel with maximum
content of SULPHUR 50 ppm
1. GENERAL
Safety Tips
Safe driving can be achieved only
through full concentration and
commitment of the driver.
1. Safety is always more important
than speed.
2. Always wear seat belt while
driving.
3. Do not load the vehicle over the
rated load limits.
4. Disconnect battery terminals
before welding on the vehicle.
5. Do not use mobile phone while
driving.
6. Do not drink and drive.
7. Do not drive if you feel sick or
sleepy.
8. Do not adjust the seat, seat belt
while driving.
9. Welding should be done only by
an authorised personnel.
10. New tyres do not give
maximum grip straight away
Do’s
and therefore should be run-in
at moderate speeds for first
150km. This will also help
ensure the tyres last longer.
11. New brake linings must always
be run-in, they do not have the
optimum friction properties
during the first 200km.
12. Damaged parabolic springs
must be completely replaced.
Individual spring leaves should
not be renewed.
13. Keep the AdBlue away from
other operational fluids such as
coolant, engine oil,
transmission oil, hydraulic oil
and brake oil and not used in
same containers and collecting
pans, if mixed with a small
amount of AdBlue can damage
the functional components like
thermostats, sensors etc.
14. Do not add water and diesel in
AdBlue tank.
Do’s and Don’ts
1. Always service your vehicle at
an authorised dealer only.
2. Always use genuine parts.
3. Check the coolant level, Top up
if it is less than the minimum
level.
4. Always keep the tyres inflated
at the recommended tyre
pressure to ensure longer tyre
life.
5. Drain the water separator daily.
6. Always use recommended
antifreeze agents in cooling
system to avoid deterioration of
engine components due to
corrosion. After filling coolant,
fit de-aeration tank cap firmly.
7. Run the engine in low idling
speed for at least two minutes
after starting and before
shutting off.
1-1
 8. Always ensure that your vehicle
is filled with diesel before riding
and parking.
9. Always start and move the
vehicle in first gear only.
10. Check air filter restriction
indicator in cluster. If it glows,
replace the primary filter with
original spare.
11. If the engine operating
temperature shoots up above
105°C, the engine protect
indicator will glow in the cluster
and the power de-rating of
engine occurs, contact the
nearest authorised
dealer immediately.
12. A daily maintenance check
needs to be performed on water
separator, coolant level and
engine oil level.
13. Avoid cranking of engine for
more than 30 seconds. A gap of
2 minutes should be left
between successive attempts.
1-2
14. Drive judiciously using rpm
meter as a guide. The engine
speed should be in green band
at all times for economical and
comfortable driving with less
gear shifting.
15. Horn mounting should be rigid.
16. Check for the proper voltage
across the horn terminals.
17. Check battery’s specific gravity
periodically. Keep battery
terminals clean and cable joints
tight. Check and apply
petroleum jelly on terminals to
avoid corrosion on a weekly
basis.
18. The fuel water separator should
be checked daily and water
content to be drained from the
fuel water separator as and
when required.
Don’ts
1. Avoid mixing different grades of
lubricants, engine oil while top
up.
2. Do not modify the chassis, load
body and suspension to carry
overload, it will only result in
premature failure.
3. Do not use adulterated fuel or
kerosene. It reduces engine and
fuel injection equipment life,
warranty will be void.
4. Do not leave loose tools or
components in the cabin while
tilting.
5. Do not use clutch pedal as a
foot rest while driving. This will
cause premature clutch lining
wear.
6. Do not drive with engine
switched off condition. This is
dangerous and can result in an
accident apart from damaging
the vehicle and reducing life of
gear box.
7. Do not fit bigger size tyres. Do
not over or under inflate tyres.
This reduces tyre life.
8. Do not overfill engine oil. This
may cause engine smoking and
high engine oil consumption.
9. Do not keep ignition key in
engaged condition, after the
engine has started. Release the
key immediately. Do not engage
the ignition key when the
engine is running. This will
damage the starter motor.
10. Do not move vehicle before air
pressure is built above 6bar and
hand brake is completely
released.
11. Do not jump start the vehicle,
Use a service battery.
12. Reinforcement by installing
additional spring leaves is not
permitted.
13. Do not remove silicon sealant
from horn while adjusting.
14. Do not tamper horn mounting
bracket nut.
15. Do not crank the toppled 19. Vehicle should not be kept idle
vehicle’s engine, as doing so more than 5 days, to prevent
may result in connecting rod the concentration from
bend or engine components changing due to settling effect
damage. in the diesel tank. If the period
16. No leakages allowed in the of off-road (due to accident/non-
exhaust system. If any leakages usage, etc) is higher than 5
observed during daily visual days, clean diesel tank and fuel
checks or in operation, request lines.
to contact the nearest
authorized Mercedes-Benz
service facility to take the
required corrective actions
without any delay.
17. Do not top up with only water
in coolant circuit, top up with
50% water: 50% glycol coolant
mixture.
18. The Bio-Diesel blends should
comply with DIN EN 14214 and
the base fuel with DIN EN 590
standards. Aged biofuel not
recommended to use in
vehicles.
1-3
Tipper Do’s and Don’ts
Do’s
Ensure that the tipper is loaded
within the specified limits.
Load the tipper in an even manner.
Always load and unload the tipper
only on a firm and level ground.
P
Engage parking brake, while
performing tipping operation.
1-4
Don’ts
Never overload the tipper
beyond the specified limits.
Do not load the tipper in an
uneven manner.
Do not perform tipping action
on uneven grounds.
Do not perform tipping action without
engaging the parking brake.
Do’s
Always provide support to the
body when working under it
Ensure that the unloading place is
free from obstructions.
Drive only when the tipper
body is settled down
Ensure that the tipper body
height is not extended.
Don’ts
Do not stay under an unsupported
body
Do not stay in and around the
working area of tipper
Do not drive with the tipper body
in lifted condition.
Do not extend the tipper body
height.
DICV-HDT-1439
Care for Environment
Mercedes-Benz is committed to
produce environment friendly
vehicles. We at Mercedes-Benz
would like to inform our privileged
customers that your Mercedes-Benz
truck meets appropriate
environmental norms and this is
being regularly validated at all the
stages of manufacturing.
As a user, you too can protect the
environment by refining your driving
style and vehicle maintenance.
Please check the below mentioned
tips for your guidance.
Driving
1. Avoid driving short trips to
reduce fuel consumption.
2. Avoid frequent and sudden
accelerations.
3. Do not overload the vehicle.
This reduces vehicle efficiency
and increases fuel
consumption.
4. Avoid using electrical
accessories which consume
high power in slow traffic
conditions or when the engine
is switched off.
5. Always warm up the engine
during the start by idling to
reduce carbon monoxide and
hydro carbon emissions.
6. Track the fuel consumption rate
regularly and in case the fuel
consumption rate is high
contact an authorised dealer.
7. Switch off the engine during
long stops at traffic jam, toll
post, etc. If the need to keep the
engine running arises, avoid
frequent acceleration of the
engine. Avoid frequent stopping
and restarting.
8. Shift to higher gears as soon as
possible for better fuel
economy.
9. Spilled AdBlue should be
flushed away with much water
into the sewage system to avoid
any problems due to its good
biodegradability.
Maintenance of the
vehicle
1. Ensure recommended
maintenance is carried out on
the vehicle regularly at an
authorised dealership.
2. If you notice any oil / fuel / air /
coolant leakage in the vehicle,
attend to it immediately or
contact an authorised dealer.
3. Use only Mercedes-Benz
recommended brands and
grades of lubricants and fuel.
4. Periodically perform emission
test and renew your emission
clearance certificate through
government authorised agents
as per local government norms.
5. Do not drain or dispose used
oils, fuel filters or coolants into
sewage, soil or open streams.
Dispose them responsibly as
per government norms or
contact an authorised dealers
for disposal guidelines.
1-5
 6. Do not tamper with the engine
settings or encourage others to
do so.
NOTICE
Dispose used oils, lubricants,
and batteries in an environment
friendly manner as per govern-
m e n t n or m s. C on t a c t y o u r
authorised dealer for disposal
guidelines.
CAUTION
Ensure proper care by wearing
protective clothing and gloves
while disposing used oil,
batteries, etc.
WARNING
Keep the oils and lubricants,
out of reach of children.
Children cannot recognise the
danger in handling them.
1-6
Optional Fitment
Audio and Mobile
Communication System
If the customer wants to fit an audio
or mobile communication system
(e.g. CB radio) the following
requirements must be fulfilled in
order to avoid malfunctions on the
vehicle at a later stage.
1. Always use equipments
approved by authorities as per
regulations.
2. The equipment must be
permanently installed.
3. Operation of portable or mobile
equipment inside the cab is
only permitted if this equipment
is connected to a permanently
installed external aerial.
4. The transmitter must be
installed separately from all
other vehicle electronics.
5. Protect the equipment from
moisture and severe mechanical
vibrations.
6. Observe the permissible
operating temperature.
7. Aerial (in two-way radio sets)
must be officially licensed.
Connection and Wiring
1. The connection should be made
only from the additional 12-volt
sockets inside the cabin for
auxiliary fitments. It is
recommended to take
connection via an additional
fuse.
2. Disconnect the unit from the
electrical system before jump
starting.
3. Cables should be wired via the
shortest possible route (not
looped) and twisted.
4. Ensure that the system has a
good earth connection to the
equipment body.
5. The aerial and connecting
cables between the transmitter,
receiver and control panel must
be routed separately from the
vehicle wiring harness in the
vicinity of the body earth.
6. Make sure that the aerial cable
is not kinked or crushed.
CAUTION
For proper and effective fixing
of additional fitment contact
any authorised dealer.
Genuine Parts
We at Mercedes-Benz, believe in
providing the best to you.
Mercedes-Benz provides you with
quality, reliable, genuine parts at
affordable competitive prices.
Genuine parts which are used in the
trucks and the genuine parts which
reach you are manufactured in the
same production line.
We ensure that most dependable
German engineered quality parts
undergo stringent quality checks at
multiple levels before it reaches our
customer. Usage of genuine parts
will ensure longer life of aggregates
which translates into maximum
profits and minimum cost of repairs.
We always recommend you to insist
on usage of genuine parts for any of
your requirements. Genuine parts
will be available at our authorised
dealers.
Experience it: “Genuine Parts”.
1-7
2. PRODUCT INFORMATION
Vehicle Identification The VIN is also punched on the left
side of the frame which can be
Vehicle Identification Number viewed from the gap between the
The VIN - Vehicle Identification front left side tyre and mudguard.
Number is fixed in all vehicles. The
VIN is unique for every vehicle.

DAIMLER INDIA COMMERCIAL VEHICLES PVT LTD

TYP
VIN MEC
GVW Kg
Kg DICV-HDT-2700
GCW
Axle 1 Kg Axle 2 Kg

xxx
Axle 3 Kg Axle 4 Kg
Axle 5 Kg

DICV-HDT-1604
VIN plate is fitted on the closing
pillar of the co-driver door.
DICV-HDT-2575
Aggregate Identification
Engine
The engine serial number plate is
fitted on left hand side of the engine
on the crankcase.
DICV-HDT-734
The engine serial number is also
punched on the right side of the
engine on the crankcase.

DICV-HDT-2574

2-1
 G131 Transmission
The gear box type and serial
number plate is fitted on right hand
side of the front housing on the gear
box.

DICV-HDT-832 DICV-HDT-013

G85 Transmission Front Axle

The gear box type and serial The front axle serial number plate is
number plate is fitted on right hand fitted on the left hand side of axle
side of the front housing on the gear DICV-HDT-211
beam.
box.
ZF Steering Box
The power steering gear box type
and identification plate is fitted on
the steering box.

DICV-HDT-014
DICV-HDT-012

2-2
Rear Axle (IR 440)
The rear axle (IR 440) serial number
and identification plate is fitted on
right hand side behind of the axle
beam.
DICV-HDT-1530
Rear Axle I (IRT 390)
The first rear axle (IRT 390)
serial number and identification
plate is fitted on right hand side
behind of the axle beam.
DICV-HDT-1545
Rear Axle II (IRT 390)
The second rear axle (IRT 390)
serial number and identification
plate is fitted on right hand side
behind of the axle beam.
DICV-HDT-1531
Rear Axle I (Meritor)
The rear axle I (Meritor) serial
number and identification plate is
fitted under the drive head.
DICV-HDT-691
Rear Axle II (Meritor)
The rear axle II (Meritor) serial
number and identification plate is
fitted under the drive head.
DICV-HDT-692
2-3
Tag Axle
The tag axle serial number and
identification plate is fitted onto the
axle beam.

DICV-HDT-016

2-4
3. TECHNICAL DATA
Technical Specification
2528CH /
S.No Aggregates 2523R 2528R (6x2) 2528R (6x4) 2528C 2528RMC
2528CX

Ready Mix
1 Category Rigid Construction Concrete
(RMC)
2 Engine OM906 LA, 6.373 litres, 6 cylinder

3 Max. Power 175kW / 238hp 210kW / 285hp @ 2200 rpm

@ 2200 rpm

4 Max. Torque (Nm) 850 Nm @ 1200 1120 Nm @ 1200 rpm to 1600 rpm
rpm to 1600 rpm
5 Emission Standards EURO 4

6 Clutch Dry - Single plate, Hydraulic actuated control with servo assistance

7 Clutch Diameter (mm) 395 430 395

8 Transmission G85 G131

9 Transmission Type Mechanical / Synchro Mechanism

10 Number of Gears 6 Forward + 1 9 Forward + 1 Reverse

Reverse

3-1
 2528CH /
S.No Aggregates 2523R 2528R (6x2) 2528R (6x4) 2528C 2528RMC
2528CX

11 Front Spring Type Parabolic leaf spring

12 Front Leaf Springs 4

(no. of leaves)
13 Rear Spring Type Semi elliptical, Multi leaf - Bogie

10 (6.18 RAR) -
Rear Leaf Spring 2528CH
14 12 9
(no. of leaves) 12 (5.39 RAR) -
2528CX

IF 7.5 - Reverse
16 Front Axle IF 6.6 - I Beam reverse elliot IF 6.6 - I Beam reverse elliot
elliot

Meritor MT-36-
IRT 390 / IR
17 Rear Axle IR 440-11 IRT 390 / IR 390 610, Hub
390
reduction

18 Brakes Full air, dual circuit, S-cam, ABS

19 Air Compressor 318

Capacity (cc)
20 Steering Type Hydraulic power assisted

21 Steering Wheel 500

Diameter (mm)

3-2
 2528CH /
S.No Aggregates 2523R 2528R (6x2) 2528R (6x4) 2528C 2528RMC
2528CX

22 Battery (Ah) 120

23 Alternator Capacity (A) 80

24 Fuel Tank 380 (tank capacity) / 355 (filling capacity) 290 (tank capacity) / 265 (filling capacity)
(Capacity in lts)

24 AdBlue tank 60 (tank capacity) / 50 (filling capacity)

(Capacity in lts)
25 Front Tyre
11.00 x 20
26 Rear Tyre

Operating Data

S.No Aggregates Specification

1 Brake System (Front and Rear) 8.1 ± 0.2 bar (max)

2 Engine Idling Speed 600 rpm

3 Maximum Permissible Coolant Temperature 105°C

4 Wheel Nut Tightening Torque (Front and Rear) 600 Nm

5 Battery Terminals Torque (+ve and -ve) 7.6 Nm

3-3
Vehicle Weight
2523R 2528R (6x2) 2528R (6x4) 2528C 2528CH 2528CX 2528RMC
S.No Aggregates
4,500 W.B 5,700 W.B 5,700 W.B 5,700 W.B 4,200 W.B 4,200 W.B 4,200 W.B 3,600 W.B

Kerb Weight
1 7,955 8,095 8,175 8,655 8,225 8,825 8,740 8,165
(Kg)

Gross
2 Vehicle Weight 26,500 26,500 26,500 26,500 26,500 26,500 26,500 26,500
(Kg)

3-4
Vehicle Dimensions
2528
S.No Aggregates 2523R 2528R (6x2) 2528R (6x4) 2528C 2528CH 2528CX
RMC

Wheelbase (WB)
1 4,500 5,700 5,700 5,700 4,200 4,200 4,200 3,600
(mm)

Overall Length
2 9,867 12,000 12,000 12,000 7,840 7,840 7,840 7,460
(OL) (mm)

Overall Width
3 2,490 2,490 2,490 2,490 2,490 2,490 2,490 2,490
(OW) (mm)

Overall Height
4 3,100 3,100 3,100 3,100 2,955 2990 2,990 2,955
(OH) (mm)

Front Track
5 2,045 2,045 2,045 2,062 2,045 2,045 2,045 2,045
Width (FT) (mm)

Rear Track
6 1,805 1,805 1,805 1,805 1,805 1,805 1,805 1,805
Width (RT) (mm)

3-5
Vehicle Dimensions - 2523R & 2528R (6x2, 6x4)

OL OW
OH

RT
WB FT

DICV-HDT-2565

3-6
Vehicle Dimensions - 2528C, 2528CH, 2528CX & 2528RMC

OW

OL
OH

WB RT
FT

DICV-HDT-2722

3-7
4. FEATURES OF CABIN
Cabin Styling

SPACIOUS AND COMFORTABLE CABIN

Aerodynamic Design
Crash Tested Cabin
Enhances fuel economy Ensures survival space
incase of collision

Fully Sealed Cabin

Less vehicle noise, Wider Cab Tilt Angle
reducing driver fatigue Ease of inspection and
repair without cab dismount

3 Piece Steel Bumper

For increased safety
and easy repairing

DICV-HDT-2553
Note: Picture for symbolic representation only, actual product may vary.

4-1
Doors Head Lamp (Dual chamber)
The doors can be opened 90° wide Powerful polycarbonate clear glass
which provides easy entry and exit head lamps are mounted on a 2

of the driver and co-driver. separate bracket behind the bumper.

1

DICV-HDT-2576

Outside Side Rear View

Mirrors
DICV-HDT-783 The outside rear view mirrors
DICV-HDT-2554
provide a better rear vision and
Proximity Mirror
Door Lock must be adjusted to required
The proximity mirror is provided
position before driving.
outside, above the cabin door on the RH side - Insert the key into the
co-driver side. door lock and turn it in clockwise
direction (1) to unlock and anti-
clockwise direction (2) to lock.
LH side - Insert the key into the
door lock and turn it in clockwise
direction (1) to lock and anti-
clockwise (2) to unlock.

DICV-HDT-2583

DICV-HDT-784

4-2
Bumper Front Blind Spot Mirror
Three piece construction of bumper The front blind spot mirror is
with in-built two foot steps for provided outside, in front of the
comfortable windshield cleaning, windshield. It provides clear
facilitates repair works apart from visibility of the blind spot in front of
providing safety during collision. the vehicle.

DICV-HDT-1326

Windshield
The windshield glass has higher
side curvature and it is pasted
which prevents beading ageing
DICV-HDT-2555 related problems such as leakage, DICV-HDT-2557
glass rattling apart from better side
Steps visibility.
Chequered steps provided at a lower
height reduce the effort during
alighting and climbing the vehicle.
The chequered steps provide extra
grip and prevent accumulation of
dust and mud in cabin.

DICV-HDT-2556

4-3
External Sun Visor Front Cabin Lid
The external sun visor provides The cabin front lid can be opened
better aerodynamic and sun ray by pressing the button (1). Press the
protection. button using a suitable device (ex.
screw driver) to avoid injuries.

DICV-HDT-2559

Bumper Footrest (Rigid)

A bumper footrest provided with in-
1
DICV-HDT-2558
built two chequered foot steps for 1

comfortable windshield cleaning. DICV-HDT-2560

Bumper Spoiler (Rigid)
Follow the below front lid operating
A bumper spoiler provided below procedure.
the front bumper improves air entry
1. Lift the front lid (2) to engage
into engine compartment for more
the stay rod (3) to the front wall
effective temperature management.
bracket.

DICV-HDT-2586

4-4
 3. Hold the front lid.
2

Stay rod engaged

position

DICV-HDT-711 40mm DICV-HDT-703

2. Lift the front lid (2) to
disengage the stay rod (3) from
the front wall bracket.
2
3
DICV-HDT-712
4. Fix the stay rod back to home
CAUTION
position on front lid. Not beyond 40 mm from stay
rod en gage d posi ti on d urin g
CAUTION disengaging the stay rod.
During operation, do not pull
the stay rod from ball joint as it
may damage the front lid panel
or stay rod ball joint
permanently.

DICV-HDT-704

4-5
Cabin Interiors
The cabin is designed ergonomically to suit the need of the driver while traveling.

5 6 7 8

10 9
11

15

2 3

3
1 4
0

17 0
1 2 3
4

1 12 13 18 19 14 16 20
DICV-HDT-2719

4-6
 1. Map and bottle holder 20. Power window switch* (Co- LH side - Rotate the window control
2. Window controls* driver) handle in anti-clockwise direction to
slide the door glass downwards, and
3. Door lock Grab Handles in clockwise direction to slide
4. Grab handle upwards.
The cabin is provided with grab
5. Provision for music system handles to facilitate the ascend and
6. Sun visor descend of the driver and co-driver.
7. Overhead storage compartment
8. Provision for speakers
9. Steering wheel
10. Coin and vertical tray
11. Blower / AC louvers
12. Blower speed control knob
DICV-HDT-032
13. Air flow mode (Face / Foot /
Glass / All...) Power Window Switch*
DICV-HDT-786
14. Hazard switch Power window switches which are
15. Over ride switch (Construction) Window Controls* provided in the dashboard are used
Engine / Exhaust RH side - Rotate the window to open/close of door window glass
brake switch (Rigid) control handle in clockwise by driver and co-driver
16. Combination switch direction to slide the door glass independently.
17. Power window switch* downwards, and anti-clockwise
direction to slide upwards.
18. AC On/Off switch*
19. AC / Heater temperature control
knob*
*if applicable

4-7
 Door Lock - Inside
To close the cab doors from inside,
use the grab handle and pull the
door gently till it locks completely.
NOTICE
I f t h e d oo rs ar e n o t p ro p e rl y
l ock ed , cab room l amp gl ows
continuously.

Music System
The provisions for music system
DICV-HDT-2198 with USB (1) and speakers (2) are
available overhead in front of the
Sun Visor 1
2 driver in the cabin.
Sun visors are provided for both the 3
A
driver and co-driver which can be
DICV-HDT-032
adjusted to the required position to
avoid glare. 1. When the door lock lever (A) is
pushed to position (1) the door
is locked securely and cannot 1 2
be opened from the outside
without a key.
2. The door lock lever normally 0

0
1
2 3

1 2 3
4

stays in this position (2) when DICV-HDT-2687

the door is closed.
3. Pull the door lock lever to
position (3) and open the door
2 3
1 4
0

0
4
1 2 3

DICV-HDT-2686 from inside.

4-8
Rear Windows Diff Lock Buzzer
The cabin is provided with two Diff lock buzzer is provided and
sliding rear windows behind the gives a beep sound whenever the
driver and co-driver seats. For fresh diff lock switch is activated.
air circulation inside the cab, when
the vehicle is operated without air
blowers, the sliding doors maybe
kept open.
DICV-HDT-1092
Non Washable Interior
Trims
Non washable interior trims are
provided inside the cabin. DICV-HDT-1444

Cruise Control
Cruise control feature controls
DICV-HDT-787
engine and continuous engine brake
together. It will maintain the stored
Cabin Lighting speed as long as the engine and
continuous brake supply sufficient
The cabin light can be switched on
output.
using the switch provided whenever
required.
DICV-HDT-2695

4-9
 Overhead Compartment
The overhead compartment is
provided in the front side of the
cabin above the driver and co-driver.

DICV-HDT-1476 DICV-HDT-038
Cruise Control Switch
Storage Information
Map and Bottle Compartment
The map and bottle compartment is DICV-HDT-040
available inside on both the doors.
DICV-HDT-1361

Cruise Control Indication

Flooring
Sturdier anti skid scuff floor liner in
both entry points into the cab for
better grip during entry, avoiding
slippage.
DICV-HDT-039

4-10
Vertical Tray AdBlue Tank Key
A vertical tray is situated on the The vehicle is provided with a set of
instrument panel to provide more two similar machine cut keys to
storage space and to place idols. access AdBlue tank.

2 3
1 4
0

0
4
1 2 3

DICV-HDT-2688

1
2 3
4
Vehicle Key
The vehicle is provided with a set of
0

0
4
1 2 3

three similar machine cut keys. The

DICV-HDT-1330 keys can be used to operate DICV-HDT-2694

Toll Ticket Tray

The toll ticket tray is found beneath
the A/C control besides the 12V
socket. It can be used to hold
cellphones while charging through
the power socket.

DICV-HDT-1332
1. Ignition
2. Fuel Tank
3. Cabin Lock

4-11
HVAC Controls (Applicable for AC Models)
The blower is fitted in all vehicles as a standard fitment which supports forced ventilation inside the cabin.
HVAC - Heating Ventilation and Air Conditioning is provided in the vehicle.

1 1 1 1

2 2

4
4
2 3
1 4
0

3 0
1 2 3
4
3

DICV-HDT-2708
1. Windscreen air vents / de mister vents
2. Side window air vents
3. Footwell air vents
4. Center air vents

4-12
 Adjusting Air Flow Set the blower switch to air
recirculation mode 1 if dust or
B unpleasant odours enter the vehicle.
2 3
1 4
Set the blower switch back to fresh
0
2 3 4 1 air 2 again as soon as possible.

1
2 3
4
This will prevent the windows from
misting up.
0

0
1 2 3
4
0
4
1 2 3 2
DICV-HDT-2712 A
DICV-HDT-187
Air conditioning system control
panel Blower switch.
1. Air conditioning switch* A. Recirculated Air
1 3
2. Blower control switch B. Fresh Air
3. Air distribution switch Turn the Ignition key to “1” position.
(Refer page no. 10-4).
4. Temperature selector* 4
DICV-HDT-188
Air flow control settings.
The Air conditioning system control Air distribution switch
panel can be used to regulate the: 0 Off
1. Air to the wind shield and
a) air flow 1 - 3 Heating/Ventilation/Cooling center and side vents
b) air distribution 4 Demisting/ventilating/Cooling 2. Air to all vents
c) temperature For precise control of the selected 3. Air to center and side and
temperature, select blower speed footwell vents
setting 1 or 2.
4. Center and side vents

*if applicable

4-13
Selecting the Temperature Demisting the Wind Screen Heating
Set the switches to the positions Set the switches to the positions
2 shown: shown:

1
DICV-HDT-189
1. Cooling off
DICV-HDT-190 DICV-HDT-191
2. Full heater output
a) Close the air vents and the a) Open the air vents and the
Use the temperature selector to set heating vents. heating vents as desired.
the desired temperature.
The full heater output is only b) If required, switch on the
NOTICE available when the engine has auxiliary heating.
reached operating temperature. If
Operate the temperature selector required, switch on the auxiliary
at least once or twice every heating.
month. This will ensure its
operational reliability.

4-14
Ventilation
Set the switches to the positions
shown:
DICV-HDT-192
a) Roll down the windows.
b) Open the air vents and the
heating vents as desired.
Unpleasant Odours
Set the switches to the positions
shown and also:
a) Roll up the side windows.
DICV-HDT-193
CAUTION
Set the air recirculation mode
only if the outside temperature
is low. Otherwise the windows
could be misted up, which
impairs visibility and prevents
you from observing traffic
conditions.
Air Conditioning System*
The air conditioning system cannot
be operated unless the engine is
running.
*if applicable
NOTICE
Switch on the air conditioning
system at least once a month for
approx. 10 minutes to prevent
damage to the air conditioning
compressor.
If the outside temperature is very
high, turn the blower switch to air
recirculation mode.
DICV-HDT-612
a) To switch on the air
conditioning: Press the air
conditioning switch. The indicator
lamp in the switch lights up.
4-15
b) To switch off the air
conditioning: Press on top of the
air conditioning switch. The
indicator lamp in the switch goes
out.
c) To set the temperature: Turn the
temperature selector to the desired
temperature.
Cooling*
Set the switches to the positions
shown and roll up the windows
DICV-HDT-194
a) Set the switches to the positions
shown and roll up the windows.
b) Open the air vents and the
heating vents as desired.
*if applicable
Dehumidifying
Set the switches to the positions
shown and also:
1
DICV-HDT-048
CAUTION
DICV-HDT-195 The air conditioning system
should be used only when the
a) Roll up the windows.
engine is in running condition.
b) Close the air vents and the
heating vents.
AC Louvers *
The air condition vents can be
adjusted by holding and moving the
knob (1) to control the air flow
direction as desired by the driver.

4-16
5. INSTRUMENT AND CONTROLS
Instrument Cluster

2 3 4 5 6 7 9 10

P
STOP 8

!
trip
12.1 km
km/h ºc
102.1 214.1km 15:30
rpm x 100
Vmin Vmax
15km/h 125km/h

20 11
P 8.1 bar

1 2
TRIP TEMP

1 19 18 17 16 15 14 13 12
DICV-HDT-2690

5-1
The Cluster contains the following 20. Odometer
indicators:- Segments Indication
Instrument Cluster and
1. Fuel Gauge Warning Indicators 1 Segment AdBlue level between
reserve level and 1/4 full
2. Speedometer
Fuel Gauge with AdBlue Gauge tank.
3. Left Turn Indicator
Fuel gauge indicates the level of AdBlue level between 1/4
4. High Beam Indicator 2 Segment
fuel in tank. In the gauge ‘1’ denotes and 1/2 full tank.
5. Low Air Pressure Warning full tank, ‘1/2’ denotes half tank and
‘0’ denotes an empty tank. 3 Segment AdBlue level between 1/2
6. Parking Lamp
and 3/4 full tank.
7. Cabin Lock Indicator
4 Segment AdBlue level between 3/4
8. Stop Lamp
and full tank.
9. Right Turn Indicator
10. Tachometer
11. Engine / Exhaust Brake
indicator
12. Air Pressure Gauge
13. Cluster Illumination Button
DICV-HDT-836
14. Cluster Illumination Button
15. Ambient Temperature and The AdBlue guage only provides a
Coolant Temperature Button general indication of AdBlue level.
The AdBlue level is indicated by DICV-HDT-1608
16. Trip Meter Button
four blue segments in the gauge. AdBlue Reserve Level
17. Tipper Control Indicator
(2528C, 2528CH & 2528CX) 1 Status bar indicator lights up in
18. MIL Lamp yellow.
19. AdBlue Gauge 2 AdBlue tank will be displayed.

5-2
AdBlue Level Indicator
AdBlue level indicator indicates the
level of AdBlue in the AdBlue tank.
DICV-HDT-1602
Distance to Empty (DTE)
Distance to empty shows the
approximate estimated distance
user can travel with the remaining
AdBlue fuel in the tank.
Tachometer
It shows the engine speed- RPM in
revolutions per minute. The vehicles
best performance can be obtained if
the engine speed is maintained
within the “Economy” sector. Refer
page 10-6 for efficient driving. This
is indicated by the green band in
the RPM meter provided in the
DICV-HDT-1603 instrument panel between 1200rpm
to 1600rpm.
Speedometer
Speedometer shows the vehicle
speed in kilometer per hour (km/h).
DICV-HDT-052
Air Pressure Gauge
DICV-HDT-051 A common air pressure gauge is
provided to indicate the air pressure
in the brake system.
5-3

1 2
DICV-HDT-053
1 2
DICV-HDT-054
Air pressure gauge is provided with
two low air pressure warning
indicator with an in-built warning
buzzer. The sensors provided in the
primary and secondary air tanks
senses the air pressure. Warning
lamp glows in primary (1) and
secondary (2) based on the pressure
difference (i.e.) The circuit which
5-4
has lower air pressure is indicated
by the warning lamp. The warning
buzzer will be activated when the air
pressure drops below 4.9 bar, and
goes above 8.1 bar in the system.
WARNING
Before moving vehicle ensure
brake pressure is more than 6
bar.
Left Turn Indicator
The left turn indicator glows
whenever the turn signal in the
combination switch is used while
the vehicle is making a left turn.
DICV-HDT-055
Right Turn Indicator
The right turn indicator glows
whenever the turn signal in the
combination switch is used while
the vehicle is making a right turn.
DICV-HDT-060
High Beam Indicator
The high beam indicator glows
when the headlight is turned on to
high and whenever the main beam
flasher is operated.
DICV-HDT-056
Low Air Pressure Warning
In brake system if pressure drops
below 4.9 bar low pressure warning
indicator will glow.
 Cab Lock Indicator
The cab lock indicator glows when
the cabin is not properly locked.

DICV-HDT-057

Brake Pressure Warning

Indicator
DICV-HDT-061
The brake pressure warning
indicator will glow for both low air Odometer DICV-HDT-062

pressure (less than 4.9 bar) and high An odometer shows (5 + 1 digits)
air pressure (more than 8.1 bar). the cumulative distance covered by 1 4 3 2

the vehicle. An additional trip

KMS

odometer is also provided. Trip

odometer can be reset by pressing DICV-HDT-063
the trip knob (1) continuously for 2
DICV-HDT-282
seconds. The brightness of the Coolant Temperature Gauge
instrument cluster is set by cluster The engine coolant temperature is
Parking Brake Indicator Illumination Button 2 and 3 (For the indicated by a LED display in the
above functions to work the park cluster. The coolant sensor indicator
When the parking brake is in lamp/ head lamp switch should be
engaged condition, the indicator will glows with an acoustic warning
in ‘ON’ position). The ambient when the engine temperature shoots
glow. temperature and coolant beyond 105°C.
temperature can be viewed by
pressing the button 4.
P
DICV-HDT-058

5-5

DICV-HDT-064
Stop the vehicle and switch off
engine when the temperature shoots
beyond 105°C. Immediately contact
an authorised dealer.
ABS Warning Indicator
DICV-HDT-065
The ABS indicator glows for
approximately 5 seconds when the
system is still effective and capable
of providing normal stopping ability.
In this condition it is recommended
to take your vehicle to the nearest
authorised dealer and get your
vehicle attended as soon as
possible.
Low Oil Pressure Indicator
When the engine oil pressure falls
below 0.5 bar, this low oil pressure
warning light glows, in such a
condition stop the vehicle and
switch OFF the engine.
DICV-HDT-066
Battery Charging Indicator
If alternator output to battery is not
available, indicator will glow.
- +
DICV-HDT-067
Engine Protect Indicator
The engine protect indicator glows
when the coolant temperature is
high (105˚C) and in turn the engine
power output is reduced. In such a
case reduce the vehicle speed and
allow the engine to cool down.

!
ignition key is turned to ON Check the oil level and top up as
position. This is normal and necessary. If the problem still
indicates the system is performing a continues, contact the nearest
self check. If the light does not authorised dealer. DICV-HDT-068
illuminate when the ignition is
turned ON or remains illuminated
after initial self check and while
driving, fault may exist in the ABS
system. In this case normal braking

5-6
Fuel Reserve Indicator Coolant Level Indicator Stop Lamp
The tank reserve indicator glows If the coolant level in the de-aeration If the brake pressure is low,
when the fuel level reaches reserve tank is too low, indicator will glow. indicator will glow.
in the tank.

STOP
DICV-HDT-179 DICV-HDT-180
DICV-HDT-069
Neutral / Reverse Gear CAN TOTAL Failure
Air Filter Restriction Indicator
If the vehicle is in neutral or When ECU signal line fails indicator
The air filter restriction indicator engaged in reverse gear, indicator will glow, immediately contact an
glows when the filter is choked with will glow in the cluster N or R authorised dealer.
impurities. Replace the air filter at respectively.
an authorised dealer.

DICV-HDT-182
DICV-HDT-178
DICV-HDT-070

5-7
Status Bar Indicator
Status bar indicator lights up in
yellow for low priority faults, also it
lights up in red for higher priority
faults.
Differential Lock Indicator
2523R & 2528R (6x2)
When differential lock is engaged
indicator will glow in the cluster.
DICV-HDT-245

PTO Indicator - 2528C,

2528CH & 2528CX
When PTO is engaged, indicator will
DICV-HDT-243
DICV-HDT-181 glow in the cluster.
2528R (6x4), 2528C, 2528CH,
WARNING 2528CX & 2528RMC
When red or yellow indi cator When first stage is engaged to
glows immediately contact an activate inter axle differential lock, DICV-HDT-242
authorised dealer. indicator will glow in the cluster.
Tipper Control Indicator -
2528C, 2528CH & 2528CX
When the tipper is operated, tipper
control indicator will glow.
DICV-HDT-244
When second stage is engaged to
activate inter wheel differential lock,
indicator will glow in the cluster.
DICV-HDT-196

5-8
Exhaust/Engine Brake Indicator
When the exhaust / engine brake
switch is ’ON’ this indicator will
glow in the cluster.
Seat Belt Reminder Indicator observed during the self-check
during ignition ON or while the
The indicator glows in the cluster
engine is running, the MIL indicator
until the driver’s seat belt is
lights up and remain steadily ON
fastened.
until the fault is rectified.

DICV-HDT-698
DICV-HDT-2127

MIL Lamp Indicator

The MIL indicator notifies the driver
of any fault related to the engine
DICV-HDT-1357 which in turn affects the exhaust
emission control. When the ignition
NOTICE is switched ON, the MIL indicator
glows and flickers during which the
Do not switch on engine/ MCM control unit performs a self-
e xh au st b rak e d u ri ng n ormal check of all the components
driving c o n d i t i on s. U se associated with it. If the self-check
judiciously only while is satisfactory, the light goes OFF
descending a slope for optimum
after the engine is cranked and
performance of engine.
running. If there is any fault
WARNING
When the MIL indicator is ON,
the engine performance and the
e m i ss i o n re g u l a t i on w i l l b e
affected. Immediately contact
t h e n e a r e s t M e r c e d e s- B e n z
authorized service center and
get the r ecom mended
assistance.

5-9
Switch Controls - 2523R & 2528R

2 5 i

6 10

13 9 LIM
8
14 0

1
7 11

12

1.12V Socket 6. INS-1 Switch 11. Head Lamp Level Adjuster

2. Hazard Warning Switch 7. Auxiliary Lamp (Fog Lamp) 12. OBD- On Board Diagnostic Port
3. Engine / Exhaust Brake Switch 8. Head Lamp Switch 13. Power Window** (Co - Driver)
4. Differential Lock Switch* 9. Cruish Control Switch 14. Power Window** (Driver)
5. INS-2 Switch 10. Speed Limit Switch DICV-HDT-2720
*2528R (6x2) has single stage differential lock switch. 2528R (6x4) has two stage differential lock switch
**if applicable

5-10
Switch Controls - 2528C, 2528CH, 2528CX & 2528RMC

2 6 i

7 12

5 n
8

16 19 17 11 LIM
10
4 0

1
9 13

18 14

15

1.12V Socket 6. INS-2 Switch 11. Cruish Control Switch 16. Power Window** (Co - Driver)
2. Hazard Warning Switch 7. INS-1 Switch 12. Speed Limit Switch 17. Power Window** (Driver)
3. Override Switch 8. PTO Switch (RMC) 13. Head Lamp Level Adjuster 18. Beacon Lamp Switch**
4. PTO Switch (2528C) 9. Auxiliary Lamp (Fog Lamp) 14. Rear Working Lamp (2528C) 19. Air Conditioner Switch**
5. Differential Lock Switch* 10. Head Lamp Switch 15. OBD- On Board Diagnostic Port
DICV-HDT-2721
*Construction & RMC has two stage differential lock switch. **if applicable

5-11
Power Socket
A 12V power socket is situated
below the air conditioner and hazard
lamp switch to charge mobile phone
and accessories.
DICV-HDT-072
Air Conditioner Switch*
The air conditioning switch activates
the air conditioner which is assured
when the back light in the switch
glows.
*if applicable
5-12
INS 1 Switch
The INS 1 switch is used to view the
various menus in the cluster.
DICV-HDT-612
Hazard Lamp Switch
This switch activates both the turn DICV-HDT-075
indicators. This is to be operated
INS 2 Switch
during an emergency situation.
The INS 2 switch is used for
toggling between the various menus
and sub-menus in the cluster.
i
DICV-HDT-074
DICV-HDT-076
Menu Navigation
MENU IllUSTRATION SUB MENU REMARKS

Error Codes Error Codes Error Codes

Red/ Yellow Error Codes
i i
Status

AdBlue Qty available Fuel Qty available Distance to Empty

Fuel and AdBlue i i

Hours Run
Engine Hours

kms kmpl Diesel consumed kmph Hours

To Reset, press the trip
Trip
i i i i switch (1) continuously
for 2 seconds

Alarm Deactivate/ Alarm activate Setting Alarm

Alarm status
Activate time Store the adjusted value
Alarm i i
i

Hours / Min
Time Time adjust
Adjustment Store the adjusted value
Time i
i

Part no Error codes Error codes

FR i i

Part no Error codes

INS i

Part no Error codes

MR i

DICV-HDT-1585

5-13
The above table shows the various
menus and sub menus and they can
be selected with the help of INS 1
and INS 2 switch.

MENU

i ENTER

ADJUST DICV-HDT-077 DICV-HDT-220

BACK
2528R (6x4), 2528C, 2528CH, CAUTION
TRIP
2528CX & 2528RMC 1. Do not operate the
1

Two stage type switch is provided differential lock switch during

DICV-HDT-176
Differential Lock Switch
2523R & 2528R (6x2)
Differential lock switch is provided
to engage the differential lock on
rear live axle in case of slippery
wheel ends. It is pneumatically
activated for inter wheel lock to be
engaged or disengaged only after
bringing the vehicle to a stationary
condition.
for inter axle lock and differential
lock in case of slippery. First stage
activates the inter axle differential
lock, and second stage activates
inter wheel lock parallelly for both
axles.
normal driving.
2. Differential lock should be
activated only when the wheels
are spinning.
3. Do not drive the vehicle more
than 5 km/h when differential
lock is engaged.
4. Do not steer the vehicle when
the differential lock is ON

5-14
PTO Switch (2528C, 2528CH &
2528CX)
PTO - Power Take Off should be
switched ON to engage PTO pump,
whenever the tipper is operated.

DICV-HDT-199
NOTICE
PTO sw itc h to be en gage d by
pressing the clutch pedal.
PTO Switch (2528RMC)
n
DICV-HDT-711
Exhaust / Engine Brake Switch
(2523R & 2528R)
The exhaust / engine brake is an
additional brake system to be used
whenever the vehicle is descending
a long slope or downhill.The
exhaust / engine brake can be
engaged by pressing the switch in
the dashboard. The engine / exhaust
brake will function if all the below
conditions are true.
DICV-HDT-078
1. The engine rpm exceeds
900rpm.
2. Clutch pedal should not be in
the depressed position.
3. Transmission should be
engaged.
4. Accelerator should not be
pressed.

PTO - Power Take Off should be

switched ON to increase the engine
idling RPM during loading and
unloading of RMC.

5-15
Brake Pedal Mounted Exhaust/
Engine Brake (2528C, 2528CH,
2528CX & 2528RMC) Exhaust/
Engine brake can be engaged along
with override switch (1) by
activating the stack switch (2) or
pressing service brake.
1
2 • Brake pedal should be in pressed
DEFAULT
Service Brake Pedal Headlight Switch
Below logic is true, exhaust/engine
The headlight switch is of two stage
brake will be engaged.
type to switch on the headlights.
Case 1
• Stack switch should be in
activated position.
• Override switch should be
OFF/ON.
or not pressed condition.

Case 2
DICV-HDT-079
ACTIVATED
• Stack switch should be in default
position. 1. Illumination- Push the switch
upwards to switch on the head
• Override switch should be
DICV-HDT-1622 lamps and parking lamps.
OFF/ON.
Stack Switch 2. Low Beam- Push the switch
• Brake pedal should be in pressed downwards to turn on the head
condition. light in low beam mode. This
also turns on the side body
Logic lamps
Engine Accelerator Clutch pedal
RPM pedal switch
>900 Not pressed Not pressed

DICV-HDT-142

5-16
Headlight Thumb wheel OBD Connector
The focus of the headlight can be The On Board Diagnostics port is
adjusted by rotating the thumb provided to the right side of the
wheel to one of the three positions steering to connect diagnostic tool.
based on the load conditions.

DICV-HDT-1893

Rear working Lamp Switch

The rear working lamp switch is
provided to the right side of the DICV-HDT-081
steering column to switch ‘ON’ the
DICV-HDT-080
rear working lamp. CAUTION
In unladen condition keep the
thumb wheel in “0” position and The OBD port is only to be used
adjust the thumb wheel to other for connecting diagnostic tool
available positions for getting better by an authorised dealer.
focus of headlight.
Combination Switch
Beacon Lamp Switch* The combination switch is mounted
This switch is used to activate the on the steering column, below the
beacon lamp. steering wheel to the left side of the
DICV-HDT-247 driver, it can control the following
accessories:-
*if applicable

5-17
 High Beam Passby Beam
The headlights high beam can be The passby beam will glow as long
engaged to high beam by moving as the combination switch is held in
the combination switch to position the ‘2’ position. The combination
‘1’. When the combination switch is switch will return back to low beam
pulled back to it’s default position, on releasing it.
the low beam is engaged.
Turn Indicator
To switch on right turn indicator
DICV-HDT-082
1 move the combination switch to
1. Horn position ‘4’ and move it to position
2. High Beam ‘3’ to switch on the left turn
3. Passby Beam indicator.
4. Turn Indicator
2
4
5. Wiper
6. Washer DICV-HDT-1624

Horn
The horn is provided in the 3
combination switch and on the
steering horn pad.
DICV-HDT-1625
The combination switch will move
to it’s default position when the turn
is completed.

5-18
Wiper Power Window Switch* Driving System
The focus of the headlight can be Introduction to driving systems
adjusted by rotating the thumb
The vehicle can be equipped with
A
wheel to one of the three positions
the following driving systems:
based on the load conditions.
• Speed limiter

DICV-HDT-085
DICV-HDT-1614
1. The wiper has three speeds
(Slow, Fast, Intermittent) it can • Cruise control
be controlled by rotating the
wiper control knob to the
DICV-HDT-2198
required speed along the ‘A’
position. Power window switches which are
provided in the dashboard are used
2. To activate the automatic
to open/close of door window glass DICV-HDT-1361
windshield wiping with water
by driver and co-driver The driving systems described here
move the wiping control knob
independently. are merely tools that helps driver to
towards ‘B’ position for the
duration till washing is required drive at a preselected speed. It is
and release once done, so that driver’s responsibility to control the
it can return to it’s original actual speed of the vehicle at all
position automatically. times.

*if applicable

5-19
Switching between driving sys-
tem functions
It is possible to switch between the
speed limiter and cruise control at
any time. The symbol for the
selected driving system appears in
the display.
Switching from cruise control to
speed limiter
Switching between cruise control
and the speed limiter is only
possible when the vehicle is in
motion.
1 4
3
2
DICV-HDT-1371
5-20
• Press selector (LIM) button (4)
briefly. Cruise control is
operationally ready but not
active. The below indication
appears in the display.
DICV-HDT-1361
• Press selected (LIM) button (4)
again briefly. The speed limiter
is on standby but not active.
The below indication appears in
the display.
DICV-HDT-1614
Speed Limiter
Using the speed limiter, we can set
the limit speed to any speed above
15 km/h. It is possible to accelerate
the vehicle up to the set limit speed
using the accelerator pedal.
The speed limiter maintains the
limit speed on downhill gradients
within a tolerance of 4 km/h,
provided the available engine
braking effect is sufficient.
WARNING
The speed limiter automatically
limits the speed. The speed
limiter is not able to detect road
and traffic conditions.
The speed limiter is only an aid
which is designed to assist
driving. Drivers are responsible
for the vehicle’s speed and
keeping a safe distance.
Activating/deactivating the speed
limiter
1
4
3
2
DICV-HDT-1371
(1) To activate the speed limiter/to
increase the limit speed.
(2) To reduce the limit speed.
(3) To deactivate the speed limiter.
(4) Selector button for the driving
system.
Activating speed limiter and stor-
ing the current speed
• Press the (LIM) button (4)
repeatedly until the below
indication appears in the
display.
The speed limiter is selected.
DICV-HDT-1614
• Drive at the desired speed.
• Briefly press the (+) button (1).
The speed limiter is activated and
stores the current speed.
If the speed limiter is activated,
below indication and the stored
maximum speed are shown in the
display.
DICV-HDT-1614
If the set limit speed is exceeded by
more than 4 km/h in overrun mode,
the continuous brake will be
automatically activated.
Deactivating
• Briefly press the (0) button (3).
The speed limiter is deactivated.
The limit speed remains stored if
driver deactivates the speed limiter
or if driver activates the cruise
control.
The limit speed becomes available
again once switch back to the speed
limiter.
Increasing or reducing the stored
limit speed
• Briefly press the (+) button (1)
or (-) button (2).
The limit speed is increased or
decreased in a step of 0.5 km/h.
(or)
• The limit speed is increased
sequentially by 0.5 km/h by
holding the (+) button (1)
continuously.
• The limit speed is decreased
sequentially by 0.5 km/h by
holding the (-) button (2)
continuously.
5-21
 • Release the button. The
selected limit speed is stored.
The vehicle is limited to the stored
speed.
Calling up the stored limit speed
• If the speed limiter has been
deactivated, briefly press the (-)
button (2).
The speed limiter reverts to the
previously stored limit speed. The
display shows the limit speed.
Exceeding the stored limit speed
It is possible to exceed the stored
limit speed, e.g. when overtaking.
• Briefly depress the accelerator
pedal beyond the full-throttle
position to the stop (kick-down).
• When overtaking is completed,
briefly release the accelerator
pedal and depress it again.
The vehicle speed is limited to
the stored limit speed again.
5-22
If at this time the vehicle is traveling
faster than the stored limit speed,
the vehicle will be slowed down
automatically with the continuous
brake.
Cruise Control
Cruise control allows to set any
speed above 15 km/h.
Use cruise control if road and traffic
conditions make it appropriate to
maintain a steady speed for a
prolonged period.
Cruise control operates the engine
management, the engine brake
automatically to keep the vehicle at
the stored speed. Cruise control is
not able to detect road and traffic
conditions.
The speed is regulated with tolerant
of 4 km/h. The speed is only
maintained for as long as the
braking performance of the
continuous brake is sufficient.
Otherwise, shift down and reduce
the speed.
Risk of Accident
WARNING
Cruise control cannot take
account of road and traffic
conditions.
Always pay attention to traffic
conditions even when cruise
control is activated.
Cruise control is only an aid
designed to assist driving. Drivers
are responsible for the vehicle’s
speed and for braking in good
time.
Do not use cruise control:
• On In road and traffic
conditions which do not allow to
maintain a constant speed (e.g.
heavy traffic or winding roads).
Otherwise it cause an accident.
• On slippery roads. Braking or
accelerating could cause the
drive wheels to lose traction.
and the vehicle could then skid
• When there is poor visibility,
e.g. due to fog, heavy rain or
snow.
If change down a gear on an incline
without adjusting the speed, cruise
control will regulate the vehicle at
max engine speed. The set speed
remains stored and the vehicle is
adjusted to this speed as soon as
this is possible in a higher gear.
Activating/deactivating cruise con-
trol
Cruise control cannot be activated:
• If the vehicle’s speed is below
15 km/h.
• If the brake pedal is depressed.
• During ABS intervention.
If cruise control cannot be activated,
_ _ . _ km/h will appear in the display
for approximately three seconds.
1 4
3
2
DICV-HDT-1371
(1) To store the current speed or a
higher speed.
(2) To store the current or a lower
speed or call up the last stored
speed.
(3) To deactivate cruise control.
Activating cruise control and stor-
ing the current speed
• Drive at the desired speed.
• Briefly press the (+) button (1)
or (-) button (2).
• Release the accelerator pedal.
Cruise control is activated and
stores the current speed.
When cruise control is activated the
below indication and the stored
speed appear in the display.
DICV-HDT-1361
Deactivating
• Briefly press the (0) button (3).
Cruise control is deactivated.
If driver deactivates cruise control or
activated the speed limiter, the
speed remains stored. If driver
switch back to cruise control, the
stored speed will become available
again.
Increasing or reducing the stored
speed
• Briefly press the (+) button (1)
or (-) button (2).
• The set speed is increased or
decreased in a step of 0.5 km/h.
(or)
5-23
 • The speed is increased
sequentially by 0.5 km/h by
holding the (+) button (1)
continuously.
• The speed is decreased
sequentially by 0.5 km/h by
holding the (-) button (2)
continuously.
• Release the button. The
selected limit speed is stored.
The vehicle is accelerated up to the
set speed or slowed down with the
continuous brake to the set speed.
Calling up the stored speed
• If cruise control has been
deactivated, press the (-) button
(2).
The vehicle is accelerated or
decelerated to the set speed.
Automatic deactivation of cruise
control
Cruise control is deactivated
automatically:
• By using the service brake.
5-24
a. For vehicle without a pedal
operated endurance or
continuous brake - If cruise
control is propelling the
vehicle at a point of time,
vehicle is braked using the
service brake. The stored
speed remains in memory.
b. For vehicle with a pedal
operated endurance or
continuous brake - If cruise
control is propelling the
vehicle at a point of time, the
vehicle is braked using the
service brake and the vehicle
speeds reaches below 10 km/
h. The stored speed remains
in memory.
• At speeds below 10 km/h. A
short warning tone sounds. The
stored speed remains in the
memory.
• When changing functions to
use the speed limiter. The
stored speed remains in the
memory.
• When the clutch pedal is
depressed for longer than five
seconds, e.g. during gear
selection. A short warning tone
will sound.
• If the transmission is in neutral
for longer than five seconds.
Notes on driving with cruise con-
trol
It is possible to exceed the stored
speed, e.g. when overtaking,
• Depress the accelerator pedal
beyond the full-throttle position
(kick-down).
• When overtaking is completed,
release the accelerator pedal.
Cruise control readjusts the speed
to the stored speed.
DICV-HDT-1361

NOTICE
Driver can use the continuous
brake for additional braking.
Cruise control remains activated.
When decelerating the vehicle
using the continuous brake,
additional braking is possible
using the service brake. Cruise
control remains activated. When
the continuous brake is
deactivated, the vehicle will
accelerate to the last stored
speed.
For vehicle without a pedal
operated endurance or
continuous brake, cruise control
is deactivated when service
brake is pressed.
For vehicle with a pedal operated
endurance or continuous brake,
cruise control is deactivated
when service brake is pressed
and vehicle speed reaches below
10 km/h. If reset the continuous
brake, but do not deactivate it,
the vehicle will accelerate itself
on inclines up to the set speed.
Idling Speed
The engine idling speed is controlled
automatically by electronic control
unit.
The idle speed is about 600 rpm
with the engine at normal operating
conditions.
1
2 DICV-HDT-1371
DICV-HDT-2135
The idling speed can be adjusted by
using the +/- button on the
dashboard.
This makes it possible to drive
auxiliary equipment such as pumps
at their working speed.
Setting the idling speed
The engine idling speed can be set
when the vehicle is stationary,
approximately between 600 rpm to
750 rpm.
1 4
2
3
• Press and hold the (+) button
(1) Idling speed increases to a
maximum of 750 rpm.
(or)
• Briefly press the (+) button (1)
The idling speed is increased by
approximately 16 rpm at a time.
• Press and hold the (-) button (2)
The engine idling speed can be
reduced to a minimum of 600
rpm.
5-25
 (or)
• Briefly press the (-) button (2)
The engine idling speed is
reduced by approximately 16
rpm at a time.
• Briefly press the (0) button (3)
The change to the idling speed
is deactivated.
The engine runs at the idling speed
set as soon as release +/- button.

NOTICE
The change in idling speed is
automatically switched off after
the vehicle has pulled away
(over approximately 20 km/h).

5-26
6. ELECTRICALS Cabin Light Location
Cabin lights are provided above the
Lighting 1
driver and co-driver seat.

Head Light Location

Powerful factory fitted headlights
provide longer range visibility during
the night.
DICV-HDT-1613

LED / Tail Light Location

The LED / tail lights are fitted to the DICV-HDT-1360
rear of the vehicle.
Auxiliary Lamp Location
Auxiliary lamps are mounted below
/ within the bumper.
DICV-HDT-2561

The headlight focus can be adjusted

using a 8 mm socket. Rotate the
focus gear (1) present behind the
headlight beneath the front grill.
DICV-HDT-1125

Rigid Construction

DICV-HDT-2562

6-1
Removal and Installation
Head Lamp Bulbs
To replace the head lamp bulb, the
access is from behind bumper, it
can be replaced easily by removing
the bulb socket.
1. Remove rubber cap from rear of
head light.
2. Pull out cable socket. DICV-HDT-1612 DICV-HDT-093

Note: Picture for symbolic

4. Refit cable socket with bulb on
representation only, actual product
the head light and press it in
may vary.
position.
2. Replace the old bulb with a new
5. After replacing bulb, check
one.
head light alignment.

Tail Lamp Bulbs / LED Tail

Lamp
DICV-HDT-1611 The tail lights are fitted to the rear
of the vehicle.
3. Replace the old bulb carefully
so that the rubber fits properly 1. Loosen the screw to remove the
between the bulb and socket. tail light cover using a screw
driver.
DICV-HDT-094

3. Refit the cover and tighten the

screws using the screwdriver.

6-2
 1. Loosen the bolt and nut (1) that
CAUTION holds the rubber pad with the
Ensure that the tail light cover is wiper blade.
secured properly with the rubber 2. Detach the rubber pad from the
seal. wiper arm.
3. Place the new wiper blade
along the wiper arm.
NOTICE 4. Tighten the bolt.

If LED tail lamp is not working, Cabin Lights DICV-HDT-097

it should be replaced as a set.
Wiper Arm
The wiper blade should be replaced
when the rubber pads wear out or if
they fail to clean the windshield
properly.
Replace the cabin lights when they
2. Replace the old bulb with a new
are blown out.
bulb.
3. Refit the transparent cover and
tighten the screws using a
screwdriver.
CAUTION
All electrical activities should be
done at an authorised dealer.

1
DICV-HDT-096

1. Loosen the screw to remove the

transparent cover using a screw
driver.
DICV-HDT-095

6-3
Fuse and Relay Box Fuse detail sticker is provided on
back side of the fuse box cover.
Location 2

The fuse and relay box is located

beneath the console in front of co-
driver.
The fuse and relay box can be
accessed by removing the console
panel (1) using a screw driver to Warning

unscrew the screws provided.

DICV-HDT-099

The spare fuse and bulbs details DICV-HDT-177

are:
Quantity

Specification 2523R, 2528R, 2528C,

1 2528CH, 2528CX &
2528RMC
Spare Halogen Bulbs
2 3
1 4
0

0
4
1 2 3

DICV-HDT-1352
H4 24V, 75/
2
Spare Fuse and Bulbs 70W

The spare fuses (2) are provided in Spare Fuse

the console cover in front of the co- 10A 7
driver.
15A 4
20A 2

6-4
Fuse Chart
The fuse chart is found on opening the console in front of the co-driver.

ALLOCATION FUSES, RELAYS ALLOCATION OF FUSES ALLOCATION OF RELAYS

GM A1 A1 A 31_A25
F1-10A Foglamps incl. trailer F20-15A Power window driver F2-10A Power socket F11-15A SCR Frame Module /LO K1 Day Time running lights
F35-10A Condensate sensor/ F2-10A Power socket supply unit term.30 K2 Horn
F2-10A Instrument-/switch illumi- F21-15A Power window co-driver
Trailer ABS t.15 K3 Stop lamp SW/Rear fog lamp
nation/Head lamp F22-10A Wiper/turn signal F3-20A RMC Cooler Fuel heater F12-30A Electro hydraulic Cab Tilt
F37-10A Windscreen washer
Ovvcleaning system/ relay t.30 (Hazard) F4-15A Central locking system F13-10A Transmission ECU/DMS/ K4 Radio/Phone/Fax 12V t. 15R
system
Distribution term.58 F23-10A Low beam right F5-10A 24V Music System Telematics K5 Radio 12V t.58
F38-10A Airbag/Tachograph/ K6 External RPM relay1
F3-15A Wiper Timer F24-10A Low beam left Instrument cluster F6-15A Transmission ECU F14 -10A Retarder ECU/Diff lock
F4-10A Radio 24V/sunroof/ F25-10A High beam right K7 Fog lamp
t.15 10A Rear Fog Lamp buzzer
Frequent-stop brake t.30 K8 Exhaust brake step1
F26-10A High beam left/ F39-10A Horn/Toll F7-10A Voltage transformer K9 External RPM Relay2/Exhaust
F5-10A Work-area lamp/Heavy Indicator lamp Collect/Diagnostic 24V/12V,8A Brake Step2
duty traffic levy t.30 F27-10A Taillamps left/ socket/Fleet -15A Voltage transformer K10 Wiper system
F7-15A Distribution term. D+ Parking lamps/ Management 24V/12V,20A
F8-10A DRL Side marker lamps/ Distribution t.15
F8-10A Roating Beacon lamp A 31_A29
F9-15A LED Flasher Trailer/Toll collect t.58 F40-10A Inter-axle/wheel
F9-10A Pusher Axle/Air Dryer K1 Lighting Switch KI.58
F10-10A Diagnostic socket/Instru F28-10A Taillamps right/ diff.locks
Heater
ment cluster/Tacho- Parking lamps/side K1 Wiper/turn signal relay K2 Lighting Switch KI.56
marker lamps/Trailer A1 Daytime driving lights F10-10A DMS/Telematics K3 Lighting Switch KI.56a
graph t.30
F29-15A Transmission control A2 Headlamp cleaning K4 Pusher Axle
F11-15A External RPM RMC
F30-10A Engine speed control system K5 Hazard SW
F12-20A Trailer ABS t.30 t.15/Hazardous goods: K6 Disconnection transmission
K4 Auxiliary water heating DC A 400 584 13 08 ZGS 001
F13-10A Interior lighting/Toll cut-off switch neutral/reverse
K5 D-Amplification
collect t.30 F31-10A Lift Axle/SCR- K7 Turn singnal
K6 Stop lamps
F15-15A Transmission/Alternator frame module t.15 K8 Washer system
K7 Reversing lamps K9 Wiper low
/Heavy-duty traffic levy F32-10A Hill Holder
t.15 F33-10A Trailer socket/Wiper- K10 Wiper High
F16-10A Power Take-Off turn signal relay t.15
F17-20A HVAC F34-15A Stop lamps/Reversing DC A 400 584 14 08 ZGS 001
F18-10A Radio/Instrument cluster lamps incl.trailer
Telephone/Fax t.15R

A 400 545 07 00 - ZGS 003

Warning

DICV-HDT-1605

6-5
Fuse Chart - 2523R & 2528R
The fuse chart is found on opening the console in front of the co-driver.

A24
A37 A25 A7
FUSE
MINI RELAYS MICRO RELAYS BASE MODULE
STRIP
Neutral /
Reverse

K6

K10

F14

15A

F15

10A
10A

10A
F29

F1
Transmission Control Alternator T.15 Fog lamp Spare

K1 Wiper / Turn signal relay

F2
Engine speed control Instrument Cluster Switch

10A
F13

10A
F16
10A
F30
K9 Spare
T.15 Illumination/ Distribution

F31

10A
20A
F12

F17

F3
HVAC Spare

K3
K5

10A
F32

10A
F18

10A
K8
F11

F4
Radio T.15R Stop Brake T.30 Spare

10A

F19

10A
F10

10A
F33

F5
K7 Turn signal relay T.15 Working Lamp Spare
K4

K4 Stop lamp / Reverse

15A
F34

10A
F20

F6
F9

Spare
lamp

F7
F35

15A

10A
F21
K6
F8

Distribution Term D+ Spare

Amplification

Voltage
Light switch

15A
10A
F22
10A

K5 Radio 12V

F36

F8
F7

transformer Turn signal relay T.30 Spare

term 56a

T58 24V/12V
D+
K5
K3

F6

10A
Wind screen washer

10A
F37

15A
F23

F9
Low beam right Spare
system

K4 Radio 12V 10A

Diagnostic socket/

10A
Light switch

F38

15A
F24

10A

F10
Stop lamps
F5

T15R Instrument Cluster T.15 Low beam left Spare

Instrument cluster T.30
term 56

K6
K2

A1

Horn/Diagnostic

10A
F25

15A
F11
10A
F39
F4

K3 Stop lamp High beam right Spare

socket/Distribution T.15

F12
F26
10A

10A

20A
F40
F3

Wheel diff locks High beam left/indicator lamp Spare

Reverse lamp
Light switch

12V Tail lamp left/Parking lamp/side

10A
F27

F13
10A

20A
10A

F41

K2 Horn
F2

Interior lighting T.30 Spare

term 58

SOCKET marker lamp T. 58

K7
K1

A2

12V Tail lamp Right/Parking

10A

F28

10A

F14
F1

K1 Fuse Puller
SOCKET lamp/side marker lamp

DICV-HDT-1353

6-6
Fuse Chart - 2528C, 2528CH, 2528CX & 2528RMC
The fuse chart is found on opening the console in front of the co-driver.

A37 A25 A24

MINI MICRO
A7
FUSE STRIP
RELAYS RELAYS BASE MODULE
K6

K10

10A
10A
F29

10A
F14

F15

F1
Alternator T.15 Fog lamp Spare

K1 Wiper / Turn signal relay

10A
Engine speed control Instrument Cluster Switch

10A
10A

10A
F13

F30

F16

F2
K9 Power take -off Spare
T.15 Illumination/ Distribution term

10A
20A
F12

F31

F17

F3
HVAC Spare

K3
K5

10A
10A
F11

F32

F18

10A
F4
K8 Radio T.15R Stop Brake T.30 Spare

10A
10A

10A
F19
F10

F33

F5
K7 Turn signal relay T.15 Working Lamp Spare

K4
K4

Stop lamp / Reverse

15A

10A
F20
F34

F6
F9

Spare
lamp

15A

10A
F35

F21
K6
F8

F7
Distribution Term D+ Spare
D+ Amplification

Voltage
Light switch

K5
10A

10A
F36

F22

15A
F8
F7
term 56a

transformer Turn signal relay T.30 Spare

K3

K5

24V/12V
Radio 12V T58
10A Wind screen washer

10A
F37

F23

15A
F9
F6

Low beam right Spare

system

K4 Diagnostic socket/ Instrument

Light switch

F10
10A
10A
10A
F38

F24

15A
Stop lamps
F5

Instrument cluster T.15 Low beam left Spare

Radio 12V T15R cluster T.30
term 56

K2

A1
K6

Horn/Diagnostic

10A
10A
F39

F25
K3

F11

15A
F4

High beam right Spare

Stop lamp socket/Distribution T.15

Interaxle/Wheel diff
10A

10A
F40

F26

20A
F12
F3

High beam left/indicator lamp Spare

locks
K2
Reverse lamp
Light switch

12V Tail lamp left/Parking lamp/side

10A
10A

10A
F13
F41

F27

20A
F2

Horn Interior lighting T.30 Spare

term 58

SOCKET marker lamp T.58

K1

K7

A2

12V Tail lamp Right/Parking lamp/side

F14
10A
10A

F28
F1

K1 Fuse Puller
SOCKET marker lamp

DICV-HDT-1354

6-7
Components Location
Wiper Motor
The wiper motor is mounted
beneath the front lid below the
windscreen.

DICV-HDT-102 DICV-HDT-2563

Alternator ECU- Electronic Control Unit

The alternator is found to the right The vehicle’s ECU-Electronic Control
side of the engine’s front. Unit & DC-DC Converter are situated
beneath the console in front of co-
DICV-HDT-101 driver above the fuse and relay box.
Starter Motor
The starter motor is mounted onto
right side of the engine’s rear side. 1

CAUTION
Do not allow any metal to con-
tact between the negative and DICV-HDT-103
positive terminals of the starter
motor to avoid short circuit, also Horn
DICV-HDT-1910
avoid contact between starter A low tone horn is fitted beneath
1. FR ECU.
positive terminal and chassis to bumper in front of the vehicle.
avoid short circuit. 2. 24V DC - 12V DC Converter.

6-8
Reverse Warning Buzzer
A reverse warning buzzer is
provided on the rear side of the
vehicle to make an alert.

DICV-HDT-1363

6-9
7. BRAKE SYSTEM
Spring Brake Actuator
The spring brake actuator is located
on the rear axle and is used for
brake actuating. Incase of
emergency situations it can be
released when there is insufficient
pressure in the brake system by
loosening the nut (1) using a 24mm
spanner in order to drive the vehicle
to the nearest authorised dealer.
1 a long slope or downhill. The
DICV-HDT-106
CAUTION
The spring brake actuator
should be repaired only by an
authorised dealer.
Service Brake
Excessive brake lining clearance is
not recommended as it can reduce
brake performance. The brake lining
should be checked frequently for
wear out through the window
located on the brake assembly back
plate. Refer Maintenance chart for
brake lining inspection and
service.
DICV-HDT-107
CAUTION
The brake lining should be
replaced once the lining edges
wears out closer to the brake
shoe.
WARNING
D i rt y b r a k e l i n e r a n d b r a k e
drum can hinder effective
braking resulting in accidents.
Always carry out an effective
brake test before operating the
vehicle in public roads.
Engine / Exhaust Brake
System
The exhaust/ engine brake is an
additional brake system to be used
whenever the vehicle is descending
exhaust brake can be engaged by
pressing the switch in the
dashboard. Refer page 5-9
Exhaust / Engine Brake Indicator.
7-1
Automatic Slack
Adjuster
The vehicle is fitted with automatic
slack adjusters for front and rear
brakes. The slack adjuster
automatically adjusts the clearance
between brake drum and brake
lining. This in turn ensures brake
chamber stroke within safe
operating limit till the lining is worn
out.

DICV-HDT-108

CAUTION
Any kind of maintenance or ser-
vice in the slack adjuster should
be performed by an authorised
dealer only.

7-2
8. WHEELS AND TYRES
Tyre and Wheel Information
Mercedes-Benz provides conventional and radial tyres. The wheel nuts are right hand threaded.

Tyre Pressure Details

2523R, 2528R (6x2), 2528R (6x4), 2528C, 2528CH, 2528CX & 2528RMC

Conventional Tyre
Tyre (11.00 x 20)

Unladen Pressure (psi) Laden Pressure(psi)

Front 75 120

Rear 75 120

8-1

NOTICE
1. The above values are cold
inflation pressure details.
2. Cold inflation pressure means
the vehicle is stand still for 4
hours without running under
shade.
Changing a Deflated Rear Axle (2523R & 2528R)
Wheel
Position the jack accordingly under
the vehicle carefully on a stable
ground.
Front Axle (2523R, 2528R, 2528C,
2528CH, 2528CX & 2528RMC)

Do not repaint
DICV-HDT-110
1. The tyres
2. Wheel nuts and threads Tag Axle (2523R & 2528R)
3. The rear wheel contact faces

Wheel Alignment
Check wheel alignment as per
maintenance chart periodically and DICV-HDT-109
adjust the toe-in if required as per
specification.

CAUTION
Perform the Toe-in only at the
authorised dealer.

8-2
Jack Positions (2528R (6x4),
2528C, 2528CH, 2528CX & WARNING
2528RMC) Use the jack only to raise the
First Rear Axle v e h i c l e f or a s h or t t i me a n d
perform a tyre change. Do not
use any other points for jacking
other than specified. Do not use
the vehicle jack ins tead o f
stands. There is a danger that
the jack cou ld give away and
vehicle can slip and cause
accidents.
DICV-HDT-202 Jack Spacer Position (2528R
Second Rear Axle (6x4), 2528C, 2528CH, 2528CX
& 2528RMC)
DICV-HDT-203
DICV-HDT-708
Follow the below procedure for
locating and positioning of Jack
spacer.
1. Position the jack spacer as
shown in the above art.
2. Holes on the spacer should be
aligned with the bracket bolts.
3. Ensure that the projection in the
jack spacer has to go inside the
cavity of braket.
4. Jack should be placed on the
below the flat surface of the
spacer for lifting.
CAUTION
Fitting the jack spacer reversely
(Projected area outside), may
cause the spacer breakage.
8-3

DICV-HDT-111
To remove and change a deflated
wheel from the vehicle follow the
procedure:
1. Clean the threads. Ensure no
mud or dust on the thread.
2. Loosen the nuts of the affected
tyre.
3. Jack the axle and remove tyres
by completely removing the
nuts.
4. Clean all the threads and
ensure no mud or dust on the
thread.
8-4
5. Fix the spare wheel into
position. In case of twin rear CAUTION
wheels please note that the tyre While refitment of wheel nuts
valve of the inner wheel should ki n dl y e n su r e i t i s fr e e from
project through the aperture in dust and impurities to improve
the rim of the outer wheel such thread life and ensure proper
that the inner wheel is torquing. Avoid overtightening
diametrically opposite to the of wheel nuts beyond the
valves of outer wheel. specified torque by standing on
6. Refit all wheels nuts, tighten the lever.
them lightly, then select
diametrically opposite nuts in a
sequence and tighten them fully
to the specified torque- 600 Nm.
7. Remove the jack and tighten all
the wheel nuts once again.
DICV-HDT-112
Spare Wheel Operation 2. To lower the spare wheel, move 4. To refit the spare wheel, insert
the sliding plate (2) towards the bottom plate (4) onto the
The spare wheel is fixed to the front and rear slowly with help spare wheel.
chassis. To remove and fix the spare of tommy bar (3).
wheel follow the below procedure:- 5. Slowly rotate the tube (5) in
clockwise direction with help of
1. Remove the four lock nuts (1). wheel spanner (6).
6. Tighten the four lock nuts.
1 2

3
5
6
DICV-HDT-1062 4

3. Completely lower the spare

DICV-HDT-1061
wheel using the tommy bar and
remove the bottom plate. DICV-HDT-1063

CAUTION CAUTION
Do not stand or place any Do not drive the vehicle without
object beneath the spare wheel tightening the lock nuts
while lowering it. properly.

8-5
Tyre Rotation Procedure Cycle 2 - Flip the tyres inside out Drive and Tag Axle Tyre
Tyre rotation is a routine preventive
for both Left hand and Right hand Rotation
sides.
maintenance practice to improve Drive axle and tag axle tyre shall be
tyre life performance. rotated in two different cycles.
Cycle 1 - Interchange the tyres
Front Axle Tyre Rotation
VEHICLE FRONT

between drive axle and tag axle as

Front axle tyres shall be rotated in shown.
LH RH
two different cycles.
Cycle 1 - Swap Left hand (LH) and 2LO 2LI 2RI 2RO

Right hand (RH) sides assembly.

DICV-HDT-501

VEHICLE FRONT NOTICE

C y c l e 1 a n d Cy c l e 2 t o b e
followed alternatively for every
LH RH 10,000km for better tyre life.
3LO 3LI 3RI 3RO

CAUTION
DICV-HDT-500
1. In case of uneven wear, tyre
rotation to be carried out even
before the kms indicated.
2. In case to case basis, if edge
2 : Drive axle LO : Left Outer RO : Right Outer
wear is visible on any specific 3 : Tag axle LI : Left Inner RI : Right Inner
tyre or both tyres, Cycle 2 can DICV-HDT-670
be carried out.

8-6
Cycle 2 - Interchange the tyres
between drive axle and tag axle as CAUTION
shown. In c ase of un ev en we ar, t yre
rotation to be carried out even
before the kms indicated.
2LO 2LI 2RI 2RO

3LO 3LI 3RI 3RO

2 : Drive axle LO : Left Outer RO : Right Outer

3 : Tag axle LI : Left Inner RI : Right Inner
DICV-HDT-671

NOTICE
C yc l e 1 an d C y c l e 2 t o b e
followed alternatively for every
10,000km for better tyre life.

8-7
9. MISCELLANEOUS INFORMATION
Warning Triangles
Two warning triangles are provided
along with the vehicle’s tool kit to
be used is case of an accident or
breakdown.
DICV-HDT-116
Note - Picture for symbolic
representation only, actual product
may vary.
If your vehicle breaks down.
1. Drive your vehicle and park it
on side of the road if it is in
drivable condition.
2. Switch on the hazard warning
lights in case your vehicle
causes an obstruction.
3. Place the warning triangle on
the front and back of the
vehicle to alert the approaching
traffic.
4. If possible, keep your sidelights
ON. If it is dark or visibility is
poor do not stand or let
anybody else stand between
your vehicle and approaching
traffic.
9-1
Tail Lamp Mounting

CAB / CHASSIS VEHICLES

TAIL LAMP DETAILS

TAIL LAMP CUM REFLEX REFLECTOR TAIL LAMP CUM REFLEX REFLECTOR
REVERSING LAMP REVERSING LAMP
BLINKER LAMP STOP LAMP
STOP LAMP BLINKER LAMP

LHS RHS

DICV-HDT-1355

9-2
Bulb Specification
For both 2523R, 2528R, 2528C, 2528CH, 2528CX & 2528RMC

S.No Bulb Specification (As per AIS-034)

1 Head Lamp Bulb (Main and Dip) 24H4 -75/70 W

2 Parking / Position Lamp Bulb - Front

24W5W
3 Side Marker Lamp Bulb

4 Parking / Position Lamp Bulb - Rear

24R10W
5 License Plate Lamp

6 Reversing Lamp bulb

7 Direction Indicator Lamp Bulb - Front

24P21W
8 Direction Indicator Lamp Bulb - Rear

9 Direction Indicator Lamp Bulb - Side

10 Stop Lamp Bulb

11 End out Marker Lamp Bulb - Front 24R5W/24W5W

12 End out Marker Lamp Bulb - Rear 24R10W/24W5W

13 Fog Lamp bulb H21 24V - 21W

9-3
10. DRIVING AND OPERATION
Seat and Seat Belts 3. Release the recliner lever to

The driver seat of ergonomic

WARNING lock the seat to the required
D o n o t p e r f o r m a n y k i n d of position.
contour design adds comfort to
drivers of all sizes. adjustments in the seat while
driving. NOTICE
Forward, Backward Sliding
Adjustment Ensure that the seat recliner is
Backrest Recliner Adjustment locked and steady after making
The driver seat’s forward and adjustments before starting to
The backrest reclining adjustment
backward adjustment bar is located drive the vehicle.
lever (2) is located on the side of the
on the front side of the seat.
seat.
Seat Height Adjustment
The seat height adjustment lever (3)
is located under the seat along the
right hand side of the driver.
2

DICV-HDT-121
DICV-HDT-122
1. Lift the bar (1) to move the seat. 3
1. Pull the reclining lever upwards
2. Move the seat to the required to unlock the backrest.
position.
2. Tilt the backrest to the desired
3. Release the lift bar to lock the position.
DICV-HDT-123
seat in the desired position. 1. Pull the height adjustment lever.

10-1
 2. Lift the seat to the desired
height.
3. Release the height adjustment
lever to lock the seat into the
desired position.
Co-Driver Seat
1. The co-driver seat is as
comfortable as the driver seat.
2. A foldable footrest is provided
for the co-driver, it can be
folded inside when not in use.
DICV-HDT-236
Seat Belts
Seat belts (1) should always be
DICV-HDT-126
worn by the driver and co-driver
CAUTION while travelling.

The co - driver seat should be

folded only when the vehicle is
stationary.
DICV-HDT-2190

Sleeper Berth
A sleeper berth is provided behind
the driver and co-driver seats. Fold
the seats and unlock the berth at
the time of use. DICV-HDT-128
The co-driver seat is equipped with
a separate seat belt.

10-2
Buckling the Seat Belt
1. Adjust the seat as required sit
straight and well back in the
seat.
2. Pull the belt out far enough to
insert the buckle (2) into the
holder until a click sound is
heard.
WARNING
After inserting the buckle,
ensure that the buckle is locked
and the belt is not twisted.
3 Adjust the seat belt to your con-
2
DICV-HDT-129
Unbuckling the Seat Belt
1. Press the red coloured release
button (3) to unlock the buckle
from the holder.
2. Allow the seat belt to retract
fully after being unbuckled. If
necessary, guide the belt back
into the retractor slot.
WARNING
Do not make any alterations in
the seat belt mechanism to
prevent malfunctioning.
CAUTION
venience before starting the
vehicle.
NOTICE
If the seat belts are damaged,
immediately replace them at an
authorised dealer.
Check Before Driving
1. Ensure that the parking brake is
engaged.
2. Check the tyres for any visual
damages and ensure proper
tyre pressure.
3. Check the water separator for
water, drain if found.
4. Check the coolant level, top up
if it is less than the minimum
level.
5. Check the engine oil level using
the dipstick, if required top up.
6. Check the clutch and steering
fluid level.
7. Check the brake system.
8. Start the engine and check the
working of indicators in the
instrument panel.
10-3
Engine Starting and 2. Fasten the belt (1).
Stopping
Starting 1
2

3
1. Place the gearshift lever in

0
“N” neutral position.

DICV-HDT-133
DICV-HDT-131 4. Turn the ignition to ON position
N 3. Insert the ignition key into the ‘2’ the battery charging
key cylinder and unlock the indicator and low oil pressure
steering from the lock position indicator will glow. Ensure all
by turning the key to position warning lights and gauges are
DICV-HDT-136 ‘1’. functioning properly, before
starting the engine.
1
2 5. Without pressing the
accelerator pedal, turn the key

3
0
clockwise onto start position ‘3’
to crank the engine. As soon as
the engine cranks, release the
ignition key to ON position ‘2’.

DICV-HDT-132

10-4
 CAUTION NOTICE NOTICE
Do not engage starter motor for
I n c ase t h e b at t e r y c h a rg i n g 1. Always move the vehi cle in
more than 30 seconds. Wait for 2
i n d i c a t or or l ow p r e ssu r e oi l first gear onl y, wh en start in g
minutes between each attempt
indicator does not go off once from rest.
to start. If the engine still fails to
the engine is started, switch OFF 2. For better performance of the
start, contact an authorised
the engine and contact an vehicle, drive the vehicle in the
dealer for assistance.
authorised dealer immediately. green band region in the
6. Once the engine has started, speedometer.
8. Release the parking brake by
allow the engine to run for 2 moving it to position “B” from
minutes minimum in idling rpm position “A”.
CAUTION
before engaging the gears. Do not crank the toppled vehi-
cle’s engine, as doing so may
NOTICE result in connecting rod bend or
engine components damage.
Idling before engaging the gear
improves the functioning of the
turbocha rger and engine A

efficiency.

7. Once the engine starts, the B

battery charging indicator and DICV-HDT-2713

low oil pressure indicator goes 9. Engage first gear and move the
off. vehicle.

10-5
Fuel Efficient Driving
1. The variable green area is an
indicator of economic driving.
DICV-HDT-135
2. The engine's optimum rpm
range is displayed during
uneconomic engine operation.
3. When the engine’s optimum
range is indicated, bring the
engine speed into the displayed
economic range by changing to
the next higher gear.
10-6
Engine Over Running
1. The vehicle is provided with a
warning indicator which
functions when the engine rpm
reaches the red band. Engine
rpm suddenly increases due to
improper gear down shifting or
excess acceleration during
downhill operation.
2. Immediately remove foot from
the accelerator pedal, reduce
the engine rpm by applying
engine / exhaust brake.
CAUTION
Do not allow the engine rpm to
reach the red band. Failure to
comply will lead to reduction in
engine performance or even it
may damage the engine.
Stopping
1. Apply the brake.
2. Engage the gear lever to neutral
position.
3. Apply the parking brake, by
moving it to position “A” from
“B”.
4. Keep the engine in idling
condition for at least 2 minutes
before stopping the engine.
NOTICE
Al lowing th e e ngin e t o ru n i n
idling rpm before stopping,
increase life of the engine and
turbocharger.
5. Rotate the ignition key
completely in anti clockwise to
turn off the engine.
6. Remove the ignition key from
the key cylinder, the steering
wheel locks automatically.
7. Make sure all lamps are
switched off.
8. Unlock and release the seat
belt.
Gear Shifting
N
DICV-HDT-136
The transmission is of manual type,
depress the clutch pedal fully before
shifting the gears. For smooth
starting of vehicle without jerks,
synchronise release of clutch pedal
with pressing of accelerator pedal,
based on the gear shift pattern.
6 Speed Transmission
1. The six speed transmission is
manually operated.
2. The transmission comprises of
six forward gears and one
reverse gear.
9 Speed Transmission
1. The 9 speed transmission is CAUTION
manually operated and 1. Do not hold the gearshift lever
arranged in a double “H” while in neutral where vehicle in
pattern. running condition.
2. The shift ranges are divided into 2. Don't drive in crawler gear at
“L-Low shift range” and “H-High down gradient.
shift range”.
3. The low shift range comprises Driving Controls
of “R-Reverse gear”, “C-Crawler
gear” and gears from “1 to 4”.
Steering and Adjustment
4. The high speed shift range
comprises of gears from “5 to
8”.
5. When the transmission is in
i
neutral, the gearshift lever is in
the shift gate between 3rd and
4th gear or between 5th and 6th
gear.
DICV-HDT-1358
WARNING The steering system helps the driver
Skip shifting from higher gear to maneuver the direction of vehicle.
to lower gear (from 6th to 4th, The steering column can be
5th to 3rd, etc) while vehicle is adjusted to the drivers requirement.
running is not advisable. This
The steering column adjustment
will severely damage the
mechanism is locked and unlocked
synchronizer and clutch parts.
manually.
10-7
1. Pull the steering column
adjustment lever fully and
adjust steering wheel.
2. Adjust the steering column to
the desired height and angle.
WARNING
D o n o t p e r f o r m a n y k i n d of
adjustments with the steering
wheel while driving. Adjust the
steering wheel only when the
vehicle is stationary with the
parking brake engaged.
DICV-HDT-2587
10-8
3. Ensure that the steering column
is locked in position before
moving the vehicle.
NOTICE
Always steer the wheels after the
vehicle starts moving.
Accelerator Pedal
DICV-HDT-140
The accelerator pedal is used to
accelerate the vehicle. Gradually
increase the acceleration to drive
the vehicle in a steady speed.
Operate the accelerator pedal
smoothly to avoid increase in fuel
consumption.
NOTICE
Do not accelerate during gear
shifting.
Clutch Pedal
DICV-HDT-141
The clutch disconnects the drive
from the engine to transmission
during a gear shift. Depress the
clutch pedal fully while shifting
gears.
CAUTION
Do not use clutch pedal as a
footrest while driving. Misuse
can lead to damage of clutch
components.
Brake Pedal Ready Mix Concrete Prior to loading
(RMC) 1. Apply parking brake.
Engine PTO

DICV-HDT-142
B
To reduce the speed of vehicle or
stop the vehicle depress brake pedal DICV-HDT-2713

gradually. Minimise the use of
service brake and use engine
exhaust brake provided to increase
the life of brake lining. Avoid
pressing the pedal repeatedly to
avoid loss of air pressure.
DICV-HDT-714 2. Switch ON the PTO. Refer page
The PTO is powered by engine has 5-10 Switch Control.
a positive drive and always power is
transmitted to the hydraulic system
of the equipment, during the engine
operation.

n
DICV-HDT-711

3. Accelerate to increase the

engine rpm from 600 to 1800.

10-9
 WARNING
After loading, release the
parking brake and ensure the
PTO remains ON position.

Prior to Unloading
1. Apply parking brake.
2. Switch OFF and ON the PTO
switch.
3. Accelerate to increase the
engine rpm to 1800.

WARNING
After unloading, release the
parking brake and ensure the
PTO remains ON position.

10-10
Tipping System Layout (2528C, 2528CH & 2528CX)

Air Control Valve

Tipping Cylinder

Air Reservior

PT Valve

Air Line to PTO

Hydraulic Tank
Oil Suction Line
Oil Delivery Line
Oil Line Valve to Cylinder
Air Line Inlet
Air Line Tip
Solenoid
Air Line Lower
PTO Input Signal to PTO
PT - Proportional Tipping

Gear Pump DICV-HDT-2466

10-11
Tipping Oil Level Check
Check the tipping oil level in the
glass indicator provided on the
reservoir. Oil level is recommended
to be above or up to the indication
mark provided (red marking). If it is
found to be below the marking, refill
tipping oil to the recommended
level.
DICV-HDT-207
NOTICE
Check oil level in the indicator
on a daily basis when the tipper
is in the normal position.
10-12
Tipping Operation • Press clutch and engage PTO
by switching ON the PTO
Precautions before tipping switch on dashboard.
• Always make sure that the • Check if the PTO switch
vehicle is on firm ground level illuminates and slowly release
before tipping. the clutch pedal.
• Check tipping oil level in the
indicator provided on the
reservoir before tipping.
• Never tip if the tipping area is
not properly illuminated.
• Never leave a vehicle
unattended while it is tipping.
Engaging PTO
DICV-HDT-221
WARNING
PTO should not be engaged
WARNING
when the vehicle is in gear. Do not drive with the PTO
engaged. Driving with PTO
• Stop the vehicle and apply engaged will dam age the
parking brake. synchronizer.
• Engage gear to Neutral.
• Ensure the tipping- air control
valve is in neutral position.
Air Control Valve Tipping ( )
Air control valve pneumatically • Pull the lever slightly up and
activates the tipping valve, which engage air control valve to ‘ ’
then control the flow of oil. It has upward position. N

three positions • Once air control valve is

TIPPING – to raise the tipper operated indicator will glow in
body. the cluster. Low

Tip
NEUTRAL – to hold tipping
cylinder in position. DICV-HDT-205
LOWERING – to lower the
Lowering ( )
tipper body.
DICV-HDT-196 • To lower the tipping body,
• Gradually press the accelerator slightly pull the lever up and
pedal to raise the tipper body. engage the air control valve to
‘ ’ downward position.
WARNING • Gradually press the accelerator
Sudden acceleration may cause pedal to lower the tipper body.
oil starvation, hydraulic cylinder • Lowering can be interrupted
and pump damage. any time by engaging the air
control valve to neutral ‘ ’
DICV-HDT-656 Neutral ( ) position.
When the desired tipping position of
the tipper body is achieved or needs
to be interrupted at any point,
engage the air control valve to
neutral ‘ ’ position.

10-13
 WARNING
Ensure load body is completely
lo wered, the sa me can be
veri fi ed b y ti p pi n g i nd ic ator
goes off.

Disengaging PTO

WARNING
The PTO must be disengaged
when the tipper is not in use.
• With the air control valve in
neutral ‘N‘ position, press the
clutch.
• Disengage the PTO by
switching OFF the PTO switch
and slowly release the clutch
pedal.

10-14
AdBlue System Layout

Air In
Instrument CAN CPC / FR
cluster Star point 1 Control Unit

CPC / FR
Air Tank

AdBlue Tank Air Supply

Controllor Unit
NOx Sensor
1 Air Solenoid

Air Valve Control

Valve

Temperature Sensor

Pressure Sensor
SCR AdBlue Air
Pressure Sensor
SCR AdBlue

SCR AdBlue
2 AdBlue
Return

Dosing Unit
4
Line
AdBlue Suction Line

SCR Catalytic Convertor

Upstream Temperature

NOx Sensor
Pressure Line

Down Stream
Sensor
Metering Valve
AdBlue

Turbo Charger
Temperature Sensors

Exhaust Out
AdBlue Level,

Injection Nozzle

Mufller with Reduction

2
1 MR Control Catalysts Convertor
3 Unit
SCR-Frame
CAN Control Unit
Star point 2
Supply Unit Control

AdBlue Suction Line

1. Suction line
AdBlue Return Line
2. Return lin
AdBlue
3. Air Supply AdBlue Pressure Line
4. Breather line Pump
AdBlue Injection Spray

Air Supply Direction

Humidity / Temperature
Sensor DICV-HDT-2168

10-15
AdBlue Level Check
When the vehicle continues to run
with an empty AdBlue tank, the
performance of the engine is
reduced considerably. Operating the
vehicle in this reduced performance
mode contradicts the emission
norms. Check the AdBlue level
illumination in the AdBlue gauge
and refill the tank with the sufficient
AdBlue.
DICV-HDT-836
NOTICE
Check AdBlue level illumination
on a daily basis and use
recommened AdBlue only.
10-16
CAUTION
Do not drive the vehicle with an
empty AdBlue tank.
Check Before Driving
1. Change to low gear.
2. Switch off the engine.
3. Engage the parking brake.
4. When parking the vehicle on a
slope, apply forward gear upon
facing up the slope and reverse
gear when facing down the
slope.
WARNING
Do not drive the vehicle with the
contaminated AdBlue to avoid
AdBlue pump damage.
Cleaning Instructions for
AdBlue Level Cap
AdBlue tank cap should be cleaned
whenever key-barrel obstruction or
difficulty in key operation observed.
2
3
4
1
DICV-HDT-1361
1. Remove cap from the AdBlue
tank.
NOTICE
Close the tank mouth / inlet
with a clean cloth to avoid the
entry of any foreign particles,
while the cap is removed.
2. Flush the key hole barrel, outer
surface (1), inner surfaces (2)
 and locking wedge (3) of the
cap with clean water and water
pressure not more than 3bar.
NOTICE
Ensure all the crystallized
AdBlue is removed with the high
pressure water.
3. After the AdBlue crystals are
washed out, remove the water
content in the cap with clean
air and air pressure not more
than 3bar.
4. Insert the key into key hole
barrel and check for its
functionality.
NOTICE
Ensure O-ring (4) is in good
condition.
5. Wipe-off the urea crystals, if
any, from the tank mouth with
wet cloth.
6. Close the tank with the cap and
ensure proper locking.
On Road Conditions
Slopes and Rough Terrains
CAUTION
Do not allow Engine over run-
ning. Failure to comply can lead
to damaging of Engine compo-
nents.
While driving down a slope, always
use the same gear used for climbing
it. Never drive on a slope with your
engine switched off or with the gear
in neutral position.
Always control speed of vehicle by
engaging the correct gear without
frequent use of braking, which can
lead to brake lining wear.
Avoid down shifting at high speeds
which may cause engine over
running. While parking on a slope,
place wheel chocks in front or
behind of the wheel apart from
engaging the parking brake. Take
proper rest before long trips,
specially on hilly terrains. Stay alert,
driving when you are tired is risky.
Parking
Before leaving the vehicle, always
engage the parking brake to ON
position. Never leave your vehicle
with engine running.
1. Change to low gear.
2. Switch off the engine.
3. Engage the parking brake.
4. When parking the vehicle on a
slope, apply forward gear upon
facing up the slope and reverse
gear when facing down the
slope.
Cab Tilting
1. Park the vehicle on a level
ground and chock the wheels.
Check if there is enough space
in front of the cabin before
tilting.
2. Shift the gear to neutral
position.
3. Engage the parking brake.
4. Check and remove any loose
objects inside the cabin before
tilting.
10-17
5. The hydraulic hand pump (1) is
located outside the cabin,
behind the co-driver side.

DICV-HDT-976 DICV-HDT-250

CAUTION NOTICE
DICV-HDT-143 Ensure no person is around the
6. Use the direction position knob 1. Oil should be topped up when
tilting range of the cabin, and tilt
on the hydraulic hand pump to it is found below the neck level.
the cabin to the extreme end. Do
lift or to bring down the cabin. 2. Oil level should be checked
not leave loose tools or compo-
when cabin is at locked position
7. Insert the lever into the slot nents in the cabin while tilting.
provided in the pump. 9. On lifting the cabin, ensure that
8. Check the fluid level in the cabin is completely tilted to
hydraulic hand pump and if its extreme position.
1 2 3 found low, keep it filled upto the
N
10. On bringing the cabin down,
F bottom neck of the hydraulic
P ensure it is locked properly by
hand pump.
Apply Parking Brake
Shift the Gear
to Neutral Position Tilt Cab Forward checking the cluster for the
4 5 6
CAUTION cabin lock indicator.
R !
P

R
1a8888 %
km/h
am
pm

Oil cap is made up of plastic.

8kml 88:88
888°° FC 888:888.
!
+

MSS SRS

Over tightening will lead to

Ensure Cab Lock Signal
Tilt Cab Downward Is Off Truck Running Condition

DICV-HDT-185 breakage of cap.

10-18

DICV-HDT-061
11. Do not drive the vehicle without
locking the cabin or when the
cabin lock release indicator is
glowing.
NOTICE
Once the cabin is closed ensure
it is locked well by pumping the
cabin lif t pump downwards
fifteen times.
In Case of Emergency
First Aid Kit Location
The first aid kit is provided in the
map and bottle compartment on the
driver door.
Vehicle Not Starting
When the engine is not starting,
check the following points.
1. Check the fuel level in the fuel
tank.
2. Check the battery condition and
it connections.
3. Check for any warning
indicators in the cluster.
4. If the warning indicator in the
cluster glows, contact an
authorised dealer.
Vehicle Overheats
If yellow light glows on the cluster
and engine coolant temperature
crosses 100°C stop the vehicle as
soon as possible and take the
following actions.
1. Check if the engine coolant
temperature reduces.
2. If the problem still continues
switch off the engine and check
the coolant level in the coolant
tank.
3. If the coolant level is very low,
allow the engine to cool down
to atmospheric temperature.
Top up with coolant.
4. Check the fan and fan belt
condition for damage.
5. Start the engine and check
coolant temperature in the
cluster.
6. If the coolant temperature does
not reduce to normal, contact
an authorised dealer.
WARNING
Do not open or refill the coolant
when it is hot in condition.
10-19
Procedure to Tow the Vehicle
Towing hooks are provided in the
front of cabin for fastening tow rope.
1. Slightly lift the lock (1) securing
the tow pin lever handle.
2. Rotate the lever 90° towards
front position.
3. Lift the tow pin lever (2).
5. Secure the tow rope (5) inside
1 2
DICV-HDT-145
6. Lower the tow pin and secure
10-20
4. Insert the tow pin (3) into the Towing
tow bracket (4). Follow the procedure when your
vehicle is being towed.
1. Disconnect the propeller shaft
during towing for safety.
2. Keep the gearshift lever in
neutral position and key in
ignition position.
4 3. Keep vehicle speed below
3
30kmph.
DICV-HDT-1356 4. If required and if possible keep
your engine running to reduce
the tow pin. poor braking performance.
WARNING
Do not use fron t bumpe r for
towing the vehicle which will
damage the front bumper leads
to vehicle accident.
5
DICV-HDT-147
the handle in place.
Tool Kit 10. Double end spanner 10 / 11 mm
The tool kit is stored behind co- 11. Double end spanner 12 / 14 mm 1
driver seat. 12. Double end spanner 13 / 15 mm
13. Double end spanner 16 / 18 mm 2

14. Double end spanner 21 / 23 mm 3

15. Screwdriver / Torx T20 4
16. Screwdriver / Torx T30
5
6

7
DICV-HDT-262
The tool kit comprises of 8

1. Tool bag 9 10
2. Ring spanner (24 - 27 mm)
11
3. 500gm hammer
12
4. 8 inch combination pliers
13
5. 8 inch adjustable spanner
6. Tommy bar and jack rod 14
(700mm length)
7. 8mm screwdriver 15

8. Wheel spanner 24 / 32 mm 16
9. Double end spanner 8 / 9 mm DICV-HDT-2699

10-21
Wheel Chocks Battery Cut-off Switch*
CAUTION
Two wheel chocks are mounted on
the frame. Till battery cut off lamp goes off,
battery cut-off switch can be
operated (emergency conditions
are excepted)

DICV-HDT-1928

Note: Picture for symbolic

DICV-HDT-995 representation only, actual product
may vary.
Battery cut-off switch is provided
near to the battery.
Due to the post run requirement
(AdBlue lines purging) for the ATS
dosing system, the battery cut-off
switch should be used in emergency
cases only.
During normal condition, battery
cut-off switch should be used after 5
minutes from engine shut off.

*if applicable

10-22
11. BODY BUILDING GUIDELINES
Guidelines and
Precautions
Mercedes-Benz publishes this body/
equipment mounting directive to
provide body manufacturers with
important technical information
about the basic vehicle. This
information must be observed by
the body manufacturer in the
production of bodies and
equipment, fittings and
modifications for vehicles.
Due to the large number of body
manufacturers and body types,
Mercedes-Benz cannot take into
account all the possible
modifications to the vehicle, e.g.
performance, stability, load
distribution, center of gravity and
handling characteristics, that may
result from the design of
attachments, bodies, equipment or
modifications. For this reason,
Mercedes-Benz can accept no body
manufacturer liability for accidents
or injuries sustained as a result of
such modifications to the vehicles if
such modifications have a negative
impact on the overall vehicle.
Accordingly, Mercedes-Benz will
only assume liability as vehicle
manufacturer within the scope of
the design, production and
instruction services which it has
performed itself.
The body manufacturer is bound to
ensure that its bodies and
equipment, fittings and
modifications are themselves not
defective, nor capable of causing
defects or hazards to the overall
vehicle. If this obligation is violated
in any way, the body manufacturer
shall assume full product liability.
Mercedes-Benz does not issue body/
equipment approval certificates for
bodies not manufactured by
Mercedes-Benz. These directives
only supply important information
and technical specifications to body
manufacturers explaining how to
handle the product.
CAUTION
General recommendations are
being highlighted below in
Operators Manual. For detailed
body building guidelines please
contact Mercedes-Benz dealer
for expert advice.
1. The body, the attached or
installed equipment and any
modifications must comply with
the applicable laws and
ordinances as well as work
safety or accident prevention
regulations, safety rules and
accident insurer leaflets.
11-1
2. The Mercedes-Benz logo and
emblem are registered
trademarks of Daimler Truck AG.
They must not be removed or
affixed in another position
without approval.
3. Third-party trademarks
• may not be affixed next to
Mercedes-Benz trademarks
• may not be affixed at any
other points on the vehicle
without necessary approval
of the department
responsible
4. After any work on the brake
system, i.e. even if merely
disassembling parts, a complete
check (operation, effectiveness
and visibility) of the entire brake
system must be performed at an
authorised dealer.
5. The permissible axle loads and
the maximum permissible gross
vehicle weight specified in the
technical data may not be
exceeded.
6. Bolted connections
11-2
If it is necessary to replace
standard bolts with longer bolts,
use only bolts:
• of the same diameter
• of the same strength grade
• of the same type
• with the same thread pitch
Mercedes-Benz recommends
the use of
genuine parts.
7. Welded connections
Welding work on the chassis
may only be carried out only by
an authorised dealers.
8. Pass-by noise
No modification (from the
original specification) is
permitted on the parts that
change the pass-by noise
quality, eg.
• engine
• exhaust system
• air intake system
• tyres, etc.,
9. Maintenance and repair of the
vehicle should not be made
difficult by the body built or
modifications done on the load
body.
10. The battery compartment must
be sufficiently ventilated, with
provision for air to enter and
exit.
11. Any additional expenses arising
from the body in connection
with warranty, maintenance or
repair will not be borne by
Mercedes-Benz.
12. When equipment, attachments
and bodies have been mounted,
it is recommended to have the
Toe setting checked by an
authorised dealer.
13. If pneumatic accessories are
installed, the following must be
observed:
• Auxiliary fitments may only
be connected to connection 24
of the 4-circuit protection valve,
if necessary a T-piece should be
 installed into the compressed
air line.
• To protect the other (on-
board) auxiliary fitments, the
connection may only be made
using an additional overflow
valve without return flow
• Do not use auxiliary fitments
that consume compressed air
continuously
14. It is strongly recommended not
to alter the vehicle overhang
from the specification offered
by Mercedes-Benz.
15. Avoid one-sided weight
distribution. The wheel load (1/2
the axle load) may be exceeded
by no more than 4%. Observe
the tyre load capacity.
16. Mercedes-Benz cannot vouch
for the handling, braking and
steering characteristics of
vehicles with attachments,
installations or modifications for
payloads with unfavourable
centers of gravity (e.g. rear-
mounted. over height and side-
mounted loads). The vehicle
body/equipment manufacturer/
converter is responsible for the
safety of the vehicle in the case
of these bodies.
17. To ensure sufficient vehicle
steerability, the minimum front
axle load must be maintained
under all load conditions.
Consult an authorised dealer in DICV-HDT-162
the event of any deviations.
18. For vehicles with drum brakes, WARNING
check that the spring-loaded Work carried out incorrectly on
brake emergency release screw t h e b r ak e h ose s , c ab l e s a n d
moves freely and is accessible lines may impair their function.
after body building. This may lead to the failure of
19. In case of any attachments or components or parts relevant to
modifications above the cabin, safety. It is str ongly
recommended to get the vehicle
• Observe the permissible checked at an authorised dealer
center of gravity location and after any modifications.
the front axle load.
• Make sure that there is
sufficient space for tilting.
11-3

22. Corrosion protection on fittings
DICV-HDT-163
20. Damage to components
If components are damaged
during disassembly (scratches,
scuff marks), they must be
professionally repaired.
This applies especially for
drilled holes and openings. Two-
component epoxy primers are
particularly suitable for repair
work.
21. Cutting of components
When cutting and grinding work
is carried out, the adjacent
painted components must be
protected against flying sparks
and shavings. Grinding dust
and shavings must be carefully
11-4
removed because these
contaminants can spread
corrosion.
All fittings must receive
adequate anti-corrosion priming
prior to installation. In addition
to galvanising, cataphoretic dip
priming and zinc-rich paint in
sufficient coatings have proved
satisfactory for this purpose.
Top coat
Cataphoretic immersion priming (KTL)
Steel
DICV-HDT-164
CAUTION
Paints and lacquers are harmful
to hea lth and to the
e n v i r on me n t i f t h e y ar e n o t
handled correctly. Dispose of
paints and lacquers in an
envi ronmentally respon sible
manner.
23. Mask the following areas before
painting
• Sealing surfaces
• Contact areas between the
wheels and wheel hubs
• Windows
• Contact areas for wheel nuts
• Door locks
• Breathers on gearboxes,
axles, etc.
24. Chassis frame extension and
wheelbase modifications on
Mercedes-Benz chassis are not
permitted. Incase of violation,
Mercedes-Benz, provides no
guarantee for any
 consequences.
25. Existing (factory-made) holes in
the upper and lower flanges of
the chassis frame must not be
enlarged (exception: mounting
holes for the end cross
member). These bore holes
must not be used to secure
assemblies.
WARNING
In case of all bodies make sure
that neither flammable objects
nor flammable liquids can come
into conta ct with hot
assemblies (including through
leak ages in the hy draulic
syst e m) su c h as th e e n g i n e ,
gearbox , ex haust system,
turbocharger, etc. Appropriate
caps, seals and covers must be
installed on the body in order to
avoid the risk of fire.
26. Mounting frame-All bodies
require a mounting frame or a
substructure that assumes the
function of a mounting frame to
ensure a reliable connection
between the chassis and the
body (except for self-supporting
bodies and mounting frames
acting as floor assemblies)
•The mounting frame
longitudinal members must lie
level on the upper flanges of the
chassis frame and follow the
course of the chassis frame.
•Position mounting-frame cross
members above the chassis
frame cross member.
• For the longitudinal members,
use flanged U-sections or
commercially available U-
sections for vehicle
construction (not rolled steel
sections).
•The dimensions of the
longitudinal members are a
function of the moment of
resistance (Wx) required for the
body and the chassis.
27. There should be a gradual
sectional transition at the
forward end of the longitudinal
members. The edges should be
deburred.
Continuous mounting frames
are required for:
• Bodies with a high center of
gravity
• High point loading
• One-sided loading
• Superstructures extending
over the cab
For example, for: tipper bodies,
glass transport frame bodies,
towing bodies, loading cranes,
hinged booms, loading
tailgates, etc.
The longitudinal body members
must extend as far forward as
possible, but at the very least
beyond the rear front spring
brackets.
11-5
 29. Friction lock connection U-Bolts
This mounting system should
2 2 be used preferably in the
1
bodywork with wood and
1
mounting frame with wood.
Always use seasoned hardwood
for making the mounting frame
• The longitudinal members
1.Mounting Frame
1.Mounting Frame
2.Chassis Frame
2.Chassis Frame
must be fixed in both
DICV-HDT-165 DICV-HDT-167
longitudinal and lateral
28. Wooden longitudinal body directions.
members
• Fixing for longitudinal
While using hard wood for
2

direction may be done by

1 longitudinal body members,
ensure that the runner follows
the chassis frame profile. Adopt
suitable design for the runner at
1.Mounting Frame
the joggle area.
2.Chassis Frame
using a bolted plate at the
rear end.
• Fixing for lateral may be
done with the help of guide
plates in front end (or extend

DICV-HDT-166 the chassis frame bracket)

and area of rear axles/rear
springs.
• Ensure that the U-Bolts do
not touch or damage any air
/ fuel pipes, electrical
harness, leaf spring, etc.

DICV-HDT-168

11-6
• Use U-Bolts on other areas
for connecting chassis frame
and mounting frame.
• Use U-Bolt guide made of
aluminium or malleable cast
iron for protection of chassis
frame.
• Wherever U-Bolts cannot be
positioned, use bracket
mounting with flexible
connection (cup springs,
rubber mountings).
• When bolts are used for
connection with wood, use
steel plates on both sides, so
that fasteners do not come
in direct contact with wood.
• Reinforce chassis long
member with proper section
to avoid local deformation of
the flanges.
• The U-Bolts shall not touch
the chassis frame long
member.
• The U-Bolts should not 30. On vehicles used to transport
interfere with the brake pipe aggressive substances, all
system and any other compressed-air lines, brake
chassis components. lines, brake hoses and electrical
wiring must be protected
against chemical reaction by
2
the body manufacturer.
31. Cement mixers may only be
3
5
mounted on chassis intended
1.Chassis Frame for this purpose (cement mixer,
4 2.Mounting Frame
3.Bracket-Mounting Frame
tipper chassis).
4.Bracket-Chassis Frame
1 5.Back Plate
DICV-HDT-169
6
5
2
3
7 1.Chassis Frame
2.Mounting Frame
3.U-Bolt
4.U-Bolt Guide
1 5.Top Plate
6.Lock Nut
4 7.Frame Reinforcement
DICV-HDT-170
11-7
12. ADBLUE AND SCR SYSTEM
SCR Guidelines
AdBlue
AdBlue the basic liquid for Euro 4
emission compliance, used with the
Selective Catalytic Reduction
system (SCR) to reduce emissions
of nitrogen oxides from the diesel
vehicle's exhaust. AdBlue is a 32.5%
solution of high-purity urea in de-
mineralized water that is clear, non-
toxic and safe to handle.
AdBlue is non explosive, neither
flammable nor harmful to the
environment. AdBlue is classified
under the minimum risk category of
transportable fluids. It is neither a
fuel, nor a fuel additive and needs to
be used in a dedicated tank on the
vehicle. It is replenished in a similar
way to refueling diesel. If you spilled
AdBlue on your hands, simply wash
it off with water.
AdBlue Consumption • AdBlue tank should not be filled
• The consumption of AdBlue or diluted with any other liquid
other than AdBlue; failing so
would be in the range of 3-5
Liters for every 100 Liters of would lead to troubles from
diesel. activation of torque limitation
mode and also might damage
• It is advisable to carry enough the SCR system components.
reserve of AdBlue before start
of your every trip. • Recovery of torque limitation
mode will automatically get
Running without AdBlue (Not executed by the system once
Recommendable) AdBlue is refilled within 2-3
• Running vehicle without AdBlue driving cycles. (2-3 vehicle ON -
is not recommendable, which OFF trips)
would activate the torque
limitation mode (Pick up drop),
in parallel AdBlue malfunction
indicator lamp would be glowing
on the Instrument cluster as an
indication of torque limitation
mode activation.
• AdBlue can be procured from
all authorized dealerships of
Mercedes-Benz.
• AdBlue is available in 20 and
210 liter packs.
12-1
AdBlue Storage and Refilling
Guidelines
• Always have the practice of
using dedicated container and
equipment’s for storing and
refilling the AdBlue tank.
• AdBlue container should not be
stored from direct contact of
sun light. Protect AdBlue
against any contamination of
fuel, oil, water, dust, dirt, metals
and detergents.
• AdBlue has to be stored
between 11ºC and 30ºC in order
to maintain its shelf life of 6
months.
• After filling AdBlue, always fix
the cap immediately to avoid
any contamination and loss of
AdBlue.
12-2
Daily maintenance Checks for
AdBlue
• Always check the AdBlue Level
and MIL before start of any trip
on the INS.
• Roughly estimate the AdBlue
requirement for the trip and
carry enough AdBlue in reserve
storage to avoid hassle free trip.
Do’s and Don’ts
Do’s
• Always operate the vehicle with
enough AdBlue quantity in
AdBlue tank.
• Use AdBlue from an authorised
suppliers only.
• Protect AdBlue against any
contamination of fuel, oil, water,
dust, dirt, metals, detergent by
using only sealed equipment’s.
• AdBlue has to be stored
between 11ºC and 30ºC in
order to maintain its shelf life of
6 months (180 days).
• AdBlue freezes around -11°C
temperature and becomes
crystallized. Care should be
taken to prevent the
crystallization of AdBlue during
storage.
• Always carry enough reserve
storage of AdBlue before start
of the trip.
• Ensure AdBlue tank cap is fitted
immediately after filling to avoid
contamination.
• AdBlue MIL glowing noticed in
INS even with sufficient AdBlue
available in the tank, vehicle to
be brought to the nearest dealer
location within 50 hrs of
operation to avoid torque
limitation (low pickup) mode
getting activated.
• AdBlue tank to be drained,
flushed and replenish with fresh
AdBlue, in case of vehicle
parked for more than 90 days.
Don’ts
• Don’t operate the vehicle
without AdBlue.
• Don’t expose the AdBlue to
direct sunlight.
• Do not purchase AdBlue from
unauthorized suppliers.
• Don’t fill any other liquid
(especially water) other than
AdBlue. This will lead vehicle to
take long time for healing from
torque limitation mode once got
activated.
• Do not the run the vehicle with
AdBlue MIL for more than
50 hrs. of operation. This will
lead to activation of torque
limitation (low pickup).
• Vehicle not to be operated
without drain, flush and
replenish with fresh AdBlue, in
case of vehicle parked for more
than 90 days.
Storage and Disposable
Procedure
Storage Procedure
The maximum shelf life of AdBlue is
6 months, which should be
maintained in cool, dry and covered
place. This should also be kept
away from direct sunlight.
Disposable Procedure
Below is the procedure to scrap the
stock of AdBlue:-
• The generation of waste should
be avoided or minimized
wherever possible.
• Disposal of this product,
solutions and any by-products
should at all times comply with
the requirements of
environmental protection and
waste disposal legislation and
any regional local authority
requirements.
• Dispose of surplus and non-
recyclable products via a
licensed waste disposal
contractor.
• Waste should not be disposed
of untreated to the sewer unless
fully compliant with the
requirements of all authorities
with jurisdiction.
• Waste packaging should be
recycled. Incineration or landfill
should only be considered when
recycling is not feasible. This
material and its container must
be disposed of in a safe way.
Empty containers or liners may
retain some product residues.
• Avoid dispersal of spilt material
and runoff and contact with
soil, waterways, drains and
sewers.
12-3
13. LUBRICANT SPECIFICATION
Lubricant Specification - 2523R & 2528R

Model or Approved Interval*

S.No Aggregates Specification Filling Capacity
Section Lubricant Km Month

MB 228.5 (SAE10W40) -
First change at
MB 228.5
25,000 km / 6 months,
(SAE10W40)/
Mercedes-Benz then at 50,000 km /
1 Engine** OM906 MB 228.3 26.30L
genuine oil 6 months.
(SAE15W40)
MB 228.3 (SAE15W40) -
B0 S50 fuel
Every 25,000 km /
6 months.

EURO IV Mercedes-Benz
As per the
2 SCR System - AdBlue® genuine 50L
consumption
(AdBlue filling) AdBlue®
SAE40 Mercedes-Benz 9L (without PTO)
G85 (2523R) 50,000 12
MB 235.12 genuine oil 9.3L (with PTO)
3 Transmission
SAE80 Mercedes-Benz 12L (without PTO)
G131 (2528R) 100,000 12
MB 235.1 genuine oil 13L (with PTO)
* Whichever is earlier: Km/Month

13-1
 Model or Approved Interval*
S.No Aggregates Specification Filling Capacity
Section Lubricant Km Month
IR 440 (6x2) 100,000 12
14L
Rear Axle I - Every 75,000 Km /
IRT 390 (6x4) SAE80W90 Mercedes-Benz 12 months
4 Rear Axle
MB 235.20 genuine oil
Rear Axle II - Every 75,000 Km /
11L
IR 390 (6x4) 12 months.

ATF Mercedes-Benz
5 Power Steering - 4L 50,000 12
MB 236.3 genuine oil
Front Axle Hub Mercedes-Benz 395 - 450
6 Front Axle MB 267.1 50,000 12
Grease genuine grease gm/Hub
Rear Axle
100,000 12
(6x2)
Rear Axle Hub Mercedes-Benz 200
7 MB 267.1
Grease Rear Axle genuine grease gm/Hub Every 100,000 Km /
(6x4) 12 months.

Chassis Grease
NLGI grade 2 Mercedes-Benz
8 (Including king - 125gm Weekly
MB 267.1 genuine grease
pin)
Mercedes-Benz
9 Hydraulic Clutch - DOT 4 0.4L 100,000 12
genuine oil
* Whichever is earlier: Km/Month

13-2
 Model or Approved Interval*
S.No Aggregates Specification Filling Capacity
Section Lubricant Km Month
Non AC - 12.5L
coolant + 12.5L
Mercedes-Benz water
10 Coolant - MB 325.0 200,000 24
genuine coolant AC - 13.5L
coolant + 13.5L
water
Top-up is necessary,
Mercedes-Benz whenever the oil level
11 Cab Tilt Oil - ATF MB 236.3 0.3L
genuine oil is lower than the neck
level.
* Whichever is earlier: Km/Month

Sulphur Table:-
Interval for changing
Sulphur content** in diesel fuel
engine oil and filter
Upto 0.05% by weight (B0 S50 fuel 50 ppm) 100%

Note: Use only Mercedes-Benz recommended brands and grades of lubricants to ensure longer life of aggregates.

13-3
Lubricant Specification - 2528C,2528CH,2528CX & 2528RMC
Approved Interval *
S.No Aggregates Model or Section Specification Filling Capacity
Lubricant Hr Km Month
MB 228.5
(SAE10W40)/ Mercedes-Benz
1 Engine** OM906 MB 228.3 26.30L 500 15,000 6
genuine oil
(SAE15W40)
B0 S50 fuel
EURO IV Mercedes-Benz
As per the
2 SCR System - AdBlue® genuine 50L
consumption
(AdBlue filling) AdBlue®
SAE90 Mercedes-Benz 12L (without PTO)
3 Transmission G131 1,500 45,000 12
MB 235.1 genuine oil 13L (with PTO)
Rear Axle I -
14L 1,500 45,000 12
IRT 390 SAE80W90 Mercedes-Benz
Rear Axle II - MB 235.20 genuine oil
11L 1,500 45,000 12
IR 390
4 Rear Axle
Rear Axle I -
25.5L+2.5L+2.5L 2,500 45,000 12
Meritor MT-36-610 SAE80W90 Mercedes-Benz
Rear Axle II - MB 235.20 genuine oil
17.5L+2.5L+2.5L 2,500 45,000 12
Meritor MT-36-610
ATF Mercedes-Benz
5 Power Steering - 4L 1,000 30,000 12
MB 236.3 genuine oil

* Whichever is earlier: Hr/Km/Month

13-4
 Approved Interval *
S.No Aggregates Model or Section Specification Filling Capacity
Lubricant Hr Km Month
Front Axle Hub Mercedes-Benz 395 - 450
6 Front Axle MB 267.1 1,000 30,000 12
Grease genuine grease gm/Hub
Rear Axle Hub Mercedes-Benz
7 Rear Axle MB 267.1 200 gm/Hub 1,500 45,000 12
Grease (IRT 390) genuine grease
Chassis Grease
NLGI grade 2 Mercedes-Benz
8 (Including king- - 175gm Weekly
MB 267.1 genuine grease
pin)
Mercedes-Benz
9 Hydraulic Clutch - DOT 4 0.4L 1,000 - 12
genuine oil
Top-up is necessary,
Mercedes-Benz whenever the oil level is
10 Cab Tilt Oil - ATF MB 236.3 0.3L
genuine oil lower than the neck
level.
Non AC -
12.5L coolant +
Mercedes-Benz 12.5L water
11 Coolant - MB 325.0 genuine 4,000 120,000 24
coolant AC - 13.5L
coolant + 13.5L
water
First change - 6 months
12 Tipping Oil - VG 68 - 55L & thereafter once in 12
months.
* Whichever is earlier: Hr/Km/Month

13-5
Sulphur Table:-
Interval for changing
Sulphur content** in diesel fuel
engine oil and filter
Upto 0.05% by weight (B0 S50 fuel 50 ppm) 100%

Note: Use only Mercedes-Benz recommended brands and grades of lubricants to ensure longer life of aggregates.

13-6
 L.H.S FRONT-S-CAM R.H.S FRONT-S-CAM
BUSH BUSH

L.H.S KING PIN R.H.S KING PIN

TOP/BOTTOM TOP/BOTTOM
Chassis Lubrication Points - 2523R & 2528R

Note: Picture for symbolic representation only, actual product may vary. L.H.S REAR FORWARD R.H.S REAR FORWARD
BRAKE-S-CAM BUSH BRAKE-S-CAM BUSH

L.H.S REAR REARWARD

R.H.S REAR REARWARD
BRAKE-S-CAM BUSH
BRAKE-S-CAM BUSH
Weekly

Monthly

DICV-HDT-2725

13-7
13-8
L.H.S FRONT-S-CAM R.H.S FRONT-S-CAM
BUSH BUSH

L.H.S KING PIN R.H.S KING PIN

TOP/BOTTOM TOP/BOTTOM
Chassis Lubrication Points - 2528R (6x4)

L.H.S REAR FORWARD R.H.S REAR FORWARD

Note: Picture for symbolic representation only, actual product may vary. BRAKE-S-CAM BUSH BRAKE-S-CAM BUSH

L.H.S REAR REARWARD R.H.S REAR REARWARD

BRAKE-S-CAM BUSH BRAKE-S-CAM BUSH
Weekly

Monthly

DICV-HDT-2724
 Weekly

Monthly
L.H.S FRONT-S-CAM R.H.S FRONT-S-CAM
BUSH BUSH

R.H.S KING PIN

L.H.S KING PIN
TOP/BOTTOM
TOP/BOTTOM

Note: Picture for symbolic representation only, actual product may vary.

L.H.S REAR FORWARD R.H.S REAR FORWARD

BRAKE-S-CAM BUSH
Chassis Lubrication Points - 2528C, 2528CH, 2528CX & 2528RMC

BRAKE-S-CAM BUSH

L.H.S REAR REARWARD

BRAKE-S-CAM BUSH

R.H.S REAR REARWARD

BRAKE-S-CAM BUSH
DICV-HDT-2723

13-9
14. MAINTENANCE AND LUBRICATION
Maintenance Chart - 2523R & 2528R

Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
A. GENERAL
1 Wash the vehicle. Every 25,000 km / On every service (Elimination based on the request only).

B. ENGINE AND FUEL SYSTEM

Check coolant level in de-aeration
1 tank, top up if necessary and leaks 50,000      
on engine parts.
Check engine oil level to maintain
between maximum and minimum
2 25,000          
level, top-up the oil whenever it is
necessary.
Visually check air ducting pipe/
3 hoses, clamps - Tighten/replace if 50,000    
necessary.
4 Flush and clean fuel tank. 50,000    
MB 228.3 (15W40) - Every 25,000 km / 6 months whichever is earlier.
Change engine oil filter and engine
5 MB 228.5 (10W40) - First change at 25,000 km / 6 months then at
oil.
every 50,000 km / 6 months whichever is earlier.

14-1
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Primary - Whenever cluster indicates
Replace air cleaner primary element
6 25,000 Secondary - On every 3rd replacement of
and secondary element.
primary element.
Air intake system - Check for
7 electrical connection to “restriction 50,000    
indicator”.
Check fan and fan belt visually and
8 50,000      
replace, if damaged.
Check fuel tank brackets, mounting
bracket and strap nuts rubber
9 50,000     
condition -Tighten/replace if
necessary.
Replace fuel filter cum water
10 separator element and engine Every 50,000 km / 6 months whichever is earlier.
mounted fuel filter.
Check valve clearance and adjust, if
11 Every 25,000 km / 6 months whichever is earlier.
necessary.
Clean the fuel injectors by using
12 50,000    
cleaning solution.
13 Check coolant concentration. 50,000     

14-2
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Check condition of radiator cap,
cooling system hoses and radiator
14 50,000    
rubber pads of radiator mounting
and tighten if necessary.
Clean the breather filter element
15 50,000    
with compressed air.
Drain and flush the cooling system.
Check thermostat for proper
16 operation. Refill the system with Every 200,000 km / 24 months whichever is earlier.
fresh coolant as per lubrication
chart.

C. TRANSMISSION, CLUTCH AND PROPELLER SHAFT

Visually check wear indicator and
1 25,000          
replace clutch disc if necessary.
Check wear on flywheel, pressure 25,000 km /
plate (wear/thermal cracks) and During clutch
2        
diaphragm condition and replace if / lining
necessary. replacement.

Check clutch release fork and 25,000 km /

mounting, rollers, bushes and
3 During clutch        
bearing (noise). Check tightening disc change.
torque of clutch booster mounting.

14-3
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Check for clutch hose condition and
4 50,000     
leakage.
25,000 km /
Whenever
Check for correct operation of gear
5 gear shift         
shift linkage and setting.
linkage
disturbed.
Check and adjust clutch pedal free
6 50,000     
play if required.

Change oil in gearbox. Clean drain G85 - Every 50,000 km / 12 months whichever is earlier
7
plug. G131 - Every 100,000 km / 12 months whichever is earlier
8 Change clutch hose. 150,000 
Replace clutch oil and bleed the
9 DOT4 - Every 100,000 km / 12 months whichever is earlier.
system.
Check and tighten if necessary -
10 clutch housing, gear box and engine 25,000         
mounting bolts.

14-4
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Check center bearing rubber
condition, replace if necessary.
Check propeller shaft center bearing
11 support bracket bolts, propeller 50,000     
shaft coupling flange bolts and
universal joint kit -Tighten/replace if
necessary.

D. FRONT AND REAR AXLE

1 Kingpin greasing. 50,000      
Check wheel alignment and adjust if
2 25,000         
necessary.
Remove front & tag axle wheel hubs.
Dismantle and clean bearing and
other components. Replace Every 50,000 km / 12 months whichever is earlier.
3
damaged/ worn-out parts. Repack
with fresh wheel bearing grease and
refit. Adjust wheel hub bearing play.
Change oil in rear axle, clean drain IR440 - Every 100,000 km / 12 months whichever is earlier.
4
plug. IRT390 - Every 75,000 km / 12 months whichever is earlier.

14-5
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Remove live rear axle wheel hubs.
Dismantle and clean bearing and
other components. Replace
5 Every 100,000 km / 12 months whichever is earlier.
damaged/ worn-out parts. Repack
with fresh wheel bearing grease and
refit. Adjust wheel hub bearing play.

E. BRAKE SYSTEM
Check compressed air is built up to
cut off pressure as mentioned in
specification, check air leakage and
1 50,000      
rectify if any. Drain the condensed
water for air reservoir check hand
brake for proper functioning.
Check hose for abrasion, damage
and free movement of yoke pin, split
2 50,000      
pin in automatic slack adjuster and
replace if required.
Inspect lining thickness, through
inspection window provided on the
3 50,000      
dust shield and lubricate “S” cam
shaft.

14-6
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Inspect brake lining, brake drums,
“S” cam shaft axial and radial play
rectify if required overhaul system if
4 Every 50,000 km or whenever Hub greasing / Brake drum removed.
play exceeds limit. Inspect oil seals
for grease leak and replace if
required.
Change shoe return spring and 50,000 km /
5 check for brake assembly mounting During Lining    
torque. Change
Check for free movement of pin in
pedal and condition of rubber boots/
6 50,000    
exhaust flaps of dual brake valve
and replace/rectify if required.
Check for air connections/hose for
leakage, electrical connections,
proper working and mountings of
relay valve, solenoid valve, quick
release valve, air dryer, purge tank,
7 50,000    
DBV, GHCV (also lever locks when
parking brakes are ON), brake
chambers, spring brake actuators,
air reservoir rectify/tighten if
necessary.

14-7
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Replace air dryer desiccant cartridge
and check for outlet pressure
8 Every 50,000 km / 6 months whichever is earlier.
difference between cutoff and cutin
is in the range of 0.6bar to 1.4bar.
Check the condition of breather tube
and ensure it is secured properly at
both ends of spring brake actuator.
9 Exhaust brake - pneumatic cylinder 50,000     
and hose condition, leakages,
mounting bolts. Replace/tighten if
necessary
Check compressor air inlet, outlet
hose, water connections, clean
cylinder head and decarbonise if
10 necessary. Check and clean delivery 50,000    
pipe for carbon deposit. Check for
oil throw. If necessary change the
ring kit.
Add shims when S-cam axial play
11 exceeds and replace S-cam shaft 50,000    
bush when radial play exceeds.

14-8
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
F. INTEGRAL PEDAL UNIT
Check housing mounting tightness,
dual brake valve pedal free play,
clutch master cylinder pedal free
1 play, free movement of brake and 50,000     
clutch pedal and proper actuation of
clutch pedal switch (for exhaust
brake) and its tightness.

G. STEERING AND SUSPENSION

Check for play in steering linkage/
1 50,000     
drag link, tighten if necessary.
Check oil level in power steering
hydraulic tank and top up if
2 necessary check hydraulic piping 25,000          
connections for leakages and rectify
if any.
Drain off hydraulic oil of power
3 steering. Replace filter cartridge and Every 50,000 km / 12 months whichever is earlier.
fill in fresh oil.

14-9
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Check steering wheel play. Tighten if
necessary - drag link rod, tie rod and
4 50,000    
check hydraulic limiter valve setting
and peak pressure.
Check and tighten the U-bolt of
front and rear springs, anti roll bar
5 25,000         
mounting bolts and shock absorber
mountings.
Visually inspect the shock absorber,
anti roll bar bushes, rubber parts,
6 25,000        
front springs and eye bushes.
Replace if necessary.
Check and tighten cab leaf spring,
7 cab lock, shock absorber & it's oil 50,000     
seepage. Replace if necessary.
Check and tighten wear pads on
8 25,000         
frame, replace if necessary.
Replace rear bogie bracket rubber
9 50,000    
bearing & nylon ring.
Check for rear bogie bracket rubber
10 bearing & nylon ring, replace if 25,000        
necessary.

14-10
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Check & tighten - V-rod, control rod,
front spring, bogie bracket,
swiveling lever bracket mounting on
11 25,000        
frame and visually check V-rod &
control rod eye bushes, front spring,
bogie spring. Replace if necessary.

H. EXHAUST
Check for muffler strap mounting
1 25,000         
and tighten if necessary.
Check for gas leaks at pipe
2 connections and flex pipe and 25,000         
rectify.

I. FRAME
Check the tightness of cross
1 member to frame side members 25,000         
mounting bolts.

J. CAB
Check tightness of rear view mirror
1 50,000      
stay & mounting of wiper motor.

14-11
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Door checker greasing, door latch
greasing, front lid latch greasing,
2 50,000     
rear spring pins greasing and check
free end of cab spring lock.
Check condition of gear shift rubber
3 bellow, gaiter at gear lever and 50,000    
steering column.
Check and clean blower/HVAC -
4 50,000     
inlet filter and replace if necessary.
Check refrigerant leakage &
5 50,000    
Pressure, if AC provided.
6 Check for cab tilt oil level. Top-up is necessary, whenever the oil level is lower than the neck level.
Conduct visual/operational check on
7 50,000    
wiper blade, replace if required.
Visually check hose connector for
leak, condition of bushes in top &
8 50,000    
bottom end of cab tilting cylinder
connections.
Check and tighten cab mounting
9 50,000     
and cab checker arm.

14-12
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Visually check condition of body
mounting rubber pad, cab bush
10 150,000 
rubber, buffers, shock absorber and
bushes, replace if necessary.
Check mounting of driver seat and
11 150,000 
tighten if necessary.

K. ELECTRICALS
Check battery mountings, tighten if
1 necessary. Clean battery post and 50,000      
terminal. Smear petroleum jelly.
Check electrolyte specific gravity &
level, top up if necessary. Also check
2 50,000      
open circuit voltage, charging
circuit.
Check air gauge connecting union,
3 fuel tank, fuel gauge sensing units 50,000     
for tightness.
Check connections and mountings
4 of starter motor, alternator and 50,000    
tighten, if necessary.

14-13
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
Drive the vehicle and perform all the
operation as per the cluster and
check the working of indicators in
cluster. Check lights, switches,
5 gauges, blinkers, wiper motor, horn 25,000         
and gauges connections, tighten if
necessary. Check for error codes in
Instrument cluster, if necessary use
Xentry diagnostic tool.
Check connections of tail lamp,
blinker lamp, head lamp and
6 tighten, if necessary. Adjust the 50,000     
head lamp focusing (after bulb
change) if required.
Check proper clamping/routing of
7 neutral switch, speedometer sensor 50,000    
cable and condition of all sensors.

L. WHEELS AND TYRES

Check and tighten wheel nuts, if
necessary (wheel nuts to be
1 Every 10,000 km.
checked for the first 100 km on
every wheel change).

14-14
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
2 Tyre rotation. Every 10,000 km.

M. AFTER TREATMENT SYSTEM

1 Clean level sensor strainer. 50,000    
2 Replace AdBlue pump main filter. 50,000    
3 Replace AdBlue pump pre filter. 25,000        
Remove metering unit pre filter at
4 air inlet. Check for moisture/oil/dust 25,000        
content. Clean or replace if required.
Remove metering unit pre filter at
5 AdBlue inlet. Check for oil/dust 25,000        
content. Clean or replace if required.

N. HVAC
25,000 km /
Check re-circulation filter & replace
1 Every        
if necessary.
12 months
25,000 km /
2 Clean re-circulation filter.        
Every 2 weeks
3 Clean fresh air filter. 25,000 km         

14-15
 Monthly
Weekly

100,000

125,000

150,000

175,000

200,000
25,000

50,000

75,000
Daily

PDI
Frequency
S.No Activity
(km)
Customer Dealer Check
O. CHECK AND OVERHAUL IF NECESSARY
Overhaul clutch booster and master
1 cylinder with service kit, check bore 100,000  
condition and replace if necessary.
Overhaul air compressor using
2 150,000 
repair kits if necessary.
Overhaul - Air dryer, quadruple
system protection valve, quick
release valve, graduated hand
control valve, dual brake valve, relay
3 150,000 
valve, front brake chamber and rear
brake chamber if necessary using
recommended repair kit and replace
if required.
Overhaul the exhaust brake &
4 100,000  
Integral pedal unit.

14-16
Maintenance Chart - 2523C, 2528CH, 2528CX & 2528RMC

Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
A. GENERAL
1 Wash the vehicle. Every 500 hrs / On every service (Elimination based on the request only).

B. ENGINE AND FUEL SYSTEM

Check coolant level in de-aeration
1 tank, top up if necessary and leaks 1,000      
on engine parts.
Check engine oil level to maintain
between maximum and minimum
2 500          
level, top up the oil whenever it is
necessary.
Visually check air ducting pipe/
3 hoses, clamps - Tighten/replace if 1,000    
necessary.
4 Flush and clean fuel tank. 1,000    

Change engine oil filter and engine MB 228.3 (15W40) / MB 228.5 (10W40) Every 15,000 km / 500 hrs /
5
oil. 6 months whichever is earlier.

14-17
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Primary - Whenever cluster indicates
Replace air cleaner primary element
6 1,000 Secondary - On every 3rd replacement of
and secondary element.
primary element.
Air intake system - Check for
7 electrical connection to “restriction 1,000    
indicator”.
Check fan and fan belt visually and
8 1,000      
replace, if damaged.
Check fuel tank brackets, mounting
bracket and strap nuts rubber
9 1,000     
condition -Tighten/replace if
necessary.
Replace fuel filter cum water
10 separator element and engine Every 15,000 km / 500 hrs / 6 months whichever is earlier.
mounted fuel filter.
Clean the fuel injectors by using
11 1,500  
cleaning solution.
12 Check coolant concentration. 1,000     

Check valve clearance and adjust, if

13 Every 15,000 km / 500 hrs / 6 months whichever is earlier.
necessary.

14-18
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Check condition of radiator cap,
cooling system hoses and radiator
14 1,000    
rubber pads of radiator mounting
and tighten if necessary.
Clean the breather filter element
15 1,000    
with compressed air.
Drain and flush the cooling system.
Check thermostat for proper
16 operation. Refill the system with Every 120,000 km / 4,000 hrs / 24 months whichever is earlier.
fresh coolant as per lubrication
chart.

C. TRANSMISSION, CLUTCH AND PROPELLER SHAFT

Visually check wear indicator and
1 1,000      
replace clutch disc, if necessary.
Check wear on flywheel, pressure 1,000 hrs /
plate (wear/thermal cracks) and During clutch
2    
diaphragm condition and replace if / lining
necessary. replacement.

Check clutch release fork and 1,000 hrs /

mounting, rollers, bushes and
3 During clutch    
bearing (noise). Check tightening disc change.
torque of clutch booster mounting.

14-19
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Check for clutch hose condition and
4 1,000     
leakage.
1,000 hrs /
Whenever
Check for correct operation of gear
5 gear shift     
shift linkage and setting.
linkage
disturbed.
Check and adjust clutch pedal free
6 1,000     
play if required.
Replace clutch oil and bleed the
7 DOT4 - Every 1,000 hrs / 12 months whichever is earlier.
system.
Check and tighten if necessary -
8 clutch housing, gear box and engine 500         
mounting bolts.
Check and tighten if necessary -
propeller shaft coupling flange bolts
9 1,000    
and universal joint kit, replace if
necessary.
Change oil in gearbox. Clean drain
10 Every 45,000 km / 1,500 hrs / 12 months whichever is earlier.
plug.

14-20
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
11 Change clutch hose. 2,000  

D. FRONT AND REAR AXLE

1 Kingpin greasing. 1,000      
1,000 hrs /
Check wheel alignment and adjust if
2 Every     
necessary.
10,000 km
Remove front wheel hubs.
Dismantle and clean bearing and
other components. Replace
3 Every 30,000 km / 1,000 hrs / 12 months whichever is earlier.
damaged/ worn-out parts. Repack
with fresh wheel bearing grease and
refit. Adjust wheel hub bearing play.
Change oil in rear axle, clean drain
Every 45,000 km / 1,500 hrs / 12 months whichever is earlier.
plug.
4
Change oil in rear axle and all hubs,
clean drain plug. (hub reduction Every 45,000 km / 2,500 hrs / 12 months whichever is earlier.
axle)

14-21
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Remove live rear axle wheel hubs.
Dismantle and clean bearing and
other components. Replace Every 45,000 km / 1,500 hrs / 12 months whichever is earlier.
5
damaged/ worn-out parts. Repack (Note - greasing for IRT 390 only)
with fresh wheel bearing grease and
refit. Adjust wheel hub bearing play.

E. BRAKE SYSTEM
Check compressed air is built up to
cut off pressure as mentioned in
specification, check air leakage and
1 1,000      
rectify if any. Drain the condensed
water for air reservoir check hand
brake for proper functioning.
Check hose for abrasion, damage
and free movement of yoke pin, split
2 1,000      
pin in automatic slack adjuster and
replace if required.
Inspect lining thickness, through
inspection window provided on the
3 1,000      
dust shield and lubricate “S” cam
shaft.

14-22
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Inspect brake lining, brake drums, S
cam shaft axial and radial play
rectify if required overhaul system if
4 Every 1,000 hrs and whenever hub greasing / Brake drum removed.
play exceeds limit. Inspect oil seals
for grease leak and replace if
required.
Change shoe return spring and
5 check for brake assembly mounting Every 500 hrs and during lining change.
torque.
Check for air connections/hose for
leakage, electrical connections,
proper working and mountings of
relay valve, solenoid valve, quick
release valve, air dryer, purge tank,
6 1,000    
DBV, GHCV (also lever locks when
parking brakes are ON), brake
chambers, spring brake actuators,
air reservoir rectify/tighten if
necessary.
Replace air dryer desiccant cartridge
and check for outlet pressure
7 1,000    
difference between cutoff and cutin
is in the range of 0.6bar to 1.4bar.

14-23
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Check for free movement of pin in
pedal and condition of rubber boots/
8 1,000    
exhaust flaps of dual brake valve
and replace/rectify if required.
Check the condition of breather tube
and ensure it is secured properly at
both ends of spring brake actuator.
9 Exhaust brake - pneumatic cylinder 1,000     
and hose condition, leakages,
mounting bolts. Replace/tighten if
necessary.
Check compressor air inlet, outlet
hose, water connections, clean
cylinder head and decarbonise if
10 necessary. Check and clean delivery 1,000    
pipe for carbon deposit. Check for
oil throw. If necessary change the
ring kit.
Add S-cam shims when axial play
11 exceeds and replace S-cam shaft 1,000    
bush when radial play exceed.

14-24
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
F. INTEGRAL PEDAL UNIT
Check housing mounting tightness,
dual brake valve pedal free play,
clutch master cylinder pedal free
1 play, free movement of brake and 1,000     
clutch pedal and proper actuation
of clutch pedal switch (for exhaust
brake) and its tightness.

G. STEERING AND SUSPENSION

Check for play in steering linkage/
1 1,000     
drag link, tighten if necessary.
Check oil level in power steering
hydraulic tank and top up if
2 necessary check hydraulic piping 500          
connections for leakages and rectify
if any.
Drain off hydraulic oil of power
3 steering. Replace filter cartridge and Every 30,000 km / 1,000 hrs / 12 months whichever is earlier.
fill in fresh oil.

14-25
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Check steering wheel play. Tighten if
necessary - drag link rod, tie rod and
4 1,000    
check hydraulic limiter valve setting
and peak pressure.
Check & Tighten the U-bolt of front
and rear springs, anti roll bar
5 500         
bracket mounting bolts and shock
absorber mountings.
Visually inspect the shock absorber,
anti roll bar bushes, rubber parts,
6 500        
front springs and eye bushes.
Replace if necessary.
Check and tighten cab leaf spring,
7 cab lock, shock absorber & it's oil 1,000     
seepage. Replace if necessary.
Check and tighten wear pads on
8 500         
frame, replace if necessary.
Replace rear bogie bracket rubber
9 1,500  
bearing & nylon ring.
Check for rear bogie bracket rubber
10 bearing & nylon ring, replace if 500        
necessary.

14-26
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Check & tighten - V-rod, control rod,
front spring, bogie bracket, plummer
block Screw & positive locking Kit,
11 swiveling lever bracket mounting on 500        
frame and visually check V-rod &
control rod eye bushes, front spring,
bogie spring. Replace if necessary.

H. EXHAUST
Check for muffler strap mounting
1 500         
and tighten if necessary.
Check for gas leaks at pipe
2 connections and flex pipe and 500         
rectify.

I. FRAME
Check the tightness of cross
1 member to frame side members 500         
mounting bolts.

J. CAB
Check tightness of rear view mirror
1 1,000      
stay & mounting of wiper motor.

14-27
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Door checker greasing, door latch
greasing, front lid latch greasing,
2 1,000     
rear spring pins greasing and check
free end of cab spring lock.
Check condition of gear shift rubber
3 bellow, gaiter at gear lever and 1,000    
steering column.
Check and clean blower/HVAC -
4 1,000     
inlet filter and replace if necessary.
Check refrigerant leakage &
5 1,000    
pressure if AC provided.
1,000 hrs /
Conduct visual/operational check on
6 Every rainy    
wiper blade, replace if required.
season
7 Check for cab tilt oil level. Top-up is necessary, whenever the oil level is lower than the neck level.
Visually check hose connector for
leak, condition of bushes in top &
8 1,000    
bottom end of cab tilting cylinder
connections.
Check and tighten cab mounting
9 1,000     
and cab checker arm.

14-28
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Visually check condition of body
mounting rubber pad, cab bush
10 Every 120,000 km / 4,000 hrs / 24 months whichever is earlier.
rubber, buffers, shock absorber and
bushes, replace if necessary.
Check mounting of driver seat and
11 2,000  
tighten if necessary.

K. ELECTRICALS
Check battery mountings, tighten if
1 necessary. Clean battery post and 1,000      
terminal. Smear petroleum jelly.
Check electrolyte specific gravity &
level, top up if necessary. Also check
2 1,000      
open circuit voltage, charging
circuit.
Check air gauge connecting union,
3 fuel tank, fuel gauge sensing units 1,000     
for tightness.
Check connections and mountings
4 of starter motor, alternator and 1,000    
tighten, if necessary.

14-29
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Drive the vehicle and perform all the
operation as per the cluster and
check the working of indicators in
cluster. Check lights, switches,
gauges, blinkers, wiper motor, horn,
5 500         
switches and gauges connections,
tighten if necessary. Check for error
codes in Instrument cluster, if
necessary use Xentry diagnostic
tool.
Check connections of tail lamp,
blinker lamp, head lamp and
6 tighten, if necessary. Adjust the 1,000     
head lamp focusing (after bulb
change) if required.
Check proper clamping/routing of
7 neutral switch, speedometer sensor 1,000    
cable and condition of all sensors.

L. WHEELS AND TYRES

Check and tighten wheel nuts, if
necessary (wheel nuts to be
1 Every 10,000 km.
checked for the first 100 km on
every wheel change).

14-30
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
2 Tyre rotation. Every 10,000 km.

M. TIPPING UNIT
Visually check the oil level in
hydraulic tank, pneumatic and
hydraulic connections for slackness,
1 1,000      
inspection of hydraulic system i.e.
P.T.O., pump, tank, valve, hoses and
couplings for leakages.
Check hoses, nuts, hydraulic
fittings, pivot bracket bolts,
attachment bolts and cylinder cradle
2 500         
mounting bracket bolts, pump
mounting bolts, fasteners on sub
frame and tighten if necessary.
Lubricate all greasing points on the
tipper (cylinder eye end, stabilizer,
3 body prop, rear hinge shaft) and 1,000     
clean breather element with
compressed air.
Once in every 4 months in normal working condition (non mining application) /
Replace breather filter element,
4 Once in every 2 months in dusty working condition (mining application) and
return line filter element.
also during oil change.

14-31
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
Drain hydraulic oil from the system
5 First change - 6 months & thereafter once in 12 months.
& replace.

N. AFTER TREATMENT SYSTEM

1 Clean level sensor strainer. 1,000    
2 Replace AdBlue pump main filter. 1,000    
3 Replace AdBlue pump pre filter. 500        
Remove metering unit pre filter at
4 air inlet. Check for moisture/oil/dust 500        
content. Clean or replace if required.
Remove metering unit pre filter at
5 AdBlue inlet. Check for oil/dust 500        
content. Clean or replace if required.

O. HVAC
Check re-circulation filter & replace
1 500 hrs        
if necessary.
Every 2
2 Clean re-circulation filter.
weeks
3 Clean fresh air filter. 1,000     

14-32
 Monthly
Weekly
Daily

1,000

1,500

2,000

2,500

3,000

3,500

4,000
PDI
Frequency

500
S.No Activity
(hrs)
Customer Dealer Check
P. CHECK AND OVERHAUL IF NECESSARY
Overhaul clutch booster and master
1 cylinder with service kit, check bore Every 1,500 hrs / 9 months whichever is earlier.
condition and replace if necessary.
Overhaul air compressor using
2 Every 3,000 hrs / 24 months whichever is earlier.
repairs kits if necessary.
Overhaul - Air dryer, quadruple
system protection valve, quick
release valve, graduated hand
control valve, dual brake valve, relay
3 Every 3,000 hrs / 24 months whichever is earlier.
valve, front brake chamber and rear
brake chamber if necessary using
recommended repair kit and replace
if required.
Overhaul the exhaust brake &
4 Every 3,000 hrs / 24 months whichever is earlier.
Integral pedal unit.

14-33
Air Intake System
Maintenance of air cleaner plays a 1. Inspect the air intake piping for
vital role in engine life and damages, cracked hoses and CAUTION
performance. Poor air cleaner loose clamps. The air filter should not be
maintenance will only yield in 2. Replace the damaged hoses cleaned but only replaced. To
excess bore wear, high engine oil and tighten loose clamps. replace the primary and second-
consumption and poor pick up. ary air filter’s contact your near-
3. Never operate the engine
without an air cleaner, damaged est authorised dealer only.
intake hoses or clamps in loose
conditions.
Air Filter
The air filter should not be removed
from the air intake system for any
regular maintenance work. The air 1
filter should not be cleaned but only
replaced whenever it is choked with
DICV-HDT-996
impurities.

DICV-HDT-150

Replace the secondary air filter (1)

with a new filter, when replacing the
primary air filter for the third time.

DICV-HDT-148
DICV-HDT-149

14-34
Air Filter Restriction
The primary air filter should be
replaced with a new filter when the
air filter choking indicator glows in
the cluster.
DICV-HDT-151
NOTICE
Air filter restriction indicator will
gl ow for a few mome nts on ce
the primary air filter is replaced,
it will turn off after the vehicle
starts to run.
Turbocharger
A Turbocharger is a centrifugal air
pump driven by the engine exhaust
gases. It is mounted on the right
hand side of the engine on the
exhaust manifold. The main purpose
of the turbocharger is to compress
air flowing into the engine. This
excess air allows in better operating
characteristics of the engine at
higher altitude.
DICV-HDT-152
Turbocharger Maintenance
The turbocharger does not need any
maintenance however the engine
aggregates has to be subjected to
periodic maintenance.
1. Change the engine oil
periodically as recommended in
the maintenance chart.
2. Perform maintenance work
regularly on the oil filter and air
filter system, as recommended
in maintenance chart.
3. Ensure that the oil and air pipe
connections are tight and free
from damage.
4. When performing any
maintenance work on the
engine, pipes leading from and
to the turbocharger must be
removed, and the openings to
the turbocharger should be
sealed to prevent entry of
foreign particles.
CAUTION
Disassembly, servicing or over-
hauling of turbochargers should
be carried out only by authorised
dealers.
14-35
Cooling System
The engine coolant’s DAT (De-
Aeration Tank) is located
underneath the front lid of the
cabin.
MIN
DICV-HDT-153
1. Visually check for the coolant
level in the coolant tank.
2. If the coolant level is less than
the minimum level, top up
using Mercedes-Benz
recommended coolant. Do not
overfill.
14-36
NOTICE WARNING
Usage of n on- rec ommen de d
Change the coolant as per
fuel or additives will result in
maintenance schedule. To
poor engine performance and
prevent damage to the cooling
void of warranty.
system use only recommended
coolant.
Fuel Tank Cap
Fuel tank cap covers the filling
WARNING mouth and its provided with
Do n ot al l ow th e c ool an t to breathing point for ingress and exit
come in contact with your skin, of air. Its also provided with a lock
eyes or clothing. In the event of to prevent unauthorised access to
contact wi th eye , ri nse t hem the tank.
thoroughly with clean water.
Cl e an ski n a n d cl ot h e s w i t h
soap and water. If discomfort
persists consult a doctor.
Fuel System
Mercedes-Benz recommends to use
EURO 4 fuels only. Any other kind
of fuel is not permitted. Do not use
adulterated fuel as they can lead to DICV-HDT-1379
engine damage.

NOTICE
Wipe and clean the fuel tank cap
and mouth before removal.
1. Flip open the key hole cover on
the fuel tank cap. Insert the key
into the key hole and turn
clockwise, rotate the cap and
take out. Rotate the key
anticlockwise and take out the
key, if required.
2. Locate the fuel tank cap in the
slot of the fuel tank and lock by
turning. Flip open the key hole
cover on the fuel tank cap and
insert the key, rotate
anticlockwise to lock cap and
take over the key. Flip the cover
and close the key hole.
Fuel Theft Protection
It is used to avoid theft of fuel from
tank neck. It is available in both
primary and additional fuel tank.
DICV-HDT-2481
Water Separator
Drain the water separator regularly.
1. Place a suitable container
under the water separator’s
drain plug.
2. Unscrew the water separator
drain valve by turning it
clockwise to drain the water
until clear fuel is visible.
DICV-HDT-154
3. Turn the drain valve anti-
clockwise and tighten the drain
valve.
CAUTION
Dispose the drained fluid in an
environment friendly manner.
Engine Oil Inspection
The engine oil level can be checked
using the dip stick provided in front
of the cabin.
1. Park the vehicle on a level
ground
2. Open the front lid to access the
dip stick (1).
14-37
 WARNING
Al w ays ch e ck th e en g i ne oi l
1 level before starting the vehicle
for the day or after half an hour
from switching off the engine,
allowing the oil to return to the
sump and when the engine
reaches an am bient
DICV-HDT-155 DICV-HDT-157 temperature.
3. Pull out the dip stick and check
the oil level. NOTICE
CAUTION
Check the oil l evel only when
the vehicle is parked on a level Dispose used oil, lubricants and
surface. Always maintain the oil batteries in an environmentally
l e v e l b e t w e e n M A X an d M I N friendly manner.
level, do not overfill.
MAX MIN

DICV-HDT-156
4. Top up with engine oil if the
level is found below the “MIN”
level.

14-38
 Refrigerant Gas* Clutch Fluid oil change period refer maintenance
The HVAC system (if fitted in your schedule. The condition of steering
The clutch fluid tank is located
vehicle) uses R134a refrigerant drop arm, drag link and track rod
behind the front lid of the cabin.
compatible with global standards. ends should be checked visually for
1. Visually check for the clutch any damage.
R134a is known as Tetrafluroethane
fluid level in the container.
(CF3CH2F) from the family of HFC
2. If the clutch fluid level is less
refrigerant which is a widely used in
than the minimum level, top up
air conditioning system in
using Mercedes-Benz clutch
automotive vehicles.
fluid. Do not overfill. MAK

CAUTION MAX
MIN

Always contact an authorised MIN

dealer to refill refrigerant
in your vehicle.
MAX

MIN
DICV-HDT-158
Power Steering Fluid
The power steering oil level should
be checked regularly and topped up
as required. Ensure that the oil is
filled sufficiently and not above the
maximum level. For power steering
*if applicable
DICV-HDT-159
1. Visually check for the steering
fluid level in the container.
2. If the steering fluid level is less
than the minimum level, top up
using Mercedes-Benz power
steering fluid. Do not overfill.
NOTICE
The power steering oil level
shou ld be chec ked onl y when
the engine is running.

14-39
Windscreen Washer
Fluid
The windscreen washer fluid
reservoir is located behind the front
lid of the cabin.
DICV-HDT-160
1. Use only fresh and clean water
to fill the reservoir.
2. Visually check the reservoir for
water level, if found less than
the required level top up with
clean water adequately.
14-40
Battery Maintenance
Check the battery condition at
authorized service center of
Mercedes-Benz periodically.
Battery Terminal Removal &
Refitment
1. Remove the negative terminal
first and then positive terminal.
DICV-HDT-716
2. Refit the positive terminal first
and then negative terminal.
WARNING
Disconnecting and connecting
th e b at te ry t ermi n al s in n on
recommended method will lead
to short circuit.
Battery Handling
1. The corrosion on the battery
terminals can be removed by
wiping the battery terminal
carefully and completely using
a soft brush. Then wipe it clean
with wet cloth. Apply petroleum
jelly.
2. Do not allow any metal to
contact between the negative
and positive terminal to avoid
short circuit.
3. Never expose the batteries to
sparks or open flame.
4. Periodically check the specific
gravity of the cells.
NOTICE
1. Al ways u se si mi l ar bat te ry
rating.
2. If the vehicle is not operated
for an extended period of time,
start the engine and allow it to
run for five to ten minutes once
i n t w o d a y s t o p re v e n t t h e
battery from draining.
 Check the fan belt periodically and
CAUTION replace the fan belt if it is worn out,
Dispose old batteries in an envi- broken or damaged.The fan belt
ronmentally friendly manner. does not need any adjustment. The
fan belt should be replaced by an
authorised dealer only.
Fan Belt
Vehicle Storage
If you plan not to use your vehicle
for a considerable period of time.
Prepare them for storage. It is
always advisable to store the vehicle
in an enclosed space.
Storage Preparation
1. Clean the vehicle.
2. Check the oil and coolant
levels.
3. Inflate the tyres to 7psi above
the specified tyre pressures.
4. Release the handbrake and
chock the wheels.
5. Disconnect the battery and
apply petroleum jelly on battery
terminals.
DICV-HDT-161
CAUTION
In case the vehicle is to be stored
in an open place, remove the bat-
tery from the vehicle and store it
upright in a safe dry place.
6. Fold the windscreen wipers
away from the windscreen.
Maintenance of Stored Vehicles
Mercedes-Benz recommends the
operator to take appropriate care
and perform the required
maintenance on stored vehicle, even
if not in use.
1. Oil level once in a month.
2. Coolant level once in a month.
3. Tyre pressures once in a month.
Removing Vehicle from Storage
1. Check the oil, coolant and fluid
levels.
2. Check battery charge and
install the battery.
3. Correct the tyre pressure.
4. Clean the vehicle.
14-41
Maintenance Records
Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

14-42
Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

14-43
 Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

Date Date Date Date

........................................ ........................................ ........................................ ........................................

km/hours
........................................ km/hours
........................................ km/hours
........................................ km/hours
........................................

14-44
Service Records
Service Dealer
Odometer Service
S.No Job No. Activities Sign and
Reading (km) Date
Stamp

10

11

12

14-45
 Service Dealer
Odometer Service
S.No Job No. Activities Sign and
Reading (km) Date
Stamp

13

14

15

16

17

18

19

20

21

22

23

24

25

14-46
15. TROUBLESHOOTING CHART
Trouble Cause Corrective Action

A. ENGINE

Weak or dead battery Recharge or replace battery

Starter motor not engag- Battery terminals corroded, starter motor / bat- Clean battery terminals, tighten starter motor
ing or engaging slowly tery connecting cables disconnected or loose / battery connecting cables

Poor ground connections Tighten the connections

Fuel tank empty Refuel

Block in fuel filter Replace the filter element

Starter motor rotates but
engine does not start
Air in fuel system Bleed the fuel system

Block in air cleaner element Replace air cleaner element

Air in the fuel system Bleed the fuel system

Engine is too cold Allow engine to warm up

Engine stops at low rpm
Idle RPM too low Adjust by an authorised dealer

Block in air cleaner element Replace air cleaner element

15-1
 Trouble Cause Corrective Action

Check for clearance by removing dust boot

Brake binding
cover

Air cleaner element blocked Replace air cleaner element

Engine lacks power
Engine brake valve defective Check engine brake is engaged in cluster

Fuel filter blocked Replace the filter element

Terminals at alternator and battery/earthing dis- Connect terminals securely after trimming the
connected, loosened, or corroded corrosion with a file. Apply petroleum jelly
and recharge the battery
Battery discharge
Low charge level Recharge the battery

Lamp switch remains on Turn off the lamp switch and recharge the
battery

Leakage in fuel system Rectify leak

Turbocharger air leak on pressure (delivery) Rectify

side

Under inflated tyre Correct tyre air pressure

High fuel consumption
Brake binding Check for clearance by removing dust boot
cover

Clutch slippage Check for wear indication in the booster

15-2
 Trouble Cause Corrective Action

Engine in emergency run- Engine control unit or drive control unit mal- Read malfunction memory in instrument clus-
ning mode, constant function ter. Contact an authorised dealer
speed 1,300 rpm

Damage in belt Replace the belt

Fan does not rotate at required RPM Contact an authorised dealer

Insufficient coolant Top up with recommended coolant

Engine overheating
Clean the radiator core. Contact an autho-
Chocked radiator
rised dealer

Check wastegate for free movement and dam-

Defective wastegate
age

Engine emits black smoke Air cleaner element is blocked Replace air cleaner element

Poor quality oil Change with the recommended oil

Oil level too high Maintain recommended oil level

High engine oil
Oil leaks Check for external leakage and rectify
consumption
Failure to observe oil changing intervals Follow the scheduled intervals

Negligence in engine warming up Perform engine warming up as instructed

15-3
 Trouble Cause Corrective Action

High engine oil

Low engine oil level Maintain recommended oil level
consumption

Lack of engine oil Replenish

Oil leakage Inspect lubrication system and retighten loos-

Low engine oil pressure
ened parts

Improper oil viscosity Change with oil having proper viscosity

Check physical damage, replace if required /

AdBlue poor quality
use diagnostics tool
Engine power is restriction
/ MIL blinking
Malfunction of any of the electronic
Replace the malfunctioning components.
components in the exhaust system

Exhaust manifold is cracked or broken Replace the exhaust manifold

Engine growling noise
SCR catalytic converter damaged or crack Replace SCR catalytic converter

Check for crystallization and clean it with

Key barrel obstruction / difficulty in key
AdBlue tank cap water and air (not more than 3 bar) / replace
operation observed
the cap

Check dosing unit AdBlue hoses connection are

Tighten the dosing unit AdBlue hoses
Urea Consumption high / loose
urea smell in cab
Leakage in AdBlue system Check for crystallization at joints and rectify

15-4
 Trouble Cause Corrective Action

Check AdBlue tank sensor for fault or replace

AdBlue level improper AdBlue level bar indication in cluster differs
AdBlue tank sensor display and also check
indication from originally available level in tank
cluster electrical connections

B. TRANSMISSION

Abnormal noise in trans- Observe for external leaks, rectify and top up
Lack of transmission oil.
mission system with recommended oil

C. STEERING

Under inflated front tyres Inflate tyres to specified air pressure

Low oil in steering system Top up with recommended oil

Hard steering
Block in reservoir filter Replace the reservoir filter element

Oil leaks Check for external leakage and rectify

Partially hard to steer the

Air pockets inside the steering system Bleed the steering system
wheel

Vehicle pulling on one

Incorrect caster angle Check and correct the caster angle
side

Abnormal noise in trans- Observe for external leaks, rectify and top up
Lack of gear oil or differential oil
mission or differential with recommended oil

15-5
 Trouble Cause Corrective Action

Steering wheel fails to

Lack of grease in steering unit Lubricate king pin unit
return to Its position

D. BRAKE

Check automatic slack adjuster operation as

Brake dragging Excessive brake lining clearance specified, check brake chamber / lining condi-
tion

Loose hub / wheel nuts Tighten to specified torque

Steering wheel shimmy Uneven tyre inflation pressure Adjust tyre pressure as specified

Irregular tyre wear Change tyre

Tyre over inflation Adjust tyre pressure as specified

Air leakage in brake circuit Check brake lines

Poor brake action
Check brake lining condition / automatic
Excessive brake lining clearance
slack adjuster operation as specified

Uneven tyre inflation pressure Adjust tyre pressure as specified

One-sided brake action
Irregular tyre wear Change tyre

E. DIFFERENETIAL

Abnormal noise in differ- Observe for external leaks, rectify and top up
Lack of differential oil.
ential system with recommended oil

15-6
 Trouble Cause Corrective Action

F. ELECTRICALS

Faulty lamp Change

Lamps not glowing Fuse burnt out Change

Poor ground connection Tighten connections

Rotate the adjusting screw in clockwise direc-

High current draw
tion

Rotate the adjusting screw in anti-clockwise

Horn direction till some sound is audible. Fine tune
the horn by iteratively rotating the screw in
Zero current draw
clockwise / anticlockwise direction. If no
sound is heard even after 3-4 turns of the
screw, replace the horn

Rotate the adjusting screw in clockwise direc-

Excessively high current tion till some continuous sound is audible &
then fine tune the horn
Horn
Fine tune the horn by rotating the screw in
Less current draw
anti-clockwise direction

15-7
 Trouble Cause Corrective Action

G. TIPPING SYSTEM (2528C, 2528CH, 2528CX)

Check the electrical sockets and replace as

Disconnect of electrical socket
necessary

Check the electrical solenoids and replace as

System does not start Electrical solenoids malfunction
necessary
when pushing START
(PTO engagement) but-
Check the components in the electrical cabi-
ton Fuse is blown
net and replace as necessary

Check the entire system for proper voltage

Insufficient system voltage
supply. Repair as necessary

Leakage of hydraulic oil Replace the cylinder or cylinder seal kit

Cylinder seal worn out or damaged cylinder
around the cylinder based on severity

Hydraulic pressure is Electrical control or valve malfunction Check for clearance by removing dust boot
present but the Tipper is
cover
not functioning

15-8
 Trouble Cause Corrective Action

Ensure the proper engagement of PTO &

Poor engagement of PTO & Pump
Pump. Adjust and repair as necessary

Check the pressure cartridge & replace if nec-

Malfunction of pressure relief valve
essary

Inspect the rotation of the pump and verify

Improper pump rotation
No hydraulic pressure proper adjustment

Insufficient hydraulic fluid Check fluid level and fill as necessary

Hydraulic suction line plugged Unplug hydraulic suction line

Replace pump if abnormality of pump

Pump malfunctioning
observed

PTO not engaged Engage PTO

Cylinder does not extend No oil in tank Fill oil tank with hydraulic oil
when the air controls is in
“tip” Stop cock below the tank closed Open stop cock

Low air pressure Increase pneumatic pressure

15-9
 Trouble Cause Corrective Action

Air pressure to low Check pneumatic pressure

Faulty pump Replace with new pump

Cylinder extends too slow
Faulty relief valve Check the relief valve and replace as neces-
sary

Body lowers when the The non return valve in tipper valve is not func- Check the non return valve in tipper valve and
clutch is pressed tioning replace as necessary

Body lowers automati- Pressure relief valve malfunctioning Replace pressure cartridge
cally when the air control
valve is in neutral posi- Internal leakage in proportional tipping (PT) Replace culprit part of PT valve or replace PT
tion valve valve based on severity.

Air hose has broken Replace with new hose

Air control fails
suddenly Check and clean the blocked port and replace
Air control is blocked by dirt
as necessary

15-10