Astra Hhd9 Euro 3 Use and Maintenance Handbook

USE AND MAINTENANCE
HANDBOOK
HHD9
Euro 3
GB
USE AND MAINTENANCE
HANDBOOK
HHD9
Euro 3
GB
The company ASTRA VEICOLI INDUSTRIALI reserves the right to make any modifications to vehicles for technical or commercial rea-
sons at any time; the information, descriptions and illustrations contained in this publication are therefore correct at the time going to
press.
This Use and Maintenance Handbook deals with optional equipment which cannot be present on your vehicle, and alternative equipment
as well (e.g. mechanical and automatic gearbox).
Moreover, the regulations in force in certain countries affect the standard equipment of the vehicle.
This publication could therefore contain information and illustrations not corresponding to the vehicle version provided on a particular mar-
ket.
ASTRA Veicoli Industriali

Product Logistics
Via Caorsana, 79 --- 29100 PIACENZA (Italy)
Tel. 0523/5431 --- Fax 0523/543459
Print cat. A3502304
First edition - OCTOBER 2012
Prepared by SIPAL S.p.A. --- Torino (Italy)

Reproduction, whether total or partial, of the text and illustrations is strictly forbidden.
HHD9 Euro3 I
--- INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX --- TRANSFER DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . 1-11

--- AFTER SALES SERVICE . . . . . . . . . . . . . . . . . . . . . . . . X --- AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
S Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V S Front steering drive axle 10 ton . . . . . . . . . . . . . . . . . 1-12
S After-sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . V S Tandem rear drive axles . . . . . . . . . . . . . . . . . . . . . . . 1-13
S Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V --- BRAKES (simplex without ABS) . . . . . . . . . . . . . . . . . . 1-14
--- WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI --- BRAKES (duplex with ABS) . . . . . . . . . . . . . . . . . . . . . . 1-15
--- ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
--- TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 --- SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
--- STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
--- POSITION OF VEHICLE IDENTIFICATION DATA --- Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 --- CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
S Model identification plate . . . . . . . . . . . . . . . . . . . . . . 1-3 S Standard fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
S Imprinting of the vehicle chassis . . . . . . . . . . . . . . . . 1-3 S Oversize fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
S Vehicle identification plate . . . . . . . . . . . . . . . . . . . . . 1-3 --- TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 1-21
S Chassis punching . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 --- VEHICLE OUTFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
S Vehicle registration number . . . . . . . . . . . . . . . . . . . . 1-4 S Set of keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
S Vehicle identification plate . . . . . . . . . . . . . . . . . . . . . 1-5 S Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
--- ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 S Vehicle outfitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
S IVECO F3B WG (Cursor 13) . . . . . . . . . . . . . . . . . . . 1-6
S Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
--- ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 INSTRUCTIONS FOR USE . . . . . . . . . . . . . . . . . . 1-25
S IVECO F3B VGT (Cursor 13) . . . . . . . . . . . . . . . . . . . 1-7 --- GENERAL INSTRUCTIONS FOR CORRECT USE
S Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 OF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
--- MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 1-8 S Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
S Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 S When driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
S Gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 S Night driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
S Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 S Driving in rain, fog and snow . . . . . . . . . . . . . . . . . . 1-28
--- AUTOMATIZED TRANSMISSION . . . . . . . . . . . . . . . . . 1-9 S Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
S Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 S Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
S Gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 S Snow chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
S Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 S Economic, ecological driving . . . . . . . . . . . . . . . . . . 1-29
--- AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . 1-10 --- Range of use of the engine . . . . . . . . . . . . . . . . . . . . . . 1-30
S ALLISON HD 4700 gear shift . . . . . . . . . . . . . . . . . . 1-10 --- LEFT HAND DRIVE VEHICLES . . . . . . . . . . . . . . . . . . . 1-31
S Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 --- CAB-EXTERNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
II HHD9 Euro3
--- EXTERNAL LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 S 12Volt current socket . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

S Front lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 --- CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55
S Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 S Controls on dashboard . . . . . . . . . . . . . . . . . . . . . . . 1-55
S Rear lights --- Version with LED taillights . . . . . . . . . 1-34 S Module holder dashboard controls . . . . . . . . . . . . . 1-56
--- DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 S Steering wheel position control . . . . . . . . . . . . . . . . . 1-57
S Central locking remote control . . . . . . . . . . . . . . . . . 1-37 S Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
S Replacing remote control battery . . . . . . . . . . . . . . . 1-38 S Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
--- DRIVERS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 S Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
--- INTERNAL LIGHTING DEVICE . . . . . . . . . . . . . . . . . . . 1-42 S Manual transmission control . . . . . . . . . . . . . . . . . . . 1-59
S Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 S Automated transmission control . . . . . . . . . . . . . . . . 1-59
--- EXTERNAL REAR VIEW MIRRORS . . . . . . . . . . . . . . . 1-43 S Automatic transmission control . . . . . . . . . . . . . . . . . 1-59
S Mirror selection and handling . . . . . . . . . . . . . . . . . . 1-44 --- RIGHT-HAND DRIVE VEHICLES . . . . . . . . . . . . . . . . . . 1-61
--- SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 --- CAB EXTERNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
S Fore and aft adjustment . . . . . . . . . . . . . . . . . . . . . . . 1-46 --- EXTERNAL LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
S Cushion angle adjustment . . . . . . . . . . . . . . . . . . . . 1-46 S Front lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
S Seat suspension adjustment . . . . . . . . . . . . . . . . . . . 1-46 S Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
S Springing system adjustment . . . . . . . . . . . . . . . . . . 1-47 S Rear lights --- Version with LED taillights . . . . . . . . . 1-64
S Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 --- DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
S Backrest angle adjustment . . . . . . . . . . . . . . . . . . . . 1-47 S Central locking remote control . . . . . . . . . . . . . . . . . 1-67
--- SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48 S Replacing remote control battery . . . . . . . . . . . . . . . 1-68
--- ELECTRIC WINDOW CONTROL . . . . . . . . . . . . . . . . . . 1-50 --- DRIVERS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70
S Electric window risers control . . . . . . . . . . . . . . . . . . 1-50 --- INTERNAL LIGHTING DEVICE . . . . . . . . . . . . . . . . . . . 1-72
--- HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51 S Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
--- COMPARTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 --- EXTERNAL REAR VIEW MIRRORS . . . . . . . . . . . . . . . 1-73
S Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 S Mirror selection and handling . . . . . . . . . . . . . . . . . . 1-74
S Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 --- SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76
S Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 S Fore and aft adjustment . . . . . . . . . . . . . . . . . . . . . . . 1-76
S Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 S Cushion angle adjustment . . . . . . . . . . . . . . . . . . . . 1-76
S Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 S Seat suspension adjustment . . . . . . . . . . . . . . . . . . . 1-76
S Rear wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 S Springing system adjustment . . . . . . . . . . . . . . . . . . 1-77
--- ACCESSORIES - DEVICES . . . . . . . . . . . . . . . . . . . . . . 1-54 S Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
S Sun blind tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 S Backrest angle adjustment . . . . . . . . . . . . . . . . . . . . 1-77
S Grip handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 --- SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
S Coat hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 --- ELECTRIC WINDOW CONTROL . . . . . . . . . . . . . . . . . . 1-80
S Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 S Electric window risers control . . . . . . . . . . . . . . . . . . 1-80
S Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54
HHD9 Euro3 III
--- HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81 S Automatic transmission warning lights . . . . . . . . . . 1-97

--- COMPARTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82 S Warning light on dashboard --- Left-hand drive
S Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82 vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98
S Upper dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82 S Warning light on dashboard --- Right-hand drive
S Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83 vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99
S Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83 --- CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 1-100
S Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83 S Position and headlight controls . . . . . . . . . . . . . . . . . 1-100
S Rear wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83 S Headlight control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100
--- ACCESSORIES - DEVICES . . . . . . . . . . . . . . . . . . . . . . 1-84 S Direction indicator control . . . . . . . . . . . . . . . . . . . . . 1-101
S Sun blind tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84 S Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101
S Grip handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84 S Windscreen washer/wiper control . . . . . . . . . . . . . . 1-102
S Coat hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84 S Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103
S Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84 S Engine braking control --- Vehicles without
S Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84 intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103
S 12Volt current socket . . . . . . . . . . . . . . . . . . . . . . . . . 1-84 S Engine braking control --- Vehicles with intarder . . . 1-103
--- CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85 S Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
S Controls on dashboard . . . . . . . . . . . . . . . . . . . . . . . 1-85 S Hazard light control . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
S Module holder dashboard controls . . . . . . . . . . . . . 1-86 S Exhaust brake pre-selection . . . . . . . . . . . . . . . . . . . 1-105
S Steering wheel position control . . . . . . . . . . . . . . . . . 1-87 S Courtesy light switch . . . . . . . . . . . . . . . . . . . . . . . . . 1-106
S Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 S Electro-pneumatic horn pre-selection . . . . . . . . . . . 1-106
S Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 S Swivelling light control . . . . . . . . . . . . . . . . . . . . . . . . 1-107
S Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 S Work light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107
S Manual gear shift lever . . . . . . . . . . . . . . . . . . . . . . . . 1-89 S Rear fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107
S Automated transmission control . . . . . . . . . . . . . . . . 1-89 S Fog light control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
S Automatic transmission command . . . . . . . . . . . . . . 1-89 S Electric battery isolator control . . . . . . . . . . . . . . . . . 1-108
--- ALL VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 S ASR off command . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109
--- INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 S ABS Off Road function control . . . . . . . . . . . . . . . . . 1-110
S Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 S Distributor-reducer (transfer) . . . . . . . . . . . . . . . . . . . 1-111
S Functions of instrument panel keys . . . . . . . . . . . . . 1-92 S Differential lock control (2 axle vehicles) . . . . . . . . . 1-112
S Warning lights panel A details . . . . . . . . . . . . . . . . . . 1-93 S Differential lock control (3-4 axle vehicles) . . . . . . . . 1-114
S Warning lights panel B details . . . . . . . . . . . . . . . . . . 1-94 S Power take off control . . . . . . . . . . . . . . . . . . . . . . . . 1-116
S Warning lights panel C details . . . . . . . . . . . . . . . . . . 1-95 S Multipower PTO on flywheel . . . . . . . . . . . . . . . . . . . 1-117
S Automated transmission display . . . . . . . . . . . . . . . . 1-96 S P.T.O. manual transmission . . . . . . . . . . . . . . . . . . . . 1-118
S Automated transmission indications on display . . . 1-96 --- TACHOMETRIC SIMULATOR . . . . . . . . . . . . . . . . . . . . 1-119
S Automatic transmission display . . . . . . . . . . . . . . . . 1-97 --- HEATING AND VENTILATION . . . . . . . . . . . . . . . . . . . . 1-120
S Automatic transmission indications on display . . . . 1-97 S Climate control system air vents . . . . . . . . . . . . . . . . 1-120
IV HHD9 Euro3
S Climate controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 --- EUROTRONIC TRANSMISSION . . . . . . . . . . . . . . . . . . 1-150

S Most common control positions . . . . . . . . . . . . . . . . 1-123 S Changing to high gears . . . . . . . . . . . . . . . . . . . . . . . 1-150
--- WARM AIR AUXILIARY HEATER (WEBASTO) . . . . . . . 1-127 S Shifting to lower gears . . . . . . . . . . . . . . . . . . . . . . . . 1-150
--- AUXILIARY HEATER (WEBASTO) . . . . . . . . . . . . . . . . . 1-128 --- STARTING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-151
S Auxiliary heater control panel . . . . . . . . . . . . . . . . . . 1-128 S Start-up in automatic mode . . . . . . . . . . . . . . . . . . . . 1-152
S Operation of the heater with key-off without S Start-up in manual mode . . . . . . . . . . . . . . . . . . . . . . 1-153
programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-130 --- DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 1-154
S Operation of the heater with key-on without S Forward movement in automatic mode . . . . . . . . . . 1-156
programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131 S Forward travel gear change in automatic mode . . . 1-156
--- USE OF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-132 S Shifting to next gear down . . . . . . . . . . . . . . . . . . . . . 1-157
S Precautions for the initial period of use . . . . . . . . . . 1-132 S Shifting to higher gears . . . . . . . . . . . . . . . . . . . . . . . 1-157
S General checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-132 S Kick-down function . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-158
S Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-133 S Maintaining the selected gear . . . . . . . . . . . . . . . . . . 1-158
--- STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-134 S Forward running in manual mode . . . . . . . . . . . . . . 1-159
S Checks before starting . . . . . . . . . . . . . . . . . . . . . . . . 1-134 S Shifting to next gear down . . . . . . . . . . . . . . . . . . . . . 1-159
S Starting from drivers cabin . . . . . . . . . . . . . . . . . . . . 1-135 S Shifting to higher gears . . . . . . . . . . . . . . . . . . . . . . . 1-159
S Starting from engine bay . . . . . . . . . . . . . . . . . . . . . . 1-136 S Shift to neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-160
S Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-136 S Reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-161
S Emergency electrical power . . . . . . . . . . . . . . . . . . . 1-137 S Protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-163
--- COLD START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-139 S “LIMP HOME” function . . . . . . . . . . . . . . . . . . . . . . . 1-164
S Starting with heater . . . . . . . . . . . . . . . . . . . . . . . . . . 1-140 --- STOPPING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 1-168
--- STOPPING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141 --- VEHICLES WITH AUTOMATIC TRANSMISSION . . . . 1-169
S Stopping from drivers cabin . . . . . . . . . . . . . . . . . . . 1-141 --- STARTING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 1-169
S Stopping from engine bay . . . . . . . . . . . . . . . . . . . . . 1-142 --- DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 1-171
--- MANUAL TRANSMISSION VEHICLES . . . . . . . . . . . . . 1-143 S Kick-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-172
--- STARTING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 1-143 S Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 1-173
--- DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 1-144 S N (Neutral) position . . . . . . . . . . . . . . . . . . . . . . . . . . 1-175
--- Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-146 S R (Reverse) position . . . . . . . . . . . . . . . . . . . . . . . . . . 1-175
S Gearbox control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-146 S Drive position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-176
S Operating the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 1-147 S Positions 6, 5, 4 and 3 . . . . . . . . . . . . . . . . . . . . . . . . 1-177
S Splitter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 S Position 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-177
--- Stopping the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-149 S Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-177
--- VEHICLES WITH AUTOMATED TRANSMISSION S Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-178
(ASTRONIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-150 S Stopping the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 1-179
HHD9 Euro3 V
--- ALL VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-181 S Electric coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-203

--- SPEED PROGRAMMER . . . . . . . . . . . . . . . . . . . . . . . . . 1-181 --- LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-203
S Engine idle speed adjustment / memorising . . . . . . 1-181 --- TOWING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 1-204
--- Vehicle speed (Cruise Control) adjustment / S Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 1-205
memorising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-183 S Propeller shaft removal . . . . . . . . . . . . . . . . . . . . . . . 1-206
--- Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-185 S Spring cylinder emergency braking device . . . . . . . 1-208
--- Changing setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-186 --- WHEEL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-210
--- Permanent disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-187 S Jacking up the vehicle . . . . . . . . . . . . . . . . . . . . . . . . 1-210
--- Temporary disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-187 S Changing a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-211
--- ENGINE BRAKE CONTROL SELECTION S Handling the spare wheel . . . . . . . . . . . . . . . . . . . . . 1-214
(vehicles without intarder) . . . . . . . . . . . . . . . . . . . . . . . . 1-188 --- DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-215
--- ENGINE BRAKE AND INTARDER CONTROL --- DIAGNOSTICS --- CONNECTIONS FOR CONTROL
SELECTION (vehicles fitted with intarder) . . . . . . . . . . 1-190 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-216
--- VEHICLE PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-193 S Use of jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-216
S Parking brake --- vehicles without trailer . . . . . . . . . . 1-193
S Parking brake --- vehicle with trailer . . . . . . . . . . . . . 1-194
S Parking brake efficiency check . . . . . . . . . . . . . . . . . 1-194 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . 1-217
--- Additional parking brake . . . . . . . . . . . . . . . . . . . . . . . . 1-195 --- INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-219
--- A.B.S. Anti-lock braking system . . . . . . . . . . . . . . . . . . 1-196 --- OPENING RADIATOR GRILL . . . . . . . . . . . . . . . . . . . . . 1-220
--- SEMI-TRAILER COUPLING . . . . . . . . . . . . . . . . . . . . . . 1-197 --- TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-221
S Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-197 S Lifting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-221
S Check closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-198 S Lowering the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-222
S Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-198 --- MAIN LEVELS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 1-224
S ABS coupling (if foreseen) . . . . . . . . . . . . . . . . . . . . . 1-198 S Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . 1-224
S Pivoting fifth wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-199 S Check engine coolant level . . . . . . . . . . . . . . . . . . . . 1-225
--- TRAILER HOOKING --- I type . . . . . . . . . . . . . . . . . . . . . 1-200 S Check windshield washer level . . . . . . . . . . . . . . . . . 1-225
--- TRAILER HOOKING --- II type . . . . . . . . . . . . . . . . . . . . 1-201 --- ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-226
--- NORMS FOR TOWING TRAILER / SEMI-TRAILER . . 1-202 S Changing engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . 1-226
S Before hitching-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-202 S Replacing engine oil filter F3B . . . . . . . . . . . . . . . . . 1-228
S After hitching-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-202 S Engine oil vapour filter change . . . . . . . . . . . . . . . . . 1-229
S When driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-202 S Accessory drive belts check . . . . . . . . . . . . . . . . . . . 1-230
--- TRAILER COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-203 S Intake-exhaust valve play adjustment . . . . . . . . . . . 1-231
S Pneumatic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 1-203 S Injector-pump pre-load adjustment . . . . . . . . . . . . . 1-231
S Electric coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-203 S VGT actuator grease application procedure . . . . . . 1-231
--- SEMI-TRAILER COUPLING . . . . . . . . . . . . . . . . . . . . . . 1-203 --- FUEL FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-232
S Pneumatic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 1-203 S Bleed fuel tank condensation water . . . . . . . . . . . . . 1-232
VI HHD9 Euro3
S Fuel tank water drain . . . . . . . . . . . . . . . . . . . . . . . . . 1-233 S Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-256

S Purging water from fuel decanter . . . . . . . . . . . . . . . 1-233 S Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-257
S Replacing fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . 1-234 S Version without retarder . . . . . . . . . . . . . . . . . . . . . . . 1-257
S Fuel circuit bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 1-236 S Version with retarder . . . . . . . . . . . . . . . . . . . . . . . . . 1-258
--- INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-238 S Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 1-259
S Intake system seal check . . . . . . . . . . . . . . . . . . . . . 1-238 --- AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . 1-260
S Turbocompressor lubrication check . . . . . . . . . . . . . 1-238 S Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-260
S Intercooler external cleaning . . . . . . . . . . . . . . . . . . . 1-238 S Hot check (80-100 ˚C) on display . . . . . . . . . . . . . . 1-260
S Main filter element cleaning/change . . . . . . . . . . . . 1-239 S Cold check (15-45 ˚C) . . . . . . . . . . . . . . . . . . . . . . . . 1-262
S Safety secondary filter element replacement . . . . . 1-240 S Hot check (80-100 ˚C) . . . . . . . . . . . . . . . . . . . . . . . . 1-263
S Replacing the VGT piloting hoses filtering S Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-264
element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-241 S Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 1-265
--- COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-242 --- DISTRIBUTOR-TRANSFER (TRANSFER) . . . . . . . . . . 1-266
S Replacing engine coolant . . . . . . . . . . . . . . . . . . . . . 1-243 S Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-266
S Checking antifreeze concentration . . . . . . . . . . . . . . 1-244 S Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-267
--- CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-245 --- TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . . . . 1-268
S Check clutch disengagement . . . . . . . . . . . . . . . . . . 1-245 S Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-268
S Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-245 --- AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-269
S Changing the hydraulic fluid . . . . . . . . . . . . . . . . . . . 1-246 --- Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-269
S Air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-246 --- Front intermediate axle . . . . . . . . . . . . . . . . . . . . . . . . . . 1-272
--- MULTIPOWER PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-247 --- Rear intermediate axle . . . . . . . . . . . . . . . . . . . . . . . . . . 1-276
S Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-247 --- Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-282
S Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-248 --- SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-286
--- ZF NMV 221 POWER TAKE OFF --- TYPE I . . . . . . . . . 1-249 S Leaf spring pins greasing . . . . . . . . . . . . . . . . . . . . . 1-286
S Oil level check/change . . . . . . . . . . . . . . . . . . . . . . . . 1-249 S Carriage pin greasing on 3 and 4-axle vehicles . . . 1-287
S Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-249 --- STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-288
--- TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-250 S Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-288
S Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-250 S Changing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 1-289
S Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-251 S Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-289
--- GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-252 S Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-289
--- Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-252 S Bleeding off air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-290
S Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-253 S Replacing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-291
S Version without retarder . . . . . . . . . . . . . . . . . . . . . . . 1-253 S Stub axle greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-292
S Version with retarder . . . . . . . . . . . . . . . . . . . . . . . . . 1-254 S Steering linkage grease application . . . . . . . . . . . . . 1-293
S Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 1-255 S Front wheel toe-in check . . . . . . . . . . . . . . . . . . . . . . 1-294
--- AUTOMATED TRANSMISSION . . . . . . . . . . . . . . . . . . . 1-256 S Front wheel toe-in check . . . . . . . . . . . . . . . . . . . . . . 1-295
HHD9 Euro3 VII
--- COMPRESSED AIR SYSTEM . . . . . . . . . . . . . . . . . . . . 1-296 S Rotary warning light bulb replacement . . . . . . . . . . 1-314
S Tank visual inspection . . . . . . . . . . . . . . . . . . . . . . . . 1-296 S Ceiling light bulb replacement . . . . . . . . . . . . . . . . . 1-314
S Air dryer functionality check . . . . . . . . . . . . . . . . . . . 1-297 S Replacing cab step light . . . . . . . . . . . . . . . . . . . . . . 1-314
S Air dryer filter change . . . . . . . . . . . . . . . . . . . . . . . . . 1-298 S List of bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-315
--- BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-299 --- ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-316
S Shoe-drum play check . . . . . . . . . . . . . . . . . . . . . . . . 1-299 S Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-316
S Check pedal distributors . . . . . . . . . . . . . . . . . . . . . . 1-299 S Battery maintenance (unsealed batteries) . . . . . . . . 1-317
--- TYRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-300 S Recharge with external devices . . . . . . . . . . . . . . . . 1-319
S Checking wheels and tyres . . . . . . . . . . . . . . . . . . . . 1-300 S Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . 1-320
S Inflating tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-300 S Interconnection control unit (fuses and relays) . . . . 1-321
--- CAB TIPPING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1-301 S Fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-321
S Oil level check / fluid change . . . . . . . . . . . . . . . . . . 1-301 --- FUSE / RELAYS HOLDER PLATE . . . . . . . . . . . . . . . . . 1-322
S Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-302 --- FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-323
--- TOWING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-303 S Fuse holder (70005) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-323
S Greasing the fifth wheel . . . . . . . . . . . . . . . . . . . . . . . 1-303 S Fuse holder (70601) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-324
S Tow hook greasing --- Type I . . . . . . . . . . . . . . . . . . . 1-304 S Fuse holder (70602) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-324
S Tow hook greasing --- Type II . . . . . . . . . . . . . . . . . . 1-304 S Fuse holder (70401) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-325
--- AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-305 S Fuse holder (70402) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-325
S Air-conditioner system maintenance . . . . . . . . . . . . 1-305 S Fuse holder (70403) not used . . . . . . . . . . . . . . . . . . 1-325
S System charge check . . . . . . . . . . . . . . . . . . . . . . . . 1-306 --- RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-326
--- SUPPLEMENTARY HEATER . . . . . . . . . . . . . . . . . . . . . 1-307 S Additional relays board . . . . . . . . . . . . . . . . . . . . . . . 1-328
S Replacing the supplementary heater fuel filter . . . . 1-307 S Supplementary flying fuse . . . . . . . . . . . . . . . . . . . . . 1-329
--- BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-308
S Replacing front windscreen wiper blade . . . . . . . . . 1-308
S Windscreen washer reservoir . . . . . . . . . . . . . . . . . . 1-308 TABLE AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 1-331
S Bodywork maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-309 --- INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-333
S Cleaning plastic parts . . . . . . . . . . . . . . . . . . . . . . . . . 1-309 S 3-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-334
S Fabric panels cleaning . . . . . . . . . . . . . . . . . . . . . . . . 1-309 S 4-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-336
S Cleaning seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-309 --- LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . . . 1-338
--- LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-310 S Engine F3B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-338
S Headlight/front sidelight bulb replacement . . . . . . . 1-310 S Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . 1-340
S Headlight alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-311 S Automated/automatic transmission . . . . . . . . . . . . . 1-342
S Front direction indicator light bulb replacement . . . 1-312 S Multipower/NMV 221 power take off . . . . . . . . . . . . 1-344
S Side direction indicator bulb replacement . . . . . . . . 1-312 S Drive-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-346
S Rear light bulb replacement . . . . . . . . . . . . . . . . . . . 1-313 S Greasing transmission shafts . . . . . . . . . . . . . . . . . . 1-348
S Front clearance light bulb replacement . . . . . . . . . . 1-314 S Suspension greasing . . . . . . . . . . . . . . . . . . . . . . . . . 1-350
VIII HHD9 Euro3
S Steering linkages, semi-trailer fifth wheel,

tow hook greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-352
S Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-354
--- SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-356
S Checking, adjusting and cleaning operations . . . . . 1-356
S Lubrication and replacement operations ---
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-358
S Lubrication and replacement operations ---
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-359
--- LUBRICANT AND HYDRAULIC FLUID TABLES . . . . . 1-360
HHD9 Euro3 IX
INTRODUCTION
This Use and Maintenance Handbook is divided into 4 parts, each of which systematically
subdivided according to subject, for quick and easy consulting.
1) Technical specifications: this contains all the characteristic data which should be read
through at least once to acquire a working knowledge of the vehicle.
2) Use of the vehicle and practical hints: this contains information relevant to the main con-
trols and instruments, and the main rules to be followed especially for new vehicles.
3) Maintenance instructions: this section contains the functional instructions for checking
and maintaining the vehicle which must be implemented to ensure satisfying operation,
cost-effective running and long life of the vehicle.
4) Tables and diagrams: contains vehicle scheduled maintenance tables and diagrams.
In this Use and Maintenance Handbook there are texts that are highlighted in a particular
manner:
Failure to heed and/or correctly carry out
procedures, technical information and
precautions given may cause injury.

precautions given may cause damage to
the vehicle.
Procedures, technical information and

precautions which must be highlighted.

precautions given may cause environ-
mental damages.
X HHD9 Euro3
AFTER SALES SERVICE

Warranty
To comply to the warranty conditions, all the instructions for correct use and maintenance
described in this manual are to be followed.
After-sales service
For any type of servicing the ASTRA V.I. Dealership is at the complete disposal of the Cus-
tomer. Equipment and skilled staff are available for maintenance or repair jobs. The ASTRA
V.I. Dealership is always willing to offer you hints and advice to ensure you get best perform-
ance from your vehicle.
Spare parts
Any spare parts used for replacements are to be “GENUINE ASTRA SPARES” which can be
obtained from the dealer warehouses and authorised workshops. Remember that a correct
order for spare parts must always include the following details:
– type of vehicle;
– chassis number;
– reference and category numbers, to be found in the Spare Parts Catalogue.
If the items are parts of a main group (engine, cab, axles, power steering, gearbox etc.) indi-
cate also the group version and serial number.
HHD9 Euro3 XI
WARNING
The handbook contains use and mainten-

ance instructions for all systems foreseen
on the vehicle by the Manufacturer.
Some systems described in the hand-
book may not be present on Your vehicle,
according to the chosen version and
market the vehicle is destined for.
Assembly of accessories, additions and modifications on the vehicle are to be carried out in
conformity with ASTRA directives. The specific document “Directive for conversion and out-
fittings” can be obtained as a guideline from the After Sales Service workshops.
It is reminded that, especially regarding the electrical system. there are several electrical
sockets available (standard or optionals) to simplify electrical operations carried out by the
outfitters.
For any exemption from the directives for the conversion it is necessary to have authorisation
from ASTRA.
It is strictly forbidden to make modifications or connections to the wiring of electronic control
units. In particular the interconnection lines between control units (CAN lines) are never to
be interfered with.
Diagnostics and maintenance operations are to be carried out by skilled personnel using
approved diagnostics equipment.
Ignoring these afore-mentioned prescriptions will annul the contractual warranty .
XII HHD9 Euro3
Page left intentionally blank

HHD9 Euro3 1-1
Technical data
1-2 HHD9 Euro3

HHD9 Euro3 1-3
POSITION OF VEHICLE IDENTIFICATION

1A 1B DATA PLATES
Model identification plate
Located on the side walls of the cab (Fig. 1A
vers. LHD, Fig. 1B vers. RHD, see arrow).
Imprinting of the vehicle chassis
Punch marked at the front end of the right-
hand side member (Fig. 2, see arrow).
342BNU001L 356ADT101L
(see following page).
Vehicle identification plate
2 On bonnet in cabin for vehicle identification
as per EU standards (Fig. 3A vers. LHD, Fig.
3B vers. RHD, see arrow).
3A 3B
272CDT001 356ADT102L
1-4 HHD9 Euro3
b 1 Chassis punching (Fig. 1)

a. right side member
b. rear axle front leaf spring
Vehicle registration number (Fig. 2)

2
1) World–wide identification of manufac-
turers (Astra Veicoli Industriali S.p.A.)
2) Type of vehicle
3) Vehicle features
4) Year of construction
5) Production facility (P=Piacenza)
6) Chassis number
HHD9 Euro3 1-5
1 3 Vehicle identification plate (Fig. 3)

1. Approved type number marking
2. Vehicle chassis punching
3. Code of country issuing type approval
4. Not used
5. Full load maximum weight legally
admissible
6. Full load maximum weight technically
admissible
7. Assembly maximum weight legally
admissible
8. Assembly maximum weight technically
admissible
9. 1st axle maximum weight legally
admissible
10. 1st axle maximum weight technically
admissible
11. 2nd axle maximum weight legally
admissible
12. 2nd axle maximum weight technically
admissible
13. 3rd axle maximum weight legally
admissible
14. 3rd axle maximum weight technically
admissible
15. 4th axle maximum weight legally
admissible
16. 4th axle maximum weight technically
admissible
17. 5th axle maximum weight legally
admissible
357ADT201L 18. 5th axle maximum weight technically
admissible
19. Axles unit maximum weight legally
admissible
20. Axles unit maximum weight technically
admissible
21. Vehicle commercial name
22. Lights inclination percentage
23. Distance between axles
24. Number of axles
25. Type of engine
26. Engine power
27. Smokiness index
1-6 HHD9 Euro3
1 ENGINE
Engine
IVECO F3B WG (Cursor 13) (Fig. 1)
4-stroke Diesel, liquid cooled, turbocharger
with Wastegate pressure limiter.
Main specifications
Number of cylinders 6
285ADT003L
Bore mm 135
Stroke mm 150
Total displacement cm3 12882
Compression ratio 16.5
Injection order 1-4-2-6-3-5
HHD9 Euro3 1-7
1 ENGINE
Engine
IVECO F3B VGT (Cursor 13) (Fig. 1)
4-stroke Diesel, liquid cooled, variable ge-
ometry exhaust gas turbocharger.
Main specifications
Number of cylinders 6
285ADT003L
Bore mm 135
Stroke mm 150
Total displacement cm3 12882
Compression ratio 16.5
Injection order 1-4-2-6-3-5
1-8 HHD9 Euro3
1 MANUAL TRANSMISSION
Clutch
Dry single disk. Diameter 17”.
Hydraulic control.
Gear shift (Fig. 1)
ZF 16 S 2320 TD,
ZF 16 S 2520 TO,
ZF 16 S 2720 TO
341BDT001L
Syncromesh manual with 8 forward gears,
split into a low range group (1- 4) and a high
range group (5 - 8), and 1 R.G, normal and
low.
Pneumatic servoshift device.
Neutral switch for preventing starting the
motor with gear engaged.
Hydrodynamic retarder (intarder) mounted
on gearbox output (optional).
Ratios
Direct Drive Over Drive
Normal Low Normal Low
1st 13.80 16.41 11.54 13.80
2nd 9.49 11.28 7.93 9.49
3rd 6.53 7.76 5.46 6.53
4th 4.57 5.43 3.82 4.57
5th 3.02 3.59 2.53 3.02
6th 2.08 2.47 1.74 2.08
7th 1.43 1.70 1.20 1.43
8th 1.00 1.19 0.84 1.00
R.G. 12.92 15.36 10.80 12.92
R.G. = Reverse Gear

HHD9 Euro3 1-9
1 AUTOMATIZED TRANSMISSION
Clutch
Dry single disk, Diameter 17”.
Electro-pneumatic control.
Gear shift
ZF 16 AS 2601 OD
Manual with 16 forward and 2 reverse gears.
Electro-pneumatic servoshift.
Automatic or manual mode selection.
Hydrodynamic intarder mounted on gear-
box output (if present).
Ratios
1st 14.12 9th 3.09
2nd 11.67 10th 2.55
3rd 9.53 11th 2.08
4th 7.88 12th 1.72
5th 6.52 13th 1.42
6th 5.39 14th 1.18
7th 4.56 15th 1.00
8th 3.77 16th 0.82
1st R.G. 13.07 2nd R.G. 10.81
R.G. = Reverse Gear
1-10 HHD9 Euro3
1 AUTOMATIC TRANSMISSION
ALLISON HD 4700 gear shift
Epicyclical automatic, 7 forward plus re-
verse.
Hydrodynamic torque converter with free
wheeldistributor .
Automatic engage converter lock-up clutch.
Hydrodynamic retarder built-in.
306ADT001L Ratios
1st 1:7.63
2nd 1:3.51
3rd 1:1.91
4th 1:1.43
5th 1:1.00
6th 1:0.74
7th 1:0.64
R.G. 1:4.80
R.G. = Reverse Gear
HHD9 Euro3 1-11
1 TRANSFER DISTRIBUTOR
STEYR VG 2700/400 (Fig. 1)
Transmission ratios:
Normal (on road): 0.913
Low (off road): 1.407
Maximum torque at input:
30.000 Nm
283092101
1-12 HHD9 Euro3
AXLES
1
Front steering drive axle 10 ton (Fig. 1)
With double reduction (central and final) in
wheel hubs by means of epicyclical gear set.
Drive shafts controlling front wheels
equipped with Cardan joints.
HHD9 Euro3 1-13
Tandem rear drive axles (Fig. 1)

1
Two drive axles in tandem with double reduc-
tion, central with bevel gear and final in wheel
hubs with epicyclical gear set.
The tandem is provided with splitter between
axles and pneumatic lock.
Differential between wheels with pneumatic
lock.
1-14 HHD9 Euro3
1 BRAKES (simplex without ABS)

Simplex wedge drum brakes (Fig. 1) on all
axles. Brake adjustment is automatic and
therefore maintenance free until total brake
lining wear.
Service brake: pneumatic operation with
two independent sections for vehicles wi-
thout tow bar, three independent sections for
vehicles with tow bar.
Parking and emergency brake: pneumatic
operation acting on rear wheel brake drums
through spring cylinder.
Engine brake: built into engine.
Retarder brake: hydraulic, installed on tran-
smission.
Auxiliary parking brake: pneumatic opera-
tion: must be engaged with engine running.
HHD9 Euro3 1-15
1 BRAKES (duplex with ABS)

Duplex wedge drum brakes (Fig. 1) on all
axles. Brake adjustment is automatic and
therefore maintenance free until total brake
lining wear.
Service brake: pneumatic operation with
two independent sections for vehicles with-
out tow bar, three independent sections for
vehicles with tow bar.
Parking and emergency brake: pneumatic
operation acting on rear wheel brake drums
through spring cylinder.
Engine brake: built into engine.
Retarder brake: hydraulic, installed on
transmission.
Auxiliary parking brake: pneumatic oper-
ation: must be engaged with engine run-
ning.
ABS
Wheel anti-lock system (ABS) with four
channel electronic system and four solenoid
valves that exercise the ABS function during
the braking phase.
Pulse generators and sensors on 1st and 3rd
axles (3-axle vehicles).
Pulse generators and sensors on 2nd and
4th axles (2-axle vehicles).
1-16 HHD9 Euro3
TYRES
Front: single (*)
Rear: double (**) or single (*)
(*) (**) (*) (**)

DIMENSION TYPE DIMENSION TYPE
bar bar bar bar
MICHELIN XZY2 8 8 MICHELIN XDY 8.5 8.5
MICHELIN XDY3 8 8 MICHELIN XZY2 8.5 8.5
MICHELIN XZH 8 8 MICHELIN XZL 8.5 8.5
PIRELLI AP05 9 - MICHELIN XZY 8.5 8.5
12.00R20
PIRELLI AT75 - 9 PIRELLI AP05 9 -
PIRELLI AT99 8.5 8.5 PIRELLI AT75 - 8.5
13R22.5
PIRELLI FG85 9 9 PIRELLI FG85 9 9
PIRELLI TG85 9 9 PIRELLI TG85 9 9
PIRELLI FG88 9 9 MICHELIN XZE2TL 9 9
315/70R22.5
PIRELLI TG88 9 9 MICHELIN XDE2TL 9 9
CONTINENTAL HSC - - PIRELLI FG88 9 9
325/95R24
CONTINENTAL HDC - - PIRELLI TG88 9 9
MICHELIN XZY2 8.5 8 20.00R20 CONTINENTAL - -
MICHELIN XDY3 8.5 8 MICHELIN XZY3 9 -
385/68R22.5
MICHELIN XZE2 8.5 8 MICHELIN XFA1+ 8.5 -
MICHELIN XDE2 8.5 8 365/85R20 MICHELIN XZL 7.5 -
MICHELIN XDE2+ 8.5 8 365/80R20 MICHELIN XZL 6 -
PIRELLI AP05 8 8 16.00R20 MICHELIN XZL 7.6 7.6
315/80R22.5 PIRELLI AT75 8 8 MICHELIN XZL 7.6 7.6
14.00R20
PIRELLI FG85 8 8 PIRELLI PS22 PISTA 7 7
PIRELLI TG85 8 8 24.00R20.5 MICHELIN XS 6 -
PIRELLI FG88 8.5 8.5 385/95R24 MICHELIN X 9 -
PIRELLI TG88 8.5 8.5 385/55R22.5 MICHELIN XFA2 9 9
CONTINENTAL HSR1 - - 525/65R20.5 MICHELIN XS 8 -
CONTINENTAL HDR - - 395/85R20 MICHELIN XZL 8.5 .
495/45R22.5 MICHELIN XDA2 9 - 525/80R25 MICHELIN XL 7 .
445/65R22.5 MICHELIN XZL 8 - 24R21 MICHELIN XZL 6 .
HHD9 Euro3 1-17
1 SUSPENSION
Front (Fig. 1):
Longitudinal single leaf springs. Telescopic
duplex hydraulic shock absorbers and roll
bar.
Rear (Fig. 2):
Single leaf springs, individual for the two
rocking axles with rocker system.
The torque bars between axle and central
support counteract the axial thrust on accel-
eration and braking.
2 Anti-roll bar on intermediate axle and on rear
axle (upon request).
Leaf spring: parabolic or semi-elliptic (upon
request).
345FDT007L
1-18 HHD9 Euro3
1 STEERING
ZF hydraulic ball bearing mounted power
steering.
Type: 8099 (Fig. 1)
Oil pump driven by engine.
Emergency pump driven by transmission.
Front wheel steering with quadrilateral kine-
matic motion assembly.
Auxiliary cylinder.
HHD9 Euro3 1-19
1 ELECTRICAL SYSTEM
Nominal voltage: 24 V
Accumulators (Fig. 1) (n˚ 2):
12 V --- 170 Ah or
12 V --- 220 Ah
Alternator: 28 V --- 90 A
The characteristics of accumulators and

274CNU102 alternator may change according to the
outfitting and the destination market.
Starter motor
24V --- 5 kW
Ground reference: negative pole.
1-20 HHD9 Euro3
1 CHASSIS (Fig. 1)
Built with rectilinear side members in high
strength “C” section steel, connected by
riveted or bolted cross-members.
Standard fuel tank
Steel, capacity 300 liters with level and
reserve indicator.
Oversize fuel tank
Steel, capacity 600 liters with level and
reserve indicator.
HHD9 Euro3 1-21
TIGHTENING TORQUES
Torque
Assembly Element Type
(Nm)
F2B engine oil magnetic drain plug
Engine
F3B engine oil magnetic drain plug
Magnetic oil drain plug
Multipower power take-off
Oil filler cap 25 ÷ 30
Oil drainage, level and filler caps 80
ZF manual transmission
Oil magnetic drain plug on clutch bell M 38 x 1.5 140
Oil filter cover fastening screw
ZF iIntarder
Oil drain plug M25x1.5 60
Side oil drain plugs
Bottom oil drain plug
ZF As-Tronic automated transmission
Filler and level cap
Oil filter cover fastening screw 20 ÷ 25
Oil drain plug 25 ÷ 32
Allison automatic transmission
Filler and level cap
Oil drain plug M22x1.5 60
ZF splitter
Oil filler and level cap M22x1.5 60
Fasteners (nut and washer) 580 ÷ 650
Wheels
Fasteners (countersunk nut) 380 ÷ 450
Magnetic oil drain plug M16x1.5 60
Oil filler and level plug M30x1.5 160
Front axle (Kessler)
Oil drain plug on transfer case M16x1.5 60
Oil level plug on transfer case M24x1.5 120
1-22 HHD9 Euro3
Torque
Assembly Element Type
(Nm)
Transfer case oil drainage cap M24x1.5 120
Intermediate axle (Kessler)
Transfer case oil filler and level plug M24x1.5 120
Rear axle (Kessler)
HHD9 Euro3 1-23
VEHICLE OUTFITTING
1
Set of keys
D Ignition/door/fuel tank keys.
D Open/close doors remote control (if pre-
sent).
Documentation
D USE AND MAINTENANCE manual.
357ADT001L Vehicle outfitting
D Lifting jack (Fig. 1).
D Jack levers/cab lifting/wheels wrench
2 (Fig. 2).
357ADT002L
1-24 HHD9 Euro3
D Standard warning triangle (Fig. 1, ref. 1).

1
In accordance with the laws of the indivi-
dual Countries the warning triangle is an
obligatory outfitting.
D Tool box (Fig. 1, ref. 2).

D 2 chocks (Fig. 2).
357ADT003L According to the outfitting the chocks

may be contained in specific cages along
the chassis.
2
357ADT004L
HHD9 Euro3 1-25
Instructions for use

1-26 HHD9 Euro3

HHD9 Euro3 1-27
GENERAL INSTRUCTIONS FOR CORRECT USE OF THE VEHICLE

Before driving
Adjust the seat, steering wheel and rear-view mirrors to obtain a correct driving position.
Check that there are no obstructions to pedal excursion, in particular the brake pedal.
Check that the horn works correctly.
Check that all external lights function correctly, and if necessary clean the lighting groups.
Check, especially when travelling by night, that headlights are correctly aligned.
Check that no oil or fluids are leaking from under the vehicle.
Check that any cargo is correctly stowed.
Check that the handbrake is on and that no dashboard warning light indicates a fault.
To prevent accidental vehicle movements, disengage the handbrake with the brake pedal pressed.
Do not apply transfers or stickers to the windscreen: these could distract or impair vision.
When driving
Long journeys should only be undertaken in ideal physical conditions.
Light, easily digestible meals help in keeping reflexes ready as well as maintaining the concentration required for safe driving.
Never drive for too many consecutive hours, but make frequent stops, taking the opportunity to stretch and generally refresh.
Make use of the wide range of adjustments offered by the heating, ventilation or air-conditioning system to maintain constant cabin air
change.
The abuse of alcohol, drugs and or certain medicines is extremely dangerous. Never undertake a journey under the influence of alcohol,
pharmaceuticals or drugs.
Careful driving also means being in a condition to foresee the mistakes or carelessness of other drivers.
Always observe speed limits and always drive in the slow lane on motorways.
Always use indicators when changing direction or lane.
Keep a safe distance from the vehicle in front. This distance varies according to speed, weather, traffic and road conditions.
Never drive with the gearbox in neutral.
Never freewheel downhill: With the engine off there is no engine braking, requiring greater force on the brake pedal.
Use engine braking by engaging a low gear to avoid overheating the brakes.
In case of breakdown, park the vehicle off the carriageway, switch on the hazard warning lights and set up the red reflecting triangle sign
to warn other drivers. Always follow the Highway Code.
1-28 HHD9 Euro3
Night driving
Take special care, reducing speed if necessary, especially on unlit roads.
Keep a greater safety distance than when driving by day: in effect it is more difficult to estimate the speed of an approaching vehicle when
only its lights are visible.
Stop and rest as soon as you feel tired. To continue would only be a hazard to yourself and others.
Use high beams only outside built-up areas an only when you are sure they do not other drivers.
Always dip headlights with oncoming traffic.
Driving in rain, fog and snow

If the road is wet the grip between the tyres and the road surface is significantly reduced, so braking distance is greater and grip when turning
is reduced. Reduce speed and keep a greater distance from the vehicles in front.
Heavy rain and fog reduce visibility. In compliance with the Highway Code, switch on dipped headlights even by day to render your vehicle
more visible.
Do not drive through puddles or flooded sections of road at high speed. Aquaplaning may cause loss of control. Use engine braking and
in all cases avoid braking sharply.
Set ventilation controls to ensure efficient windscreen demisting.
Before starting out, check the condition of windscreen wipers. If temperature is below 0˚, or if it is snowing, check that the wiper blades and
not frozen against the windscreen-
Proceed with extreme caution in case of fog. Moderate speed and avoid overtaking if possible.
Check that windscreen/headlight washer fluid contains antifreeze and anti-scale products.
In winter, even apparently dry roads may have icy patches, especially sections in the shade or lined by trees or rocks.
Parking
Switch off the engine.
Engage the parking brake.
Engage 1st gear if the vehicle is parked on a slope or reverse gear if the vehicle is facing downwards (manual gearshift vehicles only).
Never leave the key turned to MAR with the engine off to avoid flattening the batteries.
Tyres
Always reduce speed before taking on a tight bend, even if vehicle performance permits.
Avoid sharp acceleration of heavy braking.
Do not drive at constant high speeds for long periods, especially on uneven road surfaces.
Make certain that wheels are correctly balanced and adjusted.
Avoid violent impacts to tyre walls (for example when parking).
Never tamper with tyre inflation valves.
HHD9 Euro3 1-29
Do not insert any kind of tool between tyre and wheel rim.
If the rim is damaged, replace it.
If a tyre loses pressure for no apparent reason, replace the wheel and check the faulty tyre.
Tyre pressures, including the spare, must always be as specified.
Tyres that are old (over 6 years) or used should only be used in case of emergency and with due caution.
Do not leave the vehicle parked for long periods on the edge of the kerb or similar irregularities on the road surface.
Regularly check tyre tread depth, changing tyres when depth is less than the legal minimum.
The vehicle mounts ’tubeless’ tyres, meaning without inner tube. Inner tubes must not be fitted to tubeless tyres.
Certain types of tyres are fitted with wear indicators. They must be changed as soon as the indicators become visible on the tread.
Aquaplaning is more likely with worn tyre treads.
Snow chains
The use of snow chains is governed by local law in each country.
Chains should only be fitted to drive wheels.
To prevent tyre damage, do not drive on clear roads with chains fitted. In extreme cases (tunnels, etc....) proceed at low speed and in any
case remove the chains as soon as conditions permit.
Maintain moderate speed with chains mounted, avoiding potholes and driving onto the kerb.
Certain tyres of snow chain require tension adjustment after travelling a short distance.
Economic, ecological driving
Road conditions and driving style have a direct influence on fuel consumption and environmental impact.
Carry out the maintenance operations described below at regular intervals and with care.
Do not demand maximum power from the vehicle with the engine cold.
Do not rev the engine when parked.
Always avoid sharp acceleration and repeated braking/acceleration. Engage a higher gear as soon as conditions permit.
If possible, avoid driving with side windows lowered. Use the air-conditioner/ventilation system to obtain the desired conditions in the cab.
Engage a high gear whenever traffic and road conditions permit.

Limit the use of high power absorption utilities (air-conditioner on full, for example) when driving in city traffic or behind slow moving vehicles.
Revving the engine between gears or before stopping the engine serves absolutely no purpose.
Avoid accelerating on full throttle. Fuel consumption will be significantly lower with gradual acceleration.
1-30 HHD9 Euro3
1 Range of use of the engine

The following table shows indications for
correct engine use.
a white sector: minimum, low use
b green sector: economic running
The best performance/consumption ratio

is obtained when the engine rate is in the
green sector.
c yellow sector: maximum engine speed

range
d red sector: runaway rate
NEVER USE RED SECTOR.
Tachometer sector (RPM)

Engine
White Green Yellow Red
F2B/F3B 0 - 1200 1200 - 1900 2400 - 3000 3000 - 3200
HHD9 Euro3 1-31
1 LEFT HAND DRIVE VEHICLES

CAB-EXTERNAL
The cab (Fig. 1) is hinged at the front and
suspended both to front and rear on the
chassis:
D to the front by two longitudinal arms with
springs, shock absorbers and buffers.
D to the rear by two control arms with
342BNU001L springs, shock absorbers and buffers.
The cabin can be tipped forward by means
of a manually controlled hydraulic cylinder.
2 Always use the grips and steps (Fig. 2, see
arrow) specifically designed to permit easy
accessibility to get on and off the vehicle.
Always keep handles and foot-boards

clean to avoid slipping.
342BNU002L
1-32 HHD9 Euro3
1 1 EXTERNAL LIGHTING
Front lights (Fig. 1)
1. High beam
2. Parking light and headlight
3. Front direction indicator
4. Side direction indicator
5. Front clearance light
6. Rotary warning lights (if fitted)
342BNU009L
HHD9 Euro3 1-33
1 1 Rear lights (Fig. 1)

1. Direction indicator
2. Stop light
3. Side light
4. Fog warning light
5. Reversing light
6. License plate light (one side only)
7. Side clearance
228NU205
1-34 HHD9 Euro3
1 1 Rear lights --- Version with LED taillights

(Fig. 1)
2. Side light/Stop light
4. Reversing light
6. Side clearance
307HNU008L
HHD9 Euro3 1-35
1 DOORS
The vehicle has two doors symetrically

placed at each side.
The external door handle (Fig. 1, see arrow)
can be locked from the outside with a key.
To open the door pull down the external
handle.
D to block the lock, turn the key anticlock-
wise (Fig. 1, ref. 1);
D to block the lock, turn the key clockwise
(Fig. 1, ref. 2);
D to open the door, pull handle downward.
When the door is opened the cabin interior
light comes on automatically, along with the
cabin step lights.
342BNU004L
1-36 HHD9 Euro3
1 The inner side of the door has the following

controls (Fig. 1):
1. Door opening handle
2. Electric window control
3. Door closing handle
4. Knob for locking doors from the inside
5. Electric mirrors adjustment control (only
driver’s door)
342BNU005L
HHD9 Euro3 1-37
Central locking remote control

1
Briefly press the button (Fig. 1, ref. 1) on the
remote control, while pointing the control in
the direction of the vehicle, the direction indi-
cators will flash simultaneously indicating
that all doors are unlocked.
To lock the doors press the button (Fig. 1 ref.
2) still while pointing the control in the direc-
tion of the vehicle, the direction indicators will
272CNU001 flash simultaneously indicating that all doors
are locked.
1-38 HHD9 Euro3
Replacing remote control battery

1
D Insert a small coin or screwdriver into the
slot on the side of the remote control and
open it (Fig. 2).
D Replace the battery, paying attention to
the polarity.
D The remote control has a lithium battery.
CR 2032 3V
D Close the two halves of the remote control
272CNU002 checking that they are correctly coupled.
A reduction in range of the remote control

is an indicator that the battery is almost
exhausted.
Exhausted batteries are harmful to the

environment. Exhausted batteries must
be disposed of as required by law. Or it
can be handed over to the Service Net-
work that will provide for correct dis-
posal.
HHD9 Euro3 1-39

1-40 HHD9 Euro3
DRIVERS SEAT
342BNU006L
HHD9 Euro3 1-41
DRIVER’S SEAT (Fig. 1 previous page)

1. Driver’s seat adjustment controls
2. Steering wheel position control
3. Ashtray
4. Cigar lighter - 12 V power socket - Diagnostic socket
5. Gear lever
6. Differential lock / splitter / supplementary parking brake
7. Climate control system controls
8. Parking brake
9. Document holder
10. Controls lever Cruise control / retarder
11. Ignition switch
12. Dashboard
13. Steering wheel
14. Instrument panel
15. Controls lever lights / headlights / direction indicators / windscreen wiper controls
16. Pedal controls
1-42 HHD9 Euro3
1 1 INTERNAL LIGHTING DEVICE

Upper dashboard (Fig. 1)
1. Ceiling light
Press button (Fig. 2) to switch on the ceiling
light.
Press again to switch off the ceiling light.
2. Access step lighting

The light switches on when the door is
opened.
342BNU007L
1 2
342BNU008L
HHD9 Euro3 1-43
1 EXTERNAL REAR VIEW MIRRORS

The vehicle is fitted with the following exter-
nal rear view mirrors (Fig. 1, 2 and Fig. 3):
1 Left side wide-angle mirror
2 Main left side mirror
3 Right side wide-angle mirror
4 Main right side mirror
5 Right pull-in mirror
341DNU020L
1-44 HHD9 Euro3
1 Mirror selection and handling
This adjustment must be made with ve-

hicle stationary.
Using the mirror selection control (Fig. 1, ref.

1) brings up a specific page on the techome-
ter LCD (Fig. 2, ref. 1).
Use the mirror adjustment control (Fig. 1, ref.
342BNU050L 2) to adjust the selected mirror.
Without remote control the driver has to

adjust the mirrors manually.
2
285ANU002L
HHD9 Euro3 1-45
The selected mirror is identified by the num-

1 ber on the LCD (Fig. 1, ref. 1)
The selected mirror is graphically high-
lighted on the LCD (Fig. 1, ref. 2).
The mirrors controlled by the system are

(Fig. 2):
1. Main driver’s mirror
2. Driver’s wide-angle mirror
285ANU003L 3. Main passenger side mirror
4. Passenger side wide-angle mirror
2 Press the mirror heater button (Fig. 1, ref. 3)

to rapidly demist the mirrors. Press the but-
ton to turn the mirror heating system on.
Press the button again to turn the mirror
heating system off.
284CNU004L
342BNU051L
1-46 HHD9 Euro3
1 SEATS
Fore and aft adjustment
Lift lever (Fig. 1, ref. 1) to have the seat free
to move backwards or forward.
Release the lever and ensure the mech-

anism is fully.
Cushion angle adjustment

The cushion angle may be adjusted by lifting
lever (Fig. 1, ref. 2) and pulling and pushing
the backrest (12˚ max.). Release the lever
after adjustment.
Seat suspension adjustment
Lift lever (Fig. 1, ref. 3) to lower and lock the
seat; lower the lever to raise the seat (set
beforehand with lever 5).
342BNU010L
HHD9 Euro3 1-47
1 Springing system adjustment

Springing system adjustment is obtained by
lifting or lowering lever (Fig. 1, ref. 4):
D Lever up = Maximum suspension effect.
D Lever down = Minimum suspensions
effect.
With this device seat suspension is

according to road surface and weight of
the driver. The shock absorber has to be
adjusted rigidly, to avoid that on rough
surfaces the seat hits the end of stroke,
jeopardising the spring system.
Height adjustment
Lift lever (Fig. 1, ref. 4) to raise the seat; re-
lease the lever after adjustment. Seat height
is memorised automatically.
Lower lever to lower the seat (100 mm max.)
Backrest angle adjustment
Lift lever (Fig.1, ref. 5) and set the backrest to
the desired angle with your back. Release
the lever to block the backrest.
342BNU010L
1-48 HHD9 Euro3
1 SEAT BELTS
The vehicle is equipped with three-point seat
belts and automatic reel (Fig. 1).
D To fasten the belt grip the tab and insert it
into the buckle until it clicks (Fig. 2).
D To release the belt, press the button on the
top of the buckle (Fig. 3).
Do not adjust the mirrors while driving.

178NU08
178NU09
178NU10
HHD9 Euro3 1-49
1 The belt does not need to be adjusted by

hand: the webbing adjusts itself automati-
cally to the length most suited to the driver
allowing him freedom of movement pro-
vided that his movements are not abrupt.
The belt mechanism is affected by changes
in vehicle attitude and as a consequence the
belt may lock in the following cases:
D sudden braking or acceleration;
178NU08 D vehicle driving on a slope;
D when cornering.
The belt must not twist and must adhere

to the hips, not the abdomen, to prevent
the risk of slipping forwards.
Occasionally check that the anchor bolts
are fully tightened and that the belt itself
is not cut or frayed.
In case of accident of a certain gravity,
replace the belt involved, even if it does
not appear damaged.
Do not make alterations likely to reduce
seat belt efficiency
1-50 HHD9 Euro3
1 ELECTRIC WINDOW CONTROL

Electric window risers control
Left side (Fig. 1)
1. Left side window control
2. Right side window control
Right side (Fig. 2)

342BNU011L 1. Right side window control.
Press (Fig. 3, ref a) the switch to lower the

2 glass.
Pull the switch upward (Fig. 3, ref b) to raise
the glass.
The glass stops when the switch is released.
342BNU012L
342BNU013L
HHD9 Euro3 1-51
1 HATCH
To open the hatch turn the handle (Fig. 1, ref.
1) anti-clockwise.
To close the hatch proceed as follows:
D Turn the handle clockwise until closing the
hatch.
D Return the handle to its original position
(Fig. 2).
178NU02 D Turn the handle at most by a quarter turn
until reaching the stop (Fig. 3, arrow).
D Return the handle to closed position and
2 lock it by tipping the knob.
To escape from the cabin in an emergency

turn the full release handles downward
(Fig. 1, ref. 2) and push the hatch out-
wards.
272NU102X
272NU103X
1-52 HHD9 Euro3
1 COMPARTMENTS
Dashboard (Fig. 1)
1. Bottle/can holder
2. Mobile phone holder
3. Items tray (according to outfitting)
4. Gloves compartment
5. Compartment in front of passenger

(closed with lid).
Act on button and raise lid to open.
Lower lid and press until it clicks into
place.
342BNU014L
2. Loose items tray (according to outfitting)
342BNU015L
HHD9 Euro3 1-53
Door (Fig. 1)
1
1. bottle holder
2. pocket
3. pocket
Tunnel (Fig. 2)
1. coin holder
2. loose items tray
Seat (Fig. 3)
1. Compartment (closed with lid)
Act on button and lower lid to open.
Raise lid and press until it clicks to close.
2. items holder
Rear wall (Fig. 4)
1. bottle holder
342BNU016L 2. items compartment
2 3 4
342BNU017L 342BNU018L 342BNU019L

1-54 HHD9 Euro3
1 ACCESSORIES - DEVICES
Sun blind tabs (Fig. 1, ref. 1)
Grip the front edge of the tab and turn down-
ward.
Bring to position by hand.
Grip handle (Fig. 1, ref. 2)
On passenger side.
Coat hook (Fig. 1, ref. 2)
On both sides of cab.
Cigar lighter (Fig. 2, ref. 1)
Press to activate cigar lighter: a click indi-
cates it is ready for use.
342BNU020L After use return to its seat without pressing.
Ashtray (Fig. 2, ref. 2)
2 On both sides of cab.
Raise lid to open.
Lower lid to close.
12Volt current socket (Fig. 2, ref. 3)
Open cap and insert facility .
After use close cap.
342BNU021L
HHD9 Euro3 1-55
1 CONTROLS
Controls on dashboard (Fig. 1)
1. Headlamps geometry adjustment
2. External lights switch
3. Hazard lights
4. Parking brake control
342BNU022L
1-56 HHD9 Euro3
1 1 Module holder dashboard controls

(Fig. 1)
1. Engine brake switch
2. Fog light switch
3. Rear fog light
4. Mirrors heating switch
5. Horn selector switch
6. Pivoting headlamps switch
7. Ceiling light switch
8. Not used
9. Not used
10. PTO activation switch
11. PTO 1 activation switch
13. ABS switch (OFF-ROAD)
14. ASR switch
15. Additional parking brake switch
16. Work light switch
17. Electric battery master switch
18. Not used
19. Climate controls
20. Not used
21. 12 V current socket
342BNU023L
HHD9 Euro3 1-57
1 Controls on roof (Fig. 1)

1. Radio CD equipment housing
2. CB housing
3. Tachograph housing
Controls on floor
Steering wheel position control
Steering wheel position adjustment is pneu-
342BNU024L
matic, and can be regulated by means of the
button on the floor at the base of the steering
column, driver’s side (Fig. 2).
2 Proceed as follows:
D With the button pressed take the wheel in
your hands and bring it to the required
position.
D Once in position, release the button.
This operation can only be done with:

D sufficient air pressure;
D parking brake engaged.
357ANU101L
1-58 HHD9 Euro3
1 Accelerator
The accelerator is controlled by means of a
pedal on the floor to be operated by the
driver’s right foot (Fig. 1, ref. 1).
Press the pedal to increase the torque output
by the engine proportionally to the position
of the pedal.
Service brake
The service brake is controlled by means of
272NU062X a pedal on the floor to be operated by the
Press the pedal to obtain a braking effect in
proportion to the exerted pressure.
Clutch
The clutch is controlled by a pedal to be
operated with the driver’s left foot (Fig. 1, ref.
3).
Press the pedal to release the clutch. Only for
manual trasmission vehicles.
HHD9 Euro3 1-59
1 Manual transmission control

Transmission is controlled by a manually
operated lever. (Fig. 1, see arrow).
By shifting the lever, the different gears are
engaged.
The lever also has a splitter pre-selection
lever. Acting on this lever pre-selects the
engagement of reduced gears range, actu-
ated through the clutch pedal.
342BNU025L
Automated transmission control

2 The selection of different operating modes is
by means a multi-purpose lever with
pushbuttons (Fig. 2).
Moving the lever and/or pressing the
pushbuttons the required operating mode is
obtained.
Automatic transmission control

The different functioning modes selection is
357ANU102L
through a selector lever with pushbuttons
(Fig. 3).
Move the lever to obtain the required mode
3 selection.
357ANU201L
1-60 HHD9 Euro3

HHD9 Euro3 1-61
1 RIGHT-HAND DRIVE VEHICLES

CAB EXTERNAL
The cab (Fig. 1) is hinged at the front and
suspended both to front and rear on the
chassis:
D to the front by two longitudinal arms with
springs, shock absorbers and buffers.
D to the rear by two control arms with
357ANU202L springs, shock absorbers and buffers.
The cabin can be tipped forward by means
of a manually controlled hydraulic cylinder.
2 Always use the grips and steps (Fig. 2, see
arrow) specifically designed to permit easy
accessibility to get on and off the vehicle.
Always keep handles and foot-boards

clean to avoid slipping.
357ANU203L
1-62 HHD9 Euro3
1 1 EXTERNAL LIGHTING
Front lights (Fig. 1)
1. High beam
2. Parking light and headlight
3. Front direction indicator
4. Side direction indicator
5. Front clearance light
6. Rotary warning lights (if fitted)
357ANU204L
HHD9 Euro3 1-63
1 1 Rear lights (Fig. 1)

2. Stop light
3. Side light
5. Reversing light
7. Side clearance
285ANU053L
1-64 HHD9 Euro3
1 1 Rear lights --- Version with LED taillights

(Fig. 1)
2. Side light/Stop light
4. Reversing light
6. Side clearance
307HNU009L
HHD9 Euro3 1-65
1 DOORS
The vehicle has two doors symetrically
placed at each side.
The external door handle (Fig. 1, see arrow)
can be locked from the outside with a key.
To open the door pull down the external
handle.
D to block the lock, turn the key anticlock-
wise (Fig. 1, ref. 1);
D to block the lock, turn the key clockwise
(Fig. 1, ref. 2);
D to open the door, pull handle downward.
When the door is opened the cabin interior
light comes on automatically, along with the
cabin step lights.
357ANU205L
1-66 HHD9 Euro3
1 The inner side of the door has the following

controls (Fig. 1):
1. Door opening handle
2. Electric window control
3. Door closing handle
4. Knob for locking doors from the inside
5. Electric mirrors adjustment control (only
driver’s door)
357ANU206L
HHD9 Euro3 1-67
Central locking remote control

1
Briefly press the button (Fig. 1, ref. 1) on the
remote control, while pointing the control in
the direction of the vehicle, the direction indi-
cators will flash simultaneously indicating
that all doors are unlocked.
To lock the doors press the button (Fig. 1, ref.
2) still while pointing the control in the direc-
tion of the vehicle, the direction indicators will
272CNU001 flash simultaneously indicating that all doors
are locked.
1-68 HHD9 Euro3
Replacing remote control battery

1
D Insert a small coin or screwdriver into the
slot on the side of the remote control and
open it (Fig. 1).
D Replace the battery, paying attention to
the polarity.
D The remote control has a lithium battery.
CR 2032 3V.
D Close the two halves of the remote control
272CNU002 checking that they are correctly coupled.
A reduction in range of the remote control

is an indicator that the battery is almost
exhausted.
Exhausted batteries are harmful to the en-

vironment. Exhausted batteries must be
disposed of as required by law. Or it can
be handed over to the Service Network
that will provide for correct disposal.
HHD9 Euro3 1-69

1-70 HHD9 Euro3
DRIVERS SEAT
357ANU207L
HHD9 Euro3 1-71
DRIVER’S SEAT (Fig. 1 previous page)

1. Driver seat adjustment controls
2. Steering wheel position adjustment
3. Parking brake controls
4. Ignition key
5. Ashtray
6. Transmission controls
7. Cigar lighter
8. Differential lock / splitter / additional parking brake controls
9. Air conditioning controls
10. Cruise control / retarder controls lever
11. Ignition switch
12. Dashboard
13. Steering wheel
14. Instrument panel
15. Lights / headlights / turn signals / windscreen wiper controls lever
16. Pedal controls
1-72 HHD9 Euro3
1 1 INTERNAL LIGHTING DEVICE

1. Ceiling light
Press button (Fig. 2) to switch on the ceiling
light.
Press again to switch off the ceiling light.
2. Access step lighting

The light switches on when the door is
opened.
357ANU208L
1 2
357ANU209L
HHD9 Euro3 1-73
1 EXTERNAL REAR VIEW MIRRORS

The vehicle is fitted with the following exter-
nal rear view mirrors (Fig. 1):
1 Left side wide-angle mirror
2 Main left side mirror
3 Right side wide-angle mirror
4 Main right side mirror
5 Right pull-in mirror
357ANU210L
1-74 HHD9 Euro3
1 Mirror selection and handling
This adjustment must be made with ve-

hicle stationary.
Using the mirror selection control (Fig. 1, ref.

1) brings up a specific page on the techome-
ter LCD (Fig. 2, ref. 1).
Use the mirror adjustment control (Fig. 1, ref.
357ANU211L 2) to adjust the selected mirror.
Without remote control the driver has to

adjust the mirrors manually.
2
285ANU002L
HHD9 Euro3 1-75
The selected mirror is identified by the num-

1 ber on the LCD (Fig. 1, ref. 1)
The selected mirror is graphically high-
lighted on the LCD (Fig. 1, ref. 2).
The following mirrors are handled by the sys-

tem (Fig. 2):
1. Main driver mirror
2. Driver wide-angle mirror
285ANU003L 3. Main passenger mirror
4. Passenger wide-angle mirror
2 Press the mirror heater button (Fig. 2, ref. 3)

to rapidly demist the mirrors. Press the but-
ton to turn the mirror heating system on.
Press the button again to turn the mirror
heating system off.
357ANU213L
342BNU051L
1-76 HHD9 Euro3
1 SEATS
Fore and aft adjustment
Lift lever (Fig. 1, ref. 1) to have the seat free
to move backwards or forward.
Release the lever and ensure the mech-

anism is locked.
Cushion angle adjustment

The cushion angle may be adjusted by lifting
lever (Fig. 1, ref. 2) and pulling and pushing
the backrest (12˚ max.). Release the lever
after adjustment.
Seat suspension adjustment
Lift lever (Fig. 1, ref. 3) to lower and lock the
seat; lower the lever to raise the seat (set
beforehand with lever 5).
357ANU214L
HHD9 Euro3 1-77
1 Springing system adjustment

Springing system adjustment is obtained by
lifting or lowering lever (Fig. 1, ref. 4):
D Lever up = Maximum suspension effect.
D Lever down = Minimum suspensions
effect.
With this device seat suspension is

according to road surface and weight of
the driver. The shock absorber has to be
adjusted rigidly, to avoid that on rough
surfaces the seat hits the end of stroke,
jeopardising the spring system.
Height adjustment
Lift lever (Fig. 1, ref. 5) to raise the seat; re-
lease the lever after adjustment. Seat height
is memorised automatically.
Lower lever to lower the seat (100 mm max.)
Backrest angle adjustment
Lift lever (Fig.1, ref. 6) and set the backrest to
the desired angle with your back. Release
the lever to block the backrest.
357ANU214L
1-78 HHD9 Euro3
1 SEAT BELTS
The vehicle is equipped with three-point seat
belts and automatic reel (Fig. 1).
D To fasten the belt grip the tab and insert it
into the buckle until it clicks (Fig. 2).
D To release the belt, press the button on the
top of the buckle (Fig. 3).
The vehicle must be stationary to carry

285ANU056L
out this operation.
178NU09
178NU10
HHD9 Euro3 1-79
1 The belt does not need to be adjusted by

hand: the webbing adjusts itself automati-
cally to the length most suited to the driver al-
lowing him freedom of movement provided
that his movements are not abrupt.
The belt mechanism is affected by changes
in vehicle attitude and as a consequence the
belt may lock in the following cases:
D sudden braking or acceleration;
285ANU056L D vehicle driving on a slope;
D when cornering.
The belt must not twist and must adhere

to the hips, not the abdomen, to prevent
the risk of slipping forwards.
Occasionally check that the anchor bolts
are fully tightened and that the belt itself
is not cut or frayed.
In case of accident of a certain gravity, re-
place the belt involved, even if it does not
appear damaged.
Do not make alterations likely to reduce
seat belt efficiency
1-80 HHD9 Euro3
1 ELECTRIC WINDOW CONTROL

Electric window risers control
Left side (Fig. 1)
1. Left side window control
2. Right side window control
Right side (Fig. 2)

357ANU215L 1. Right side window control.
Press (Fig. 3, ref a) the switch to lower the

2 glass.
Pull the switch upward (Fig. 3, ref b) to raise
the glass.
The glass stops when the switch is released.
357ANU216L
357ANU217L
HHD9 Euro3 1-81
1 HATCH
To open the hatch turn the handle (Fig. 1, ref.
1) anti-clockwise.
To close the hatch proceed as follows:
D Turn the handle clockwise until closing the
hatch.
D Return the handle to its original position
(Fig. 2).
178NU02 D Turn the handle at most by a quarter turn
until reaching the stop (Fig. 3, arrow).
D Return the handle to closed position and
2 lock it by tipping the knob.
To escape from the cabin in an emergency

turn the full release handles downward
(Fig. 1, ref. 2) and push the hatch out-
wards.
272NU102X
272NU103X
1-82 HHD9 Euro3
1 COMPARTMENTS
Dashboard (Fig. 1)
1. Bottle/can holder
2. Mobile phone holder
3. Items tray (according to outfitting)
4. Gloves compartment

(closed with lid).
Act on button and raise lid to open.
Lower lid and press until it clicks into
place.
357ANU218L
2. Loose items tray (according to outfitting)
357ANU219L
HHD9 Euro3 1-83
1Door (Fig. 1)
1. bottle holder
2. pocket
3. pocket
Tunnel (Fig. 2)
1. coin holder
2. loose items tray
Seat (Fig. 3)
1. Compartment (closed with lid)
Act on button and lower lid to open.
Raise lid and press until it clicks to close.
2. items holder
Rear wall (Fig. 4)
1. bottle holder
2. items compartment
357ANU220L
2 3 4
357ANU221L 357ANU222L 342BNU019L

1-84 HHD9 Euro3
1 ACCESSORIES - DEVICES
Sun blind tabs (Fig. 1, ref. 1)
There are three sun blind tabs.
Grip the front edge of the tab and turn down-
ward.
Bring to position by hand.
Grip handle (Fig. 1, ref. 2)
On passenger side.
Coat hook (Fig. 1, ref. 3)
Cigar lighter (Fig. 2, ref. 1)
Press to activate cigar lighter: a click indi-
357ANU223L cates it is ready for use.
After use return to its seat without pressing.
Ashtray (Fig. 2, ref. 2)
2
Raise lid to open.
Lower lid to close.
12Volt current socket (Fig. 2, ref. 3)
Open cap and insert facility .
After use close cap.
357ANU224L
HHD9 Euro3 1-85
1 CONTROLS
Controls on dashboard (Fig. 1)
1. Headlamps geometry adjustment
2. External lights switch
3. Hazard lights
4. Parking brake control
357ANU225L
1-86 HHD9 Euro3
1 1 Module holder dashboard controls

(Fig. 1)
1. Engine brake switch
2. Fog light switch
3. Rear fog light
4. Mirrors heating switch
5. Horn selector switch
6. Pivoting headlamps switch
7. Ceiling light switch
8. Not used
9. Not used
10. PTO activation switch
13. ABS switch (OFF-ROAD)
14. ASR switch
15. Additional parking brake switch
16. Work light switch
17. Electric battery master switch
18. Not used
19. Climate controls
20. Not used
21. 12 V current socket
357ANU226L
HHD9 Euro3 1-87
1 Controls on roof (Fig. 1)

1. Radio CD equipment housing
2. CB housing
3. Tachograph housing
Controls on floor
Steering wheel position control
Steering wheel position adjustment is pneu-
357ANU227L
matic, and can be regulated by means of the
button on the floor at the base of the steering
column, driver’s side (Fig. 2).
D With the button pressed take the wheel in
your hands and bring it to the required
position.
D Once in position, release the button.
This operation can only be done with:

D sufficient air pressure;
D parking brake engaged.
357ANU228L
1-88 HHD9 Euro3
1 Accelerator
The accelerator is controlled by means of a
pedal on the floor to be operated by the driv-
er’s right foot (Fig. 1, ref. 1).
Press the pedal to increase the torque output
by the engine proportionally to the position
of the pedal.
Service brake
The service brake is controlled by means of
272NU062X a pedal on the floor to be operated by the
Press the pedal to obtain a braking effect in
proportion to the exerted pressure.
Clutch
The clutch is controlled by a pedal to be op-
erated with the driver’s left foot (Fig. 1, ref. 3).
Press the pedal to release the clutch.
HHD9 Euro3 1-89
1 Manual gear shift lever

Gear shift is controlled by a lever used by the
right hand (Fig. 1, ref. 1).
Move the lever to engage the various gears.
The lever also has a splitter selector lever
(Fig. 1, ref. 2). This lever engages low range
gears, engaging with the clutch pedal.
Automated transmission control
357ANU229L A multifunctional lever with buttons (Fig. 2) is
used to select the various operating modes.
Tip the lever and/or press the buttons to se-
2 lect the required mode.
Automatic transmission command
A selection lever (Fig. 3) is used to select the
various operating modes.
Move the lever to select the required mode.
357ANU230L
357ANU231L
1-90 HHD9 Euro3
ALL VEHICLES
INSTRUMENTS
Instrument panel (Fig. 1)
341DNU001L
HHD9 Euro3 1-91
Instrument panel (Fig. 1)

1) Front axles brake wear warning light
Red light indicates front brakes have reached the wear limit
2) Rear axles brake wear warning light
Red light indicates rear brakes have reached the wear limit
3) Rear axle brakes air pressure indicator.
4) Front axle brakes air pressure indicator.
5) ABS failure warning light
Yellow light indicates ABS system is not functioning
6) Braking system failure warning light
Red light indicates there is a failure in the braking system
7) Rev counter
8) Digital speedometer
9) LCD screen with hour-counter and partial trip display
10) Partial trip reset button
11) Fuel level indicator
12) Fuel reserve warning light
Red light indicates fuel tank level is in reserve
13) Engine water overheating
Red light indicates the engine water is overheated
14) Engine water temperature indicator
15) Instruments illumination adjustment button
A) Warning lights panel A

B) Warning lights panel B
C) Warning lights panel C
See the below for further information

regarding instrument panel.
1-92 HHD9 Euro3
1 Functions of instrument panel keys

Key 1 (Fig. 1, ref. 1):
Instrument illumination adjustment.
or
Error memory display.
Refer to the DIAGNOSTIC chapter for mo-

re information
1 285ANU009L 2
Key 2 (Fig. 1, ref. 2):
Press key 2 for less than three seconds to
2 display trip km or total km
Trip odometer reset
With trip odometer displayed on LCD (Fig. 2,
ref. 1), press key 2 for more than three sec-
onds to zero the indicated distance.
Units of measure conversion (Km - miles)
To convert the units of measure displayed on
the LCD, proceed as follows:
D With ignition key out, press both buttons
(Fig. 1, ref 1 and 2).
D Holding the buttons down, turn the key to
MAR and wait 10 seconds.
1
285ANU010L
HHD9 Euro3 1-93
1 Warning lights panel A details

1 Automatic gear converter functioning warning light.
Yellow light indicates lock-up clutch is not engaged.
2 Retarder on warning light.
Yellow. Indicates that hydraulic retarder is active.
3 Engine brake engaged warning light.
Yellow. Indicates that the engine brake is engaged.
4 Rear traverse differential locked warning light.
Yellow. Indicates that the rear differential clamp is engaged.
5 Transfer box longitudinal differential locked warning light.
Yellow. Indicates that the transfer box differential clamp is engaged.
6 Tandem longitudinal differential locked warning light.
Yellow. Indicates that the tandem longitudinal differential is engaged.
7 External lights on warning light.
Green. Indicates that the side lights (and dip headlights) are on.
8 Main beam on warning light.
Blue. Indicates that main beam headlights are on.
9 Parking brake engaged warning light.
341DNU002L Red. Indicates that the parking brake is engaged.
10 Left direction indicator warning light.
Green. Indicates that the left direction indicator has been activated.
11 Power steering main circuit failure warning light.
Red. Indicates there is a failure on the power steering main circuit.
12 Power steering emergency circuit failure warning light.
Red. Indicates there is a failure on the power steering emergency circuit.
1-94 HHD9 Euro3
1 Warning lights panel B details

1. Seat belt not fastened warning light
1 2 Red. Indicates that the driver’s seat belt is not fastened.
2. Warning light
Yellow. Indicates a general vehicle fault.
3. Preheating on warning light
Yellow. Indicates that the engine preheating system is active.
4. ECM warning light
Yellow. Indicates an ECM malfunction.
4 3
285ANU012L
HHD9 Euro3 1-95
1 Warning lights panel C details

1. Second speed limit engaged warning light.
Yellow. This indicates that the second speed limiter is engaged.
2. ABS off warning light.
Yellow. Indicates ABS off.
3. ASR off warning light
Yellow. Indicates ASR off.
4. Engine oil temperature high warning light.
Red. Indicates that the engine oil temperature is high.
5. Low trailer brake air pressure warning light.
Red. Indicates trailer air brake malfunction.
6. Power steering oil level low warning light.
Red. Indicates that the power steering oil level is insufficient.
7. Alternator warning light.
Red. Indicates that the current delivered to the alternator is insufficient.
8. Water in fuel pre-filter warning light.
Yellow. Indicates the presence of water in the fuel pre-filter.
9. Hazard lights on warning light.
341DNU003L Red. Indicates that the hazard warning lights are on.
10. Right direction indicator warning light.
Green. Indicates that the right direction indicator has been activated.
11. Cab unhooked warning light
Red. Indicates that the cab has not been secured correctly.
12. Air filter clogged warning light
Yellow. Indicates that the engine air filter is clogged.
1-96 HHD9 Euro3
1 Automated transmission display (Fig. 1)

Automated transmission indications on display (Fig. 2)
The display shows information on gearbox condition.
A Gear engaged indicator (e.g. 1./.16 or N, RL and RH).999
Other information displayed:
CH = system self-diagnosis, displayed when ignition is switched on.
AL = insufficient air, shown alternating with usual indication.
FP = bring accelerator pedal to idling position: if the indication on the display remains,
there is a fault in the system and it is not possible to continue travelling.
CL = shown in alternation with the current indication and indicates a clutch overload.
CW = clutch worn. Replace as soon as possible.
_ _ = gear shift. Displayed when changing gear.
357ANU100L EE = displayed in case of dialogue error between display and electronic control unit.
HT = electronic control unit temperature too high.
nn = alphanumerical code identifying a fault detected by the control unit. For example:
2
68 = fault 68 detected in system.
B Arrow up/down: along with number of bars displayed indicate the possible gear shifts.
C Bars: along with arrows, indicate the number of possible gear changes or downshifts
(max. 4).
D Wrench: system error. Displayed when operation is only possible with certain limitations.
Take vehicle to specialised garage as soon as possible.
E STOP: displayed with previous indication: indicates that the vehicle must be stopped im-
228NUR24 mediately due to serious fault in system.
HHD9 Euro3 1-97
1 Automatic transmission display (Fig. 1)

Automatic transmission indications on display
The display shows information concerning
transmission condition.
A Indication of gear engaged (e.g. D, N, R
or 2…6).
B Alphanumeric code that identifies a fault
detected by the control unit: (2 charac-
ters for 4 times, total 8 characters, e.g.
d1/P_/07/22).
To view the fault codes the relevant pro-

cedure has to be activated.
357ANU233L
C Bolts wrench: system error. Go to the
nearest authorised garage.
2
Automatic transmission warning lights
(Fig. 2)
1. automatic transmission failure warning
light.
2. automatic transmission oil temperature
high warning light.
357ANU239L
1-98 HHD9 Euro3
1 Warning light on dashboard --- Left-hand

drive vehicles
1. PTO 1 on gearbox engaged warning
light.
Yellow light indicates that PTO 1 on
gearbox is engaged.
2 PTO 2 on gearbox engaged warning
ligh.
gearbox is engaged.
3 PTO on flywheel engaged warning light.
Yellow light indicates that PTO on flyw-
heel is engaged.
4 Splitter unit reduced gear ratio engaged
warning light.
Green light indicates that splitter unit
reduced gear ratio is engaged.
5 Low range engaged warning light.
Green light indicates that the gear low
range is engaged.
341DNU004L 6 Trailer ABS failure warning light.
Yellow light indicates that the trailer ABS
system is not functioning.
7 Reduced gears engaged warning light.
Green light indicates that the gearbox
reduced gears are engaged.
8 Windshield washer liquid level warning
light.
Red light indicates that windshield
washer liquid level is low.
9 Front transverse differential locked war-
ning light.
Yellow light indicates that front differen-
tial lock is engaged.
HHD9 Euro3 1-99
1 Warning light on dashboard ---

Right-hand drive vehicles
1 Front transverse differential locked war-
ning light.
Yellow light indicates that front differen-
tial lock is engaged.
2 Windshield washer liquid level warning
light.
Red light indicates that windshield
washer liquid level is low.
3 Splitter unit reduced gear ratio engaged
warning light.
Green light indicates that splitter unit
reduced gear ratio is engaged.
4 Reduced gears engaged warning light.
Green light indicates that the gearbox
reduced gears are engaged.
5 Low range engaged warning light.
Green light indicates that the gear low
range is engaged.
356ANU101L 6 Trailer ABS failure warning light.
Yellow light indicates that the trailer ABS
system is not functioning.
7 PTO on flywheel engaged warning light.
Yellow light indicates that PTO on flyw-
heel is engaged.
8 PTO 2 on gearbox engaged warning
ligh.
gearbox is engaged.
9. PTO 1 on gearbox engaged warning
light.
gearbox is engaged.
1-100 HHD9 Euro3
1 CONTROL OPERATION
Position and headlight controls (Fig. 1)
The control has three positions:
D position 0: off;
D position 1: first click: position lights on;
D position 2: second click: headlights on.
272NU043X Headlight control (Fig. 2)

The control has three positions.
D position 0: normal headlights;
1
2 D position 1 (light push forward): high
beams;
D position 2 (pull lever back): Beam flasher.
2
272NU044X
HHD9 Euro3 1-101
1 1 Direction indicator control (Fig. 1)

The control has three positions:
D position 0 off;
D position 1 (up) right direction indicators;
0
D position 2 (down) left direction indicators.
Horn (Fig. 2)
2 The horn can be sounded by pressing the
272NU045X
indicated points (Fig. 2, ref. 1, 2).
1
2
272NU046X
1-102 HHD9 Euro3
Windscreen washer/wiper control

3 1
The control (Fig. 1) has four positions:
2 D position 0 = disengaged;
D position 1 = intermittent;
D position 2 = slow;
D position 3 = fast.
1
0 Pushing the end of the ring (Fig. 2, see
272NU047X arrow), the windscreen wiper makes one
sweep.
The windscreen washer is the button (Fig. 3,
2 see arrow) on the control stick.
Pressing the windscreen washer button also
activates slow windscreen wiper operation.
Releasing the washer button, the wiper
makes three more cleaning strokes before
stopping.
272NU048X
272NU049X
HHD9 Euro3 1-103
1 Ignition switch (Fig. 1)

The ignition switch has three positions:
D position 0 (STOP): all off, key may be
removed;
D position 1 (MAR): ready to start, electrical
power on, key locked in;
D position 2 (AVV): starting engine.
272NU056X Engine braking control --- Vehicles with-

out intarder
The device is controlled by turning the end
2 part of the lever (Fig. 2) and which has three
positions (from 0 to 2), corresponding to one
only braking level.
Positions 1 and 2 are equivalent.
272NU057X
Engine braking control --- Vehicles with
intarder
part of the lever (Fig. 3) and which has seven
3 position lever (from 0 to 6), corresponding to
progressively higher levels of braking.
272NU058X
1-104 HHD9 Euro3
1 Cruise control
The vehicle is fitted with an engine speed /
vehicle speed control.
Memory control (Fig. 1, ref. 1).
RESUME: Pulling the lever memorises the

current regulator setting / recalls memorised
341DNU007L
setting.
OFF: Operate the lever to deactivate the
clutch.
2
1 Speed setting control
ON button (+): pressing the button (Fig. 2,

ref. 1) increases the rpm / vehicle speed
value.
2
ON button (-): pressing the button (Fig. 2, ref.
2) decreases the rpm / vehicle speed value.
272NU060X
HHD9 Euro3 1-105
1 Hazard light control

Press the control (Fig. 1, ref. 1) to turn the
hazard lights on.
Press again to switch the hazard lights off.
Exhaust brake pre-selection
The control (Fig. 2) has three positions:
D position 0: the exhaust brake is applied
1 272NU055X when the command is actuated;
D position 1: the exhaust brake is applied
when the accelerator pedal is released;
D position 2: exhaust brake applied each
2 time the brake pedal is pressed;
All Cruise Control operations are deacti-

vated when the exhaust brake is applied.
285ANU039L
1-106 HHD9 Euro3
1 Courtesy light switch

Press the button (Fig. 1) to turn the courtesy
light on.
Press the button again to turn the courtesy
light off.
Electro-pneumatic horn pre-selection

Press the control (Fig. 2) to operate the elec-
285ANU021L
tro-pneumatic horn by means of the horn
control on the left steering stalk.
Press the control again to operate the electric
horn by means of the horn control on the left
2 steering stalk.
285ANU022L
HHD9 Euro3 1-107
1 Swivelling light control

Press the button (Fig. 1) to turn the swivelling
light on.
The warning light (Fig. 1, ref. 1) indicates that
the swivelling light is on.
Press the button again to switch the swivel-
ling light off.
Work light
342ANU001L Press the button (Fig. 2) to switch the work
light on.
2 the work light is on.
Press the button again to switch the work
light off.
Rear fog light
The rear fog light will only come on when

the dipped beam headlights are switched
on (light and headlight control in second
position).
342ANU002L
Press the button (Fig. 3) to switch the rear fog
light on.
3 The warning light (Fig. 3, ref. 1) indicates that
the rear fog light is on.
Press the button again to switch the rear fog
light off.
342ANU003L
1-108 HHD9 Euro3
1 Fog light control

Press the button (Fig. 1) to turn the fog lights
on.
the fog lights are on.
Press the button again to switch the fog lights
off.
Electric battery isolator control

342ANU004L
Press the pushbutton (Fig. 2) to switch on the
main power supply.
2 This switch replaces the manual switch
located near the battery case.
After a certain time from activation or
after the engine has been switched off,
the batteries disconnect automatically.
306ANU002L
HHD9 Euro3 1-109
1 ASR off command

Press the button (Fig. 1) to turn the ASR sys-
tem off.
Press the button again to switch the ASR sys-
tem off.
Vehicle traction can be improved by pres-

sing the ASR button in particular terrain
conditions (deep snow, mud, etc.).
342ANU005L The corresponding warning light will
come on.
1-110 HHD9 Euro3
1 ABS Off Road function control

Press the button (Fig. 1) to activate the ABS
Off Road function.
Press the button to restore the brakes anti ---
lock device (ABS).
Under certain road surface conditions

(deep snow, mud, etc.) vehicle braking
can be improved activating the ABS
342ANU006L exclusion key.
When this button is pressed the ABS sys-
tem is:
D cut out up to 15 km/h;
D made less sensitive between 15 km/h
and 40 km/h;
D restored over 40 km/h.
The driver is warned of activation by
the related warning light .
The ABS system is automatically
restored at each engine re-start .
Pressing this button with a normal road

surface the wheels may lock in the case
of braking.
HHD9 Euro3 1-111
1 Distributor-reducer (transfer)
Position knob (Fig. 1):
D Position 0:travelling on road (normal
ratios).
D Position 1, “tortoise” symbol:off-road use
(step-up ratios).
Shift from one range to the other must

take place with the vehicle stopped and
gearbox in neutral.
To shift from normal to reduced:

D turn knob (Fig. 1) to position 1.
For vehicles fitted with retarder ZF

(Intarder3): with reduced gears engaged
do not exceed MAXIMUM SPEED = 50
km.
To pass from the step-up ratio to the normal

ratio:
D turn knob (Fig. 1) to position 0.
1-112 HHD9 Euro3
1 Differential lock control (2 axle vehicles)

Front transverse differential lock (4x4
vehicles only) (Fig. 1)
0) Lock disengaged.
1) Lock engaged.
We recommend engaging the front trans-

verse differential lock once the rear longi-
tudinal and transverse differential locks
are engaged.
Reat longitudinal distributor and transverse

2 differential lock (4x4 vehicles only) (Fig. 2)
0) Lock disengaged.
1) Longitudinal differential distributor lock
engaged.
2) Rear transverse differential lock enga-
ged.
The rear transverse differential only

engages when the longitudinal lock is
already engaged.
Rear transverse differential lock (4x2 vehi-

3 cles only) (Fig. 3)
0) Lock disengaged.
1) Lock engaged.
HHD9 Euro3 1-113
Differential lock engagement

D To engage the lock, turn the knob to
engage position.
D Lock engagement is indicated by activa-
tion of the corresponding warning light.
D To disengage the lock turn the knob to dis-
engage position.
D Lock disengagement is indicated by deac-
tivation of the corresponding warning
light.
The differentials must be engaged with the vehicle stopped and with the wheels
straight.
If the lock does not disengaged immediately, change direction in order to eliminate any
tension present.
Proceed with caution when lock is engaged. Do not engage the lock on roads that do
not require its use.
In muddy or slippery conditions do not allow the wheels to slip when the differential
lock is not engaged, as this will lead to serious damage to the gearing (a few seconds
are enough).
Do not engage the differential while a wheel is slipping as this will also cause serious
damage to gearing.
After use, always check that the locks are disengaged checking both the warning
lights and the position of the control button.
1-114 HHD9 Euro3
1 Differential lock control (3-4 axle

vehicles)
Front transverse differential lock 6x6, 8x6
and 8x8 vehicles only) (Fig. 1)
0) Lock disengaged.
1) Lock engaged.
We recommend engaging the front trans-

verse differential lock once the rear longi-
tudinal and transverse differential locks
are engaged.
2 Interaxle longitudinal differential lock and

rear transverse differential lock (Fig. 2)
0) Lock disengaged.
1) Interaxle longitudinal differential lock
engaged.
2) Rear transverse differential lock enga-
ged.
We recommend engaging the interaxle

longitudinal lock after the longitudinal
distributoir lock has already been
engaged.
3 The rear transverse differential lock only
engages once the longitudinal lock has
been engaged.
Longitudinal distributor differenital lock (6x6,

8x6 and 8x8 vehicles only) (Fig. 3)
0) Lock disengaged.
1) Lock engaged.
HHD9 Euro3 1-115
Differential lock engagement

D To engage the lock turn the know to
engage position.
D Engagement is indicated by the activation
of the corresponding warning light on the
cluster.
D To disengage the lock turn the knob to dis-
engage position.
D Lock disengagement is indicated by deac-
tivation of the corresponding warning light
on the cluster.
The differentials must be engaged with the vehicle stopped and with the wheels
straight.
If the lock does not disengaged immediately, change direction in order to eliminate any
tension present.
Proceed with caution when lock is engaged. Do not engage the lock on roads that do
not require its use.
In muddy or slippery conditions do not allow the wheels to slip when the differential
lock is not engaged, as this will lead to serious damage to the gearing (a few seconds
are enough).
Do not engage the differential while a wheel is slipping as this will also cause serious
damage to gearing.
After use, always check that the locks are disengaged checking both the warning
lights and the position of the control button.
1-116 HHD9 Euro3
1 Power take off control
The vehicle has the following power take

offs:
A D P.T.O on flywheel (Multipower or NMV
221).
D PTO on transmission.
The power take offs are controlled by a
switch on the dashboard.
285ANU023L
A. P.T.O I control on gearbox
Power take-off activated is indicated by
the warning light on the pushbutton
2 (Fig. 1, ref. 1).
B. P.T.O II control on gearbox
B (Fig. 1, ref. 1).
C. P.T.O control on flywheel
(Fig. 1, ref. 1).
285ANU024L
A maximum of 3 power take offs can be
controlled simultaneously.
3
285ANU025L
HHD9 Euro3 1-117
1 Multipower PTO on flywheel

1 Engage procedure:
D Gearbox in neutral, vehicle stationary,
engine off.
D Turn ignition switch to MAR.
Make sure that braking system low pres-

sure warning light is off. If it is not, start
the engine, wait until the warning light
272NU087X
switches off then switch off the engine.
D Press the corresponding PTO button.
D Wait for the yellow light on cluster.
1 2
D Start the engine.
In case of electrical or pneumatic com-

mand fault, the PTO can be engaged man-
ually as follows:
D Remove the Multipower connector ring
(Fig. 1, ref. 1) or (Fig. 2, ref. 1) NMV
221;
228NMR32X
D Fully insert an M12x1.5 bolt.
Disengage procedure:
D Switch off the engine
D Press the corresponding button.
D Check that corresponding light goes out
on cluster.
1-118 HHD9 Euro3
1 P.T.O. manual transmission
Engage procedure:
D Gear idling, vehicle stationary, engine at
minimum.
Make sure that the braking system low

pressure warning light is off. Otherwise
wait until it switches off.
342ANU007L
D Gearbox in neutral, vehicle stationary,
engine idling.
2 D Press the clutch pedal full down.
D Press the corresponding PTO button
(Fig. 1; Fig. 2).
D Wait for the light to light up on cluster.
D Release the clutch pedal.
Disengage procedure:
D Press the clutch pedal full down.
342ANU008L
D Press the corresponding PTO button
(Fig. 1; Fig. 2).
D Check on cluster that corresponding light
goes out .
D Release the clutch pedal.
HHD9 Euro3 1-119
1 TACHOMETRIC SIMULATOR
The tachometric simulator (Fig. 1) permits
correct electronic management of the clus-
ter.
For more information, refer to the corre-

sponding publications.
285ANU026L
1-120 HHD9 Euro3
1 HEATING AND VENTILATION

Climate control system air vents (Fig. 1)
1. Windshield defrosting air outlets
2. Side ventilation air outlets
3. Door windows de-frosting air outlets
4. Central ventilation air outlets
5. Foot ventilation air outlets
j cool air
J warm air
342BNU43L
HHD9 Euro3 1-121
1 Climate controls (Fig. 1)

1. Temperature adjustment control:
2. Four-speed electric fan control
3. Air distribution control knob (see sym-
bols)
4. Internal recirculation control:
- not pressed: external air inlet
- pressed: internal recirculation
5. Conditioner control with incorporated
warning light (only climate control ver-
sion)
- not pressed: off
- pressed: engaged
Symbols
342BNU44L
Ventilation outlets
Foot cooling/outlets
Foot cooling
Foot cooling/windshield
Windshield de-misting and

side vent windows
Climate control
Recirculation
1-122 HHD9 Euro3
Proceed as follows (figure on previous page):

For all versions:
D start engine;
D turn the knob (Fig. 1, ref. 1) of fan control, to set the required ventilation level;
D turn the knob (Fig. 1, ref. 2) to set the required temperature inside the passenger compart-
ment;
D turn the knob (Fig. 1, ref. 3) to the required position according to the climate control require-
ments (feet-outlets-windshield, see also next page).
D if there is heavy environment pollution press pushbutton (Fig.1, ref. 4) to activate internal
recirculation.
Only for versions with climate control:
D press the switch (Fig. 1,ref. 5) to start the air conditioner;
D to disengage the air conditioner, press the switch again.
With the knob (Fig. 1, ref. 1) in position 0
(off) there is no electrical enable to the
conditioner control.
Hints for use:
D keeping permanently in recirculation position can cause misting of the windows. Period-
ically press button (Fig 1, ref. 4) to ensure a change of air.
D Do not keep the conditioner on for long times with the fan (Fig. 1, ref. 1) at minimum to avoid
ice forming on the evaporator.
D If the cab is overheated (vehicle has remained parked for a long time under the sun) turn
the knob (Fig. 1, ref. 1) anticlockwise , and the knob (Fig. 1, ref. 2) clockwise, switch on the
conditioner and keep the windows open for a few minutes.
D In the case of a very humid environment switch on the conditioner and fully turn the knob
(Fig. 1, ref. 3) clockwise; if necessary adjust the temperature with the knob (Fig. 1, ref. 2),
using the conditioner as a dryer.
D Run the system for a few minutes to ensure full efficiency at least once a week, regardless
of the temperature.
Any water dripping from under the

vehicle with the air-conditioner on is due
to normal condensation discharge.
HHD9 Euro3 1-123
1 Most common control positions

Normal temperature position
342BNU45L
1-124 HHD9 Euro3
1 De-misting -de-frosting position
To obtain a rapid increase in air

temperature, press the recircula-
tion start button: however, it is
not advisable to keep this posi-
tion for a long time.
342BNU46L
HHD9 Euro3 1-125
1 Maximum heating position
342BNU47L
1-126 HHD9 Euro3
1 Maximum cooling position
For versions with air conditioner

press the start button.
342BNU48L
HHD9 Euro3 1-127
1 WARM AIR AUXILIARY HEATER

(WEBASTO)
The vehicle is equipped with a hot air gener-
ator (Fig. 1, see arrow) to heat the passenger
compartment with engine off.
To activate the generator, proceed as fol-
lows:
D Enable the heater by means of the wheel
(Fig. 2, ref. 1).
357ANU103L
D Start the auxiliary heater moving the knob
(Fig.1, ref. 2) clockwise from position ”0”.
2 Continuing to turn the knob clockwise
increases the air temperature.
Continuing to turn the knob anticlockwise
reduces the air temperature.
Proceed as follows to disconnect the gener-
ator:
D Set the knob on ”0”.
D Deactivate the heater by means of the
wheel (Fig. 1, ref. 1).
357ANU104L
1-128 HHD9 Euro3
1 AUXILIARY HEATER (WEBASTO)

The vehicle is provided with an auxiliary
heater for heating the engine coolant when
the engine is off. Ignition of the heater can be
programmed by means of a display for set-
ting the required parameters (Fig. 1).
Auxiliary heater control panel (Fig. 2)
1. Time
357ANU105L 2. Programming
3. Heating
4. Back
6 87 9 10 11 5. Forward
2 6. Stored
7. Remote control symbol
8. Day of the week or programmed day
9. Current time or programmed time
10. External temperature
11. Operation indicator
1 2 3 4 5
285ANU043L
HHD9 Euro3 1-129
6 87 9 10 11 1 Before setting the time and day of the week

Briefly press the button (Fig. 1, ref. 1). 12:00
will blink on the display. Set the current time
during the buttons (Fig. 1, ref. 4 and 5). The
digits will stop blinking when the time is
stored. The day of the week will blink on the
display. Set the day using the buttons (Fig. 1,
ref. 4 and 5). The day will be stored when the
1 2 3 4 5 indication stops blinking. The indication will
285ANU043L light up when the key is inserted. It will go out
10 seconds after removing the key.
How to set the time and day of the week
Hold the button (Fig. 1, ref. 1) pressed until
the time starts blinking. Adjust as described
for the first setting. To set the time only, press
the button twice (Fig. 1, ref. 1) after setting
the time to skip setting the day. After chang-
ing the day of the week, press the button
(Fig. 1, ref. 1) to make the day blink for less
time.
1-130 HHD9 Euro3
6 87 9 10 11 1 Operation of the heater with key-off with-

out programming
Symbol (Fig. 1, ref. 11) heater working.
Turning the heater on
Briefly press the button (Fig. 1, ref. 3). Sym-
bol (Fig. 1, ref. 11) and the heating time will
appear. The default setting is 120 minutes. It
1 2 3 4 5 may be modified temporarily or perma-
285ANU043L nently.
Temporarily changing the heating time
Press button (Fig. 1, ref. 4) after turning on to
shorten the operation time (down to 1 min-
ute). Press the button (Fig. 1, ref. 5) to extend
the heating time (up to 120 minutes).
Permanently changing the heating time
Do not turn the heater on. Press the button
(Fig. 1, ref. 4) and hold it pressed for approxi-
mately 3 seconds until the indication blinks
on the display. Release briefly. Set the heat-
ing time (from 10 to 120 minutes) using the
buttons (Fig. 1, ref. 4 and 5). The new setting
will be stored when the indication disap-
pears from the display.
Turning the heating off
Briefly press the button (Fig. 1, ref. 3). The
symbol (Fig. 1, ref. 11) disappears from the
display. The heater will continue to operate
for a few minutes to allow the device to cool
down correctly (wash-out step).
HHD9 Euro3 1-131
6 87 9 10 11 1 Operation of the heater with key-on with-

out programming
Symbol (Fig. 1, ref. 11) heater working.
Turning the heater on
symbol (Fig. 1, ref. 11), the time and day of
the week will appear. The heater will work
1 2 3 4 5 until the key is on. At key off, the remaining
285ANU043L heating time (15 minutes) may be extended
(up to 120 minutes) by pressing the button
(Fig. 1, ref. 5) or shortened (down to 1 min-
ute) by pressing the button (Fig. 1, ref. 4).
Turning the heater off
symbol (Fig. 1, ref. 11) disappears from the
display. The heater will continue to operate
for a few minutes to allow the device to cool
down correctly (wash-out step).
1-132 HHD9 Euro3
USE OF THE VEHICLE

1
Precautions for the initial period of use
When the vehicle is new a brief running-in
period of at least 150/200 hours is required:
Observe the following precautions during
this time:
D do not demand maximum engine power;
D after starting, warm the engine slowly;
342BNU001L avoid driving at high revs too soon;
D frequently check the oil level;
D check the tightening of the wheel bolts.
General checks
Before starting to use the vehicle, check:
D tyre conditions;
D correct functioning of all lights, headlights
and windshield wiper;
D fuel level in tank;
D any faults or low levels indicated on the
instrument board;
D check service brake and parking brake
efficiency.
Visually inspect the vehicle, checking

working conditions and for damage/prob-
lems which may cause damage to the
vehicle or injury to operators.
HHD9 Euro3 1-133
1 Refuelling
Put out naked flames while refuelling. Do

not smoke.
Proceed as follows:
D clean the filler area, open the filler cap
(Fig. 1, ref. 1) with the key and refuel with
the specified fuel type;
342BNU001L
D close the filler cap carefully.
Keep the fuel tank as full as possible.

Use fuels of the specified types supplied
by petroleum companies.
Do not use other than specified fuels. Use
of other than specified fuels can cause
severe engine damage.
1-134 HHD9 Euro3
1 STARTING ENGINE
Exhaust gases are poisonous.

Check for adequate ventilation before
starting the engine in a confined space.
Always engage the handbrake before
starting the engine.
Checks before starting

272CNU093
Check that the main switch (Fig. 1) is on.
A: power off
B: power on
2
Make all the required daily checks (for more
information see MAINTENANCE IN-
STRUCTIONS).
Especially check:
D engine oil level;
D engine coolant level;
D tyre condition;
272BNU079
D tow-hook /semi-trailer fifth wheel condi-
tion.
Power up the vehicle electrical system turn-
ing the ignition switch to MAR (Fig. 2, ref. 1)
and check:
D fuel level;
D lights, warning light, horn and windscreen
wiper function;
HHD9 Euro3 1-135
1 Starting from drivers cabin

Proceed as follows:
D Check that the parking brake is engaged;
D turn the ignition key to MAR (Fig. 1, ref. 1);
D wait until the engine pre-heating light
(Fig. 2) goes out.
If the key is not turned to start the engine

272BNU100
within a few econd, the key must be
turned to STOP (Fig. 1, ref. 3) and the pro-
cedure repeated.
2 D turn the ignition key to AVV (Fig. 1, ref. 2)
and release it as soon as the engine starts.
Do not press the accelerator pedal while

starting the engine.
If the engine does not fire immediately, do

not insist on the starter motor for more
356ANU001L than 15 seconds.
Do not leave the engine idling for a pro-

longed period of time, whether cold or hot.
After starting the engine, drive the vehicle
gently for a certain period, with medium to
low engine revs, to allow it to warm up.
1-136 HHD9 Euro3
1 Starting from engine bay

The engine can be started with the cabin
tipped in the following way:
D Turn the ignition switch (Fig. 1, ref. 1) to
MAR position;
D tip the cabin and press the starter button
(Fig. 2, see arrow).
Engine starting is only possible if:

272BNU079
D gearbox is in neutral;
D parking brake is engaged.
2
Tow starting
The engine cannot be started in any case

in presence of a battery fault, because the
control units are not powered.
Manual transmission vehicles

178NU47 Proceed as follows:
D turn the ignition switch (Fig. 1) to MAR;
D engage a medium-low gear according to
working conditions.
Vehicles with hydro-mechanical/automatic/
automated transmission
The engine cannot be started by towing.
HHD9 Euro3 1-137
4 1 Emergency electrical power
When the batteries are discharged, connect

the vehicle to external batteries to restart it.
The vehicle is equipped with a 24 volt

electrical system with negative and earth.
Only use 24 volt batteries to jump start the
3 2 1 engine.
Proceed as follows:
D lay the cables on the ground ensuring that
the terminals do not touch metal parts or
each other; connect one end of the red
cable (A) to the POSITIVE terminal (Fig. 1,
238NU44
ref. 1) of the flat battery;
D connect the other end of the red cable (A)
to the POSITIVE terminal (Fig. 1, ref. 2) of
the external battery;
D connect one end of the black cable (B) to
the NEGATIVE terminal (Fig. 1, ref. 3) of
the external battery;
D connect the other end of the black terminal
(B) to any point of the chassis of the vehicle
(Fig. 1, ref. 4) to be started which is cer-
tainly connected to earth.
1-138 HHD9 Euro3
4 1 Select a connection point as distant as

possible from the vehicle batteries.
Make sure that the two vehicles do not
come into contact.
Respect the sequence of the operation.
Do not reverse the polarity when making
the connection.
Use cables with a suitable cross-section
3 2 1 area.
Never use a battery charger to start the
engine.
Do not disconnect the accumulators even
if they are discharged.
238NU44
The use of a booster is permitted follow-
ing the use instructions of the said instru-
ment.
Always start the engine a previously

described.
After starting the engine, disconnect the
cables by reversing the connection
sequence.
The vehicle electrical system must work

in presence of battery, even if flat.
In any case verify the causes of the batteries

discharge.
HHD9 Euro3 1-139
COLD START
The following table shows the precautions to be adopted for starting the engine at temperatures lower than 0 ˚C.
For more information on fluids, refer to

the MAINTENANCE INSTRUCTIONS
chapter.
Temperature [˚C]
Operations
From 0 to -19 From -19 to -25 Lower than -25
Starting procedure normal with heater with heater
replace with Artic diesel fuel replace with suitable fuel
Fuel wash out the engine and auxil-
add suitable percentage of additive
iary heater feeding circuit
Engine oil no replacement needed replace with suitable type
Engine coolant appropriate percentage of antifreeze
Transmission oil no replacement needed
Power steering steering fluid no replacement needed
Windscreen washer fluid appropriate percentage of antifreeze
Batteries check maximum charge by measuring electrolyte density
1-140 HHD9 Euro3
1 Starting with heater

Proceed as follows:
D Start the supplementary heater (Fig. 1) as
described above.
D Let the heater run for at least 60 minutes.
D Start the engine (Fig. 2) as described
above.
D Check that the oil pressure reaches the
357ANU105L maximum value within thirty seconds:
otherwise stop the engine, start the auxili-
ary heater for at least 10 minutes and start
the engine again.
2 D After starting the engine, keep the heater
running to warm up the engine faster.
The vehicle can be used at maximum

power only after the liquid temperature.
272BNU100
HHD9 Euro3 1-141
1 STOPPING ENGINE
Stopping from drivers cabin
To stop the engine, proceed as follows:
D bring the engine to idle speed for a few
minutes to reached steady state tempera-
ture and ensure turbocompressor lubrica-
tion;
D turn the ignition switch to STOP (Fig. 1, ref.
272BNU091 0) and remove the key.
DO NOT switch off the engine with the

vehicle in motion to prevent loss of power
steering.
DO NOT remove the key from the ignition
switch with vehicle in motion to prevent
locking the steering.
Vehicles with automated transmission: if

the gearbox is not in neutral when the
engine is stopped, the system automati-
cally sets this position when the key is
removed from the switch.
In this condition there is no mechanical
connection between engine and wheels,
and the vehicle may roll forward if the
parking brake is not applied.
1-142 HHD9 Euro3
1 After switching off the engine the engine

control unit has to carry out a series of
diagnostic procedures that require elec-
trical power for a few seconds.
For this reason, before cutting out the bat-
teries wait at least 10 seconds.
Premature deactivation of the electric
power through the circuit breaker (Fig. 1,
position A) can cause considerable oper-
272CNU093 ating problems on the engine control sys-
tem. Therefore this manoeuvre is only to
be performed in cases of extreme neces-
sity.
2 After five (5) consecutive engine emerg-
ency switch-off operations, on the next
start the engine starts normally but is
unable to provide power and remains at
idle speed.
To restore complete function, contact the
Service Network.
Stopping from engine bay
178NU45
To stop the engine, proceed as follows:
D press the button (Fig. 2, see arrow) until
the engine stops.
3 After using the vehicle, always
disconnect the accumulators through the
circuit breaker (Fig. 1, position A) or by
acting on the switch (Fig. 3).
306ANU002L
HHD9 Euro3 1-143
1 MANUAL TRANSMISSION
VEHICLES
STARTING THE VEHICLE
1 Before starting the vehicle, make sure that
the tractor brake low pressure warning lights
and trailer brake low pressure warning lights
(if fitted ) are off, and that brake air pressure
has reached 6 bar (Fig. 1). If necessary wait
178NM81 a few minutes for the compressor to charge
the air tanks.
To start the vehicle proceed as follows:
2 D press the clutch pedal (Fig. 2, ref. 3);
Press the pedal full down to fully disen-

gage the clutch to prevent premature
wear to synchronisers.
D engage a low gear (1st to 3rd according to

gradient);
285ANU027L D release the parking brake, then release the
clutch while pressing the accelerator
pedal (Fig. 2, ref. 1).
3 The vehicle must be started in the right
gear, especially if loaded and/or on a hill
to prevent premature clutch wear.
Proceed to engage the next gear pressing

the clutch down before selecting the gear.
272NU062X
1-144 HHD9 Euro3
1 DRIVING THE VEHICLE

In normal driving conditions the danger
warning lights (RED) must be off.
If one or more warning lights come on, stop
the vehicle and ascertain the cause.
When driving, check that:
2 1 D fuel level(Fig. 1, ref. 1) is not at minimum;
285ANU028L Never totally empty the fuel tank to pre-

vent any deposits or condensation water
from the tank reaching the injectors.
2 D engine coolant temperature light (Fig. 1,
ref. 2) remains at around 90˚ C;
D the engine oil pressure (Fig. 2) is suitable;
the warning light will go out after the en-
gine has started;
285ANU045L
HHD9 Euro3 1-145
1 D the rear (Fig. 1, ref. 1) and front (Fig. 1, ref.

2) brake air pressure is suitable (max. 12
bars, min. 5.5 bars).
1 2 D the alternator warning light (Fig. 2) is off.
Do not exceed maximum engine speed,

especially on downhill stretches.
Never run down hill in neutral or with
clutch disengaged.
285ANU046L Use auxiliary brakes for long downhill
stretches (engine brake, intarder) to pre-
vent service brakes from overheating.
2 Do not for any reason use the parking
brake when travelling (except in emer-
gency).
285ANU030L
1-146 HHD9 Euro3
1 GEARBOX
The operations to control the gearbox are the
same as those on traditional type synchro-
nised gearboxes, i.e. without requiring
doubling of the clutch when changing up
and without intermediate acceleration when
changing down.
The individual gears can be engaged only
when the parts to be mated reach the same
178NU52 speed. It is therefore important to press the
gear lever evenly until the gear is engaged.
2
To avoid damaging the toothing of the
gear, reverse should only be engaged
when the vehicle is stationary.
Gearbox control (Fig. 1)

When the low range group is selected
(“Tortoise” on warning light, Fig. 2, ref. 1) and
341DNU005L
the gearbox is in neutral, the gear lever is
positioned between 3rd and 4th gear where-
as when the high range group is selected
(“Tortoise” off warning light, Fig. 2, ref. 1) and
the gearbox is in neutral, the lever is posi-
tioned between 5th and 6th.
To engage 1st and 2nd and 7th and 8th, the
gear lever must be moved towards the left or
right to overcome the slight resistance of the
positioning springs.
The selections 3rd/4th and 5th/6th are separ-
ated by a harder spring click.
HHD9 Euro3 1-147
1 Strike rapidly with the palm of your hand to

overcome elastic resistance to shift range.
The lever will position itself automatically for
the desired selection of 3rd/4th and 5th/6th
(Fig. 1).
During change-over the gear shift
automatically activates, indicated by the
relevant LOW SPLIT warning light (fig. 2).that
switches on or off.
To protect the clutch, the engine and the
178NU52
gearbox against run-away speed rates,
SPECIAL CARE MUST BE TAKEN TO
AVOID ERRONEOUS OPERATIONS when
2 a lower gear is engaged.
In particular:
D A lower gear must be engaged only when
the vehicle speed is lower than the maxi-
mum speed of the gear .
D Shift from range 5/6 to range 3/4 only if the
vehicle speed is slower than approximate-
ly 30 km/h.
D Do not shift up or down more than two ra-
341DNU006L
tios (four half ratios) at a time.
Any passage from the high range to the low
range other than the passage 5th and 4th
3 used for normal driving conditions must be
avoided. The lever should not be used to set
the low range even when the vehicle is mo-
mentarily in neutral.
Operating the clutch
The clutch pedal (Fig. 3, ref. 1) must be fully
depressed each time a gear is changed.
Changed gear effected only if the clutch is
completely disengaged.
272GNU0099
1-148 HHD9 Euro3
Splitter control
1
The splitter control which makes it possible
to divide each of the eight gears (and re-
verse) occurs via the pre-selection valve lo-
cated in the control lever and operated by the
pre-selection lever (Fig. 1):
D lever upwards (position A) = > normal
gears
D lever downwards (position B) = > step-up
gears
To control the splitter the lever should be
worked and the clutch pedal fully de-
pressed.
A valve activated by the clutch pedal com-
mands the splitter control cylinder, so that
switching is obtained. To obtain correct
splitter operation, engagement and disen-
gagement movements must not be abrupt.
Engagement of reduced gears is indicated
by the relevant LOW SPLIT warning light
178NU53 (Fig. 2) that switches on.
The use of the splitter is particularly useful in
certain cases, for example:
D to exploit the maximum power of the en-
2 gine when difficulty is experienced when
driving off, overtaking or travelling uphill;
D when travelling in urban areas or when tra-
velling in a queue when you wish to main-
tain the engine at an economical rpm.
341DNU006L
HHD9 Euro3 1-149
1 STOPPING THE VEHICLE

To stop the vehicle proceed as follows:
D release the accelerator pedal (Fig. 1, ref. 1)
and gradually press the brake pedal (Fig.
1, ref. 2);
D when the vehicle is drawing to a halt, de-
press the clutch pedal (Fig. 1, ref. 3) and
move the gear lever to neutral;
D when the vehicle has come to a halt, en-
272NU062X
gage the parking brake.
DO NOT switch off the engine with the

vehicle in motion to prevent loss of power
steering.
DO NOT remove the key from the ignition
switch with vehicle in motion to prevent
locking the steering.
1-150 HHD9 Euro3
1 VEHICLES WITH AUTOMATED

TRANSMISSION (ASTRONIC)
EUROTRONIC TRANSMISSION
The ZF AsTronic selection system is a combi-
nation of an electro-pneumatic engagement
transmission with an automated clutch.
Gear change is facilitated by an electroni-
357ANU106L
cally controlled gear selector (joy-stick, Fig.
1). It is also possible to set a completely auto-
matic selection mode.
2 F function key
N idle position pushbutton
R reverse gear lock ring.
After each action the selection lever

returns to the initial position.
Changing to high gears

147NU10 D With a step in (+) direction (Fig. 2, ref. a)
the gear shifts by one higher gear.
D With two steps in (+) direction (Fig. 2, ref.
3 b) the gear shifts by two higher gears.
Shifting to lower gears
D With one step and movement in (---) direc-
tion (Fig. 3, ref. a) the gear shifts to a lower
gear.
D With two steps and movement in (---) direc-
tion (Fig. 3, ref. b) the gear shifts by two
lower gears.
147NU12
HHD9 Euro3 1-151
1 STARTING UP
When the engine has been started the
display shows the symbol N (Fig. 1). The
system is in manual mode.
Start-up is only enabled after sufficient

air pressure has been reached.
If the pressure is not sufficient the display
shows the symbol AL.
357ANU107L If, stopping the vehicle, due to low air
pressure the clutch does not disengage,
the engine stops.
2 If gear shift takes place with air pressure
too low, the gear may remain in idle, and
no motion is transmitted. Moreover, there
is no braking effect of the engine brake.
If engine start-up is not possible because
a gear has remained engaged and it is not
possible to select idle position due to
insufficient air pressure, it is necessary to
autonomously supply air to the transmis-
357ANU108L sion from an external source.
1-152 HHD9 Euro3
1 Start-up in automatic mode

D start engine;
D press the function key (F) (Fig. 1);
The system sets the best take-off gear that
is shown on the display (Fig. 2, for exam-
ple 3rd gear);
Each time the F key is pressed the system

changes from manual mode to automatic
147NU11 and vice-versa.
To start on slopes that are more than 40%

2 it is OBLIGATORY to select manual mode.
D release the parking brake pressing the

accelerator pedal at the same time (Fig. 3,
ref. 1); the clutch engages and the vehicle
starts.
With vehicle travelling uphill, if the acce-

lerator pedal is not pressed sufficiently,
357ANU109L
the vehicle starts to move backward.
In this case the clutch engages and disen-
gages at brief intervals (misfiring).
3 This also occurs when moving forward
with reverse gear engaged travelling
downhill.
Avoid that the vehicle can move in the
opposite direction to that of the engaged
ratio.
If the vehicle moves forward without a
gear engaged, the engine brake action is
not available.
272NU005MY
HHD9 Euro3 1-153
1 Start-up in manual mode

D start engine;
D move the gearshift by one position (Fig. 1)
pushing in (+) direction.
The system sets the best take-off gear that
is shown on the display (Fig. 2, for exam-
ple, 3rd gear);
D if necessary change the required starting
gear moving the lever forward (+) or back-
357ANU110L
ward (---);
To start on slopes that are more than 40%

2 it is OBLIGATORY:
D to select the take-off gear,
D do not change gear when driving uphill.
D release the parking brake and at the same

time press the accelerator pedal (Fig. 2,
ref. 1); the clutch engages and the vehicle
starts.
357ANU117L
With vehicle travelling uphill, if the acce-
lerator pedal is not pressed sufficiently,
the vehicle starts to move backward.
3 In this case the clutch engages and disen-
gages at brief intervals (misfiring).
This also occurs when moving forward
with reverse gear engaged travelling
downhill.
Avoid that the vehicle can move in the
opposite direction to that of the engaged
ratio.
If the vehicle moves forward without a
272NU005MY
gear engaged, the engine brake action is
not available.
1-154 HHD9 Euro3

In normal driving conditions the danger
warning lights (RED) must be off.
If one or more warning lights come on, stop
the vehicle and ascertain the cause.
When driving, check that:
2 1 D fuel level(Fig. 1, ref. 1) is not at minimum;
285ANU028L Never totally empty the fuel tank to pre-

vent any deposits or condensation water
from the tank reaching the injectors.
2 D engine coolant temperature light (Fig. 1,
ref. 2) remains at around 90˚ C;
the warning light will go out after the en-
gine has started;
285ANU045L
HHD9 Euro3 1-155

bars, min. 5.5 bars).
1 2 D the alternator warning light (Fig. 2) is off.

especially on downhill stretches.
Never run down hill in neutral or with
clutch disengaged.
285ANU046L Use auxiliary brakes for long downhill
stretches (engine brake, intarder) to pre-
vent service brakes from overheating.
2 Do not for any reason use the parking
brake when travelling (except in emer-
gency).
285ANU030L
1-156 HHD9 Euro3
1 Forward movement in automatic mode

Running in automatic mode takes place:
D when the vehicle has been started in auto-
matic mode;
D when with the vehicle in manual mode the
function key (F) is pressed (F) (Fig. 1).
Forward travel gear change in automatic

147NU11
mode
Gear changes take place automatically
according to these parameters:
D running situations;
D full load;
D accelerator pedal position;
D vehicle speed;
D engine speed.
When running the display shows the gear
set.
HHD9 Euro3 1-157
1 The gear set by the system can be changed

by acting on the lever without exiting from
automatic mode:
Shifting to next gear down
D With one step and shift in (---) direction
(Fig. 1, ref. a) shifts to a lower gear.
D Two steps and movement in (---) direction
(Fig. 1, ref. b) shifts two gears down.
147NU12
Shifting to higher gears
D One step in (+) direction (Fig. 2, ref. a)
2 shifts to a higher gear
b) shifts two gears up.
147NU10
1-158 HHD9 Euro3
1 Kick-down function
Pressing the accelerator pedal beyond the
hard limit stop point causes the control sys-
tem to set POWER mode.
Before shifting up, each gear is maintained
up to the corresponding maximum engine
speed, downshifting in case of sharp accel-
eration.
The system remains in automatic mode dur-
147NU11 ing kick-down.
Maintaining the selected gear
In automatic mode, if the current gear has to
be maintained (for example to accelerate be-
fore beginning a climb), press function but-
ton F without moving the lever.
The system shifts to manual mode: no fur-
ther gear shifts are possible except those
made by means of the lever.
To return to automatic mode, press function
button F again without moving the lever.
HHD9 Euro3 1-159
1 Forward running in manual mode

Running in manual mode takes place:
D when the vehicle has been started in
manual mode;
D with the vehicle in automatic mode the (F)
function key is pressed (Fig. 1).
Shifting to next gear down
D With one step and shift in (---) direction
147NU11 (Fig. 2, ref. a) shifts to a lower gear.
D Two steps and movement in (---) direction
(Fig. 2, ref. b) shifts two gears down.
2
Shifting to higher gears
D One step in (+) direction (Fig. 3, ref. a)
shifts to a higher gear
b) shifts two gears up.
147NU12
147NU10
1-160 HHD9 Euro3
1 Shift to neutral
D Press the function key (N) (Fig. 1).
The N symbol appears on the display. Ma-
nual mode is enabled.
It is also possible to shift to neutral while

driving. Shifting to neutral interrupts the
dynamic coupling of the driveline. Engine
braking in this case is not enabled.
147NU09
It is possible to shift to neutral at any time

and from any gear, even with the vehicle
moving.
Simply shift the lever in the required di-
rection or press the function key (F).
To avoid holding the clutch disengage sys-

tem operating during stops longer than 1 or
2 minutes with the engine running (for exam-
ple in a traffic jam or at a level crossing) it is
advisable to shift to neutral by pressing func-
tion key (N). This avoids unnecessary use of
the disengage system.
HHD9 Euro3 1-161
1 Reverse gear
Reverse gear is only available in manual

mode.
The system is equipped with two reverse

gears:
RL = slow reverse
RH = fast reverse
147NU15
Engaging reverse
The vehicle has to be stationary.
D Stop the vehicle completely.
If the vehicle is still moving the reverse

gear engagement does not take place.
It is not important whether the gear is in
idle position or a forward gear is enga-
ged.
147NU16
D Slow reverse: pull the collar (R) upward
and shift the lever one click in direction (---)
(Fig. 1).
D Fast reverse: pull the collar (R) upward
and shift the lever two clicks in direction
(---) (Fig. 2).
With the vehicle stationary and already in re-
verse it is still possible to shift from RL to RH
and vice-versa.
Push the lever with the collar pulled up and
shift respectively:
D one click in direction (---) for RL;
D two clicks in direction (---) for RH.
1-162 HHD9 Euro3
1 Reverse gear disengagement

Proceed as follows:
D Stop the vehicle completely.
If the vehicle is still moving the reverse

gear disengagement does not take place.
D Pull the collar (R) upward and move the

147NU17 lever by one position in (+) direction
(Fig. 1).
or
2 D Press the function key (N) (Fig. 2).
The display will show the symbol N. Manual
mode is activated.
Any forward gear can be selected.
147NU09
HHD9 Euro3 1-163
1 Protection functions
Clutch protection
If the clutch overheats (for example due to
CL many consecutive starts at short intervals, or

with low speed gear selected for too long)
the CL symbol appears on the display and
an alarm will sound.
In this situation the driver must perform a ma-
noeuvre that eliminates the overload (for
example accelerating the vehicle to engage
the clutch, stopping the vehicle or start-out
selecting a low gear).
If the accelerator is pressed the system

will engage the clutch regardless of the
overload signal, worsening the condition
of the clutch itself (except in 1st and RL).
This may cause the clutch to slip with en-

gine over-revving and may even allow the
vehicle to slip backwards if starting out
on a hill.
Engine over-rev protection

The system does not permit engagement of
gears not compatible with engine sped and
load conditions.
1-164 HHD9 Euro3
1 “LIMP HOME” function
The LIMP HOME function is useful in

emergency conditions.
The system will not work in the usual man-
ner in these conditions.
Proceed with the utmost care.
Check that the air pressure is maximum.
Check vehicle performance under con-
307HNU004L
trol: the gear indicator may show a diffe-
rent gear from the one actually engaged
in some conditions.
2 Use
The symbol LH will blink on the display when
the LIMP HOME function is working (Fig. 1).
Activation by driver
D stop the engine;
D turn the key to the MAR position;
D within 5 seconds, press the function but-
147NU04 ton (Fig. 2, ref. N) and hold it pressed for
at least 5 seconds.
Symbol LH (Fig. 1) blinking
D LIMP HOME function on;
D gearbox in neutral;
D clutch disengaged.
HHD9 Euro3 1-165
1 Gearbox lever functions

D for shifting one gear at time up (+) o down
(---);
D all forward gears and one reverse are avai-
lable;
D function button (Fig. 1, ref. F): engage/di-
sengage clutch.
Clutch state display
147NU04 D Clutch engaged: bar with arrow pointing
downward (Fig. 2, ref. 1).
D Clutch disengaged: bar with arrow poin-
2 ting upward (Fig. 2, ref. 2).
D The indicator will stop blinking during a
gear shift. It will resume blinking after the
gear is engaged.
307HNU005L
1-166 HHD9 Euro3
1 Operation
D Activate emergency mode and start the
engine.
D Press and release the brake.
D Engage the required gear by repeated
operating the gear lever (Fig. 2):
(a) forward (+) to shift up
(b) backward (---) to shift down
147NU04 The gears to be used in LIMP HOME mode
must be selected when the vehicle is sta-
tionary only.
2 Movements of the gear lever while the sy-
stem is travelling will not be taken into ac-
count by the system.
D Engage the clutch: hold the button (Fig. 1,

ref. F) pressed until the bars and down-
ward pointing arrow appears (Fig. 3, ref.
1).
307HNU005L The clutch may be engaged with delay or

suddenly.
307HNU006L
HHD9 Euro3 1-167
1 Uphill starting
D If the clutch is engaged by means of the
button (Fig. 1, ref. F) when the brake is
pressed, release the brake pedal briefly in
order to be able to disengage the clutch
with the accelerator again.
Driving downhill
D The clutch will be automatically engaged
when the vehicle is travelling downhill with
147NU04
a gear engaged.
Restoring normal operation (RESET)
D Turn the key to the STOP position and wait
for the indicator to go out.
D Turn the key back to the MAR position.
1-168 HHD9 Euro3
1 STOPPING THE VEHICLE

With the accelerator pedal (Fig. 1, ref. 1) re-
leased, decelerate the vehicle with the servi-
ce brakes (Fig. 1, ref. 2) until stopping. Du-
ring this operation the clutch automatically
disengages before the vehicle stops, pre-
venting the engine from stalling.
When the vehicle stops, if a higher gear than
the last selected pick-up gear is engaged,
272NU005MY the system will automatically shift to the last
selected pick-up gear.
When the vehicle stops, if a lower gear than
the last selected pick-up gear is engaged,
that gear is maintained.
Always shift to neutral by pressing function
button (N) for stops longer than 1-2 minutes
with the engine running.
With the vehicle stationary, engine run-
ning and gear engaged, simply press the
accelerator to move off with the vehicle.
Always shift to neutral (N) and engage the
parking brake before exiting the vehicle
with the engine running.
If the transmission is not in neutral (N), a
buzzer will sound if the driver attempts to
exit the vehicle.
Pulling the handbrake when driving on
slippery roads may stall the engine. In
this event power steering is NO LONGER
AVAILABLE!
HHD9 Euro3 1-169
1 VEHICLES WITH AUTOMATIC

TRANSMISSION
STARTING THE VEHICLE
1 Before starting the vehicle, check that the
warning lights indicating low tractor brake air
pressure and low trailer brake air pressure (if
present) are off, and that the brake air pres-
sure has reached 6 bars (Fig. 1): if required,
178NM81 wait for a few minutes for the compressor to
adequately recharge the air reservoirs.
To drive off proceed as follows:
2 D release the parking brake and press the
brake pedal (Fig. 3, ref. 2);
D take the lever (Fig. 2) to D position (drive);
D wait for 1-2 seconds to enable gear en-
gagement;
D release the brake pedal and press the ac-
celerator (Fig. 3, ref. 1): vehicle will start off
smoothly.
357ANU201L
272NU005MY
1-170 HHD9 Euro3
1 The automatic transmission will select the

most suitable gear for vehicle running condi-
tions (engine speed and load).
Driving off can also take place with gear

lever in intermediate positions (1, 2, 3).
In these positions, the gearbox excludes
the gears higher than the selected one
(e.g. when selecting position 2, the trans-
357ANU201L mission will exclude engagement of
gears higher than second gear).
Run engine idle with gearbox in position

N (neutral) for at least 5 minutes when
driving off temperature is below ---15˚C.
HHD9 Euro3 1-171

Under normal conditions the danger warn-
ing lights and danger display indications
(RED) should be off. If one or more of the
warning lights/indications should come on,
stop the vehicle and find the cause.
When driving check that:
2 1
D the fuel tank level (Fig. 1, ref. 1) is not mini-
285ANU028L
mum;
Never fully drain the fuel tank to prevent

dirt and condensation on the bottom of
2 the tank from reaching the injection sys-
tem.
D the engine coolant temperature (Fig. 1, ref.

2) should remain about 90˚C;
the warning light will go out after the
engine has started;
285ANU045L
1-172 HHD9 Euro3

bars, min. 5.5 bars);
D the alternator warning light (Fig. 2) is off.

especially downhill.
Never travel with the transmission in Neu-
tral.
357ANU238L Avoid using the auxiliary brakes (engine
brake, intarder) on long downhill
stretches to prevent overheating the ser-
2 vice brakes.
Never use the parking brake (expect in an
emergency) when travelling.
Kick-down
The kick down device operation (i.e. depress
accelerator pedal beyond limit stop) enables
the driver to “force” down-shifting when run-
285ANU030L
ning. This device can be used to have higher
vehicle pickup after a moderate slowing
down (i.e. not causing automatic shifting to
a lower gear).
Do not use this device continuously because
it causes rough use of the transmission,
stresses the assembly and leads to higher
fuel consumption.
HHD9 Euro3 1-173
1 Automatic transmission
1. Safety button to be pressed to allow
selector lever movement.
2. MODE button : to choose a second set-
ting of the automatic transmission con-
trol unit.
PERFORMANCE mode: default set-
ting, button not pressed, LED off.
ECONOMY mode: second setting, but-
ton pressed, LED on.
The MODE button incorporates a warning

light (ref. 3) that switches on when the
button is pressed.
3. Display: Shows the ratio engaged

when vehicle is travelling, and fault
codes when requested.
4. DIAGNOSTIC button: to view fault
357ANU234L
codes on the display.
1-174 HHD9 Euro3
1 It is not possible to shift from position N

to position D or R if the parking brake is
applied.
Positions N, D and R can only be selected

and released by pressing the safety but-
ton (Fig. 1, see arrow).
357ANU235L Only the positions Neutral, Reverse, 2

can be used when the oil temperature is
colder than 7˚C (19˚F). All other posi-
tions will not be available even if they are
selected.
Forward or reverse must only be engaged

when the vehicle is stationary.
Never idle the vehicle with reverse en-
gaged for longer than 5 minutes to pre-
vent damage to the transmission.
HHD9 Euro3 1-175
1 The selection lever has the following posi-

tions:
N (Neutral) position
This position must be selected:
D to start the engine;
D to operate the power take-off;
D when the vehicle is momentarily left with
the engine running.
R (Reverse) position
This position must be used for reversing the
vehicle.
An external buzzer will sound when Re-

verse is selected.
357ANU236L
1-176 HHD9 Euro3
1 Drive position
This position must be used for driving the ve-
hicle in the normal conditions.
Automatic transmission control system se-
lects the most suitable gear and controls en-
gagement of converter automatic lock-up
clutch according to engine speed and load.
The automatic transmission may keep

shifting down and up when travelling
uphill (“gear hunting”).
In this case, it is advisable to manually se-
lect the lower gear and reduce speed.
The control system tends to shift to high-

er gears to decrease engine load when
travelling downhill. This decreases the
engine brake effect and increases speed.
357ANU236L In this case, select a more suitable gear
to prevent speeding up.
HHD9 Euro3 1-177
1 Positions 6, 5, 4 and 3
These positions should be used occasional-
ly when selection should be limited to the first
three gears, cutting out the higher gears and
first gear, due to particular load or road con-
ditions.
The lower is the selected position, the

higher is engine braking effect, since
higher gears engagement is progressive-
ly excluded.
Position 2
This position must be used to control vehicle
speed uphill and especially downhill on par-
ticularly steep roads.
Position 1
There transmission does not shift and out-
357ANU236L puts maximum torque to wheels.
1-178 HHD9 Euro3
1 Fault
The “Check Trans” warning will on the side
panel (Fig. 1, ref. 1) will light up to indicate a
possible automatic transmission fault. The
error code will appear on the display by the
side of the selection lever (Fig. 2, see arrow).
If the “check trans” warning light comes

on, park the vehicle by the side of the
272NU005AL road in a safe place and call a Service
workshop as soon as possible.
2 High automatic transmission oil temperature

is indicated by the corresponding warning
light on the side panel (Fig. 1, ref. 2).
357ANU237L
HHD9 Euro3 1-179
1 Stopping the vehicle

To stop the vehicle proceed as follows:
D Release the accelerator pedal (Fig. 1, ref.
1) and press the brake pedal (Fig. 1, ref. 2).
D When the vehicle is drawing to a halt,
move the gear lever to N (Neutral).
The torque converter permits keeping the

vehicle stationary with the selection lever
272NU005MY in any position by pressing the brake ped-
al. Avoid however to maintain this posi-
tion for long periods since it causes a
sudden gearbox oil temperature in-
crease.
D When the vehicle has come to a halt, en-

gage the parking brake.
1-180 HHD9 Euro3

HHD9 Euro3 1-181
1 ALL VEHICLES
SPEED PROGRAMMER
Engine idle speed adjustment / memoris-
ing
The speed programmer is a device that acts
on the engine power supply management
system, controlling rotation speed both with
341DNU008L
vehicle stationary and in motion, so that cer-
tain conditions are met.
Keep the brake pedal pressed throughout

the operation.
Conditions:
D engine at idle speed;
D engine at temperature over 30 ˚C.
1-182 HHD9 Euro3
D Action the Cruise Control lever (Fig. 1, ref.
1) toward the steering wheel (RESUME)
until engine speed reaches the basic
stabilised rate (approx 550 rpm);
D Adjust speed as required using ON + (Fig.
1, ref. 2) or ON --- (Fig. 1, ref. 3) (pivoting
head key).
272GNU0106 Each touch of the ON key increases or

decreases engine speed by circa 20 rpm.
Engine idle speed must be between the
following values:
D minimum value: 550 rpm
D maximum value: 750 rpm
Adjust idle speed according to needs
(noise, vibration, etc.).
D When required speed is reached, move

the Cruise Control lever again toward the
steering wheel (RESUME) for about 5 sec-
onds.
D Release the brake pedal.
This will memorise the new speed even after
stopping the engine, and the new setting will
be valid for all subsequent restarts.
If the procedure is not carried out cor-

rectly and/or problems are encountered
during it, the previously memorised
speed is maintained.
HHD9 Euro3 1-183
1 Vehicle speed (Cruise Control) adjust-

ment / memorising
The system controls and maintains vehicle
speed.
The Cruise Control must not be used in

heavy traffic conditions or on roads
where constant speed adjustment is
necessary.
272GNU0106
If the set speed is no longer achievable
the device cuts-out automatically.
If vehicle speed increases by more than

2 kph over the set value (e.g. on descend-
ing road) to slow the vehicle and maintain
set speed, engine braking is automati-
cally engaged.
If vehicle speed increases more than 4
km/h also the retarder (if present)
engages.
1-184 HHD9 Euro3
1 Vehicles with automated transmission: if

the vehicle speed exceeds 6 km/h, the
transmission will shift down (automatic
mode only). The automated trans-
mission, in automatic mode, will shift
down whenever necessary (increase
coolant flow rate).
Vehicles with automated transmission

272GNU0106
without retarder: if the vehicle speed
increases to over 4 km/h despite the inter-
vention of the exhaust brake, the trans-
mission with automatically shift down (in
automatic mode only).
Conditions:
D engine brake lever/retarder not engaged;
D vehicle moving with gear engaged;
D vehicle speed greater than 20 kph;
D brake pedal not pressed;
D clutch pedal not pressed.
Control Vehicle speed regulation
ON + Increases speed
ON --- Decreases speed
RESUME Selects last set speed
OFF Cancels speed regulation
HHD9 Euro3 1-185
1 Enable
Proceed as follows:
The function can be enabled only if the

brake pedal has been pressed at least
once after starting the vehicle.
D Bring the vehicle to the steady speed to

272GNU0106 maintain with the accelerator pedal;
D Press the ON button (+) (Fig. 1, ref. 2)
once: the speed value is automatically
memorised;
D Release the accelerator pedal.
1-186 HHD9 Euro3
1 Changing setting
Proceed as follows:
D after activating the function press ON (+)
(Fig. 1, ref. 2) to increase vehicle speed;
or
D after activating the function press ON (---)
(Fig. 1, ref. 3) to decrease vehicle speed.
272GNU0106 Tip Function

Briefly press the pivoting ON button (+) (Fig.
1, ref. 2) or ON (---) (Fig. 1, ref. 3) to change
speed in 1 kph steps.
Ramp Function
Holding the pivoting ON button (+) pressed
(Fig. 1, ref. 2) or (---) (Fig. 1, ref. 3) increases
speed continuously.
HHD9 Euro3 1-187
1 Permanent disable
Proceed as follows:
D Pulling (OFF) the Cruise Control lever (Fig.
1, ref. 1);
or
D Operate the brake or engine brake pedal;
or
D Press/turn the accelerator pedal
341DNU009L (demanding a higher speed than set) for
more than 60 seconds.
After disabling it is possible to return to

the previous setting by pulling the Cruise
Control lever toward the steering wheel
(RESUME).
If the set speed is no longer achievable
the device cuts-out automatically.
To prevent disabling the engine brake or
intarder on downhill stretches, the Cruise
Control remains active if the brake pedal
is pressed at speed over 4 kph.
Temporary disable
Proceed as follows:
D Operate the clutch pedal (if present) the
system shifts to stand-by. After disengag-
ing the clutch the vehicle returns to the
cruising speed set previously.
D Press/turn the accelerator pedal for more
than 60 seconds. As soon as the acceler-
ator is released the function automatically
resumes at the last set value.
1-188 HHD9 Euro3
1 ENGINE BRAKE CONTROL SELECTION

(vehicles without intarder)
part of the lever (Fig. 1) and (Fig. 1), which
has three positions (from 0 to 2):
D position 0: disabled;
D position 1: 50% engine braking;
D position 2: 100% engine braking.
272BNU065
For the same lever positions, maximum

engine braking effect is achieved by
engaging lower gears, since braking is
proportional to engine revs.
Engine brake engagement disables all
cruise control operations
Whatever the setting, the function is dis-
abled as soon as the accelerator pedal is
pressed.
HHD9 Euro3 1-189
1 To enable the device:

D not press the switch (Fig. 1 item 0);
D rotate the terminal part of the lever (Fig. 2)
to the required braking position.
To disable the device:
D return the end part of the lever to position
0.
284CNU014L
Use the retarder to reduce vehicle speed
on turns or downhill, to prevent overheat-
ing the brakes.
2
Function warning light (Fig. 3) switches on:
D bringing the ignition switch to MAR (RUN)
for three seconds (test);
D in fixed mode until the retarder performs its
braking action;
D flashing if there is a system fault.
272BNU065
272GNU104
1-190 HHD9 Euro3
1 ENGINE BRAKE AND INTARDER CON-

TROL SELECTION (vehicles fitted with
intarder)
part of the lever (Fig. 1) and (Fig. 1), which
has seven positions (from 0 to 7), correspon-
ding to progressively higher levels of braking
(as shown in table, Fig. 2).
272BNU066 For the same lever positions, maximum

engine braking effect is achieved by
engaging lower gears, since braking is
2 proportional to engine revs.
Engine brake engagement disables all
cruise control operations
Whatever the setting, the function is auto-
matically disabled as soon as the acceler-
ator pedal is pressed.
228NUR53
HHD9 Euro3 1-191
1 To enable the device:

D not press the switch (Fig. 1, item 0);
D rotate the terminal part of the lever (Fig. 2)
to the required braking position.
To disable the device:
D return the end part of the lever to position
0.
284CNU014L
Vehicles with automated gearbox (in
automatic mode): with the lever in posi-
tion 6, the transmission automatically
shifts to the lower gear whenever this is
2 needed to ensure maximum efficiency of
the exhaust brake.
Continuous use of the retarder increases the

temperature of the oil and the coolant.
Proceed as follows to avoid overheating:
D position 1-2-3: undetermined intarder on
time;
272BNU066 D position 4-5-6: maximum intarder on time
2 minutes.
The braking effect is gradually reduced so as
to prevent exceeding the maximum allowed
temperature of the coolant.
1-192 HHD9 Euro3
1 Function warning light (Fig. 1) switches on:

D bringing the ignition switch to MAR (RUN)
for three seconds (test);
D in fixed mode until the retarder performs its
braking action;
D flashing if there is a system fault.
272GNU105
HHD9 Euro3 1-193
1 VEHICLE PARKING
B Parking brake --- vehicles without trailer
The parking brake (Fig. 1) has two positions:
D position A: engaged, vehicle braked;
D position B: disengaged, vehicle NOT
braked.
A To engage the parking brake bring the lever
to position A.
To disengage the parking brake raise the col-
lar and bring the control lever to position B.
Never use the parking brake (unless in an

emergency) when the vehicle is running.
The parking brake must be engaged in

the following situations:
D temporary or prolonged parking of the
vehicle;
D when loaading/unloading the vehicle.
1-194 HHD9 Euro3
1 Parking brake --- vehicle with trailer

B The parking brake (Fig. 1) has two positions:
D position A: engaged, vehicle braked;
D position B: disengaged, vehicle NOT
braked.
To engage the parking brake bring the lever
A to position A.
To disengage the parking brake raise the col-
lar and bring the control lever to position B.
Never use the parking brake (unless in an

2 emergency) when the vehicle is running.
The parking brake must be engaged in
the following situations:
D temporary or prolonged parking of the
vehicle;
D when loaading/unloading the vehicle.
Parking brake efficiency check

Proceed as follows:
D bring the vehicle (tractor + trailer) on an
appropriate slope;
D set the lever in position A (Fig. 1);
D press and push (Fig. 2) the lever keeping
it in position: the vehicle must not move.
In this position the trailer parking brake is

excluded.
Any movement of the vehicle indicates an
insufficiency of the TRACTOR parking
brake.
When released, the lever returns to position A.

HHD9 Euro3 1-195
1 Additional parking brake

The additional parking brake (Fig. 1) has two
positions:
D position 0: off;
D position 1: on.
To engage the additional parking brake, turn

the knob to position 1 and wait for 5 to 6 sec-
onds.
The additional parking brake is of the

non-proportional type and can be en-
gaged only after engaging the parking
brake.
Since it is pneumatically operated, it must
be used only with running engine and for
short periods of time.
1-196 HHD9 Euro3
1 A.B.S. ANTI-LOCK BRAKING SYSTEM

The A.B.S. system provides optimal braking
and perfect vehicle control in all conditions.
in particular:
D it prevents wheel locking while braking in
any road conditions;
D it reduces stopping distance;
D increases safety for the driver who can
maintain vehicle stability and direction.
Functioning check or any faults on the ABS
system are indicated with the ignition key on
“MAR”.
2
1. Tractor ABS (yellow) (Fig. 1); also the
generic warning light switches on. This
indicates a fault on the tractor ABS
system.
2. Trailer ABS (yellow) (Fig. 2); also the
generic warning light switches on.
This indicates a fault on the trailer ABS
system.
When there is an A.B.S. circuit fault. the

vehicle braking related to that circuit
takes place in normal mode. In any case
it is necessary to go as soon as possible
to the nearest After Sales dealership .
HHD9 Euro3 1-197
1 SEMI-TRAILER COUPLING
Coupling
Proceed as follows to open the fifth wheel:
D raise the safety lever (Fig. 1, ref. 1);
D move the bolt (Fig. 2, ref. 2) forwards to
release the first stop notch (Fig. 3, see
arrow);
D pull the bolt fully to the second stop notch
JSK38-50_03 (see arrow).
Proceed as follows to couple the semi-trailer:
D immobilise the semi-trailer;
2
The semi-trailer skid plate should be
approx. 5 cm lower than the top of the fifth
wheel.
D reverse the tractor so that it is in line with

the semi-trailer, the locking mechanism
functions automatically;
D drive the tractor forwards to check that the
JSK38-50_05
semi-trailer is hooked-up correctly;
D check the closure as shown below;
3 D lift the supporting legs;
D connect the electric and pneumatic con-
nections.
309FNU005L
1-198 HHD9 Euro3
1 Check closure
D check that the safety lever (Fig. 1, ref. 1) is
in the lower position;
D the back plate must uniformly rest on the
fifth wheel (see arrow).
Uncoupling
Proceed as follows:
D immobilise the vehicle;
D lower the supporting legs;
D disconnect the pneumatic and electric
connections;
D open the fifth wheel as described above;
D move the tractor forwards.
When the coupling pin is released the

locking mechanism will automatically
rearmed and the fifth wheel will be in
coupling position.
309FNU006L
ABS coupling (if foreseen)

1 2 When using a tractor without a semi-trailer,
particular attention should be paid to recon-
necting the ABS coupling in its seating. After
inserting it, press hard on the bracket (Fig. 2)
until it locks into position. If this is not carried
out water may get into the system causing
corrosion and malfunctioning of the device.
178NU85
HHD9 Euro3 1-199
1 Pivoting fifth wheel
Crosswise pivoting movements may be

enabled for off-road use only.
Crosswise pivoting must be blocked for
safety reasons when travelling at high
speed on roads.
How to enable crosswise pivoting

307FNU007AL D Loosen the hexagonal head screws (Fig.
1, ref. 1) on each side.
D Extract the two lock teeth (Fig. 1, ref. 2) to
2 reach end of travel in the slot (see arrow).
D Fasten the hexagonal head screws again
(Fig. 1, ref. 1) at a tightening torque of 80
Nm.
How to lock crosswise pivoting
D Loosen the hexagonal head screws (Fig.
2, ref. 1) on each side.
D Insert the two lock teeth (Fig. 2, ref. 2) to
307FNU007BL reach end of travel in the slot (see arrow).
D Fasten the hexagonal head screws again
(Fig. 2, ref. 1) at a tightening torque of 80
Nm.
1-200 HHD9 Euro3
1 TRAILER HOOKING --- I type

Proceed as follows:
D ensure that the chocks are positioned
under the rear wheels;
D the front axle can still be moved;
D adjust the height of the trailer draw bar to
that of the pintle hook;
D lift the lever (Fig. 1, see arrow);
307HNU002L D hook the trailer to hook (Fig. 1, ref. 1);
D reverse the tractor and insert the trailer
eyebolt in the bell-shaped head: the lever
2 will snap down;
D check coupling by checking that the lever
is down (Fig. 2, see arrow) and the safety
pins are retracted (detail).
307HNU003L
HHD9 Euro3 1-201
1 TRAILER HOOKING --- II type

Proceed as follows:
D secure the trailer with chocks under the
rear wheels, so that the front axle can be
manoeuvred;
D adjust the height of the trailer draw bar to
that of the pintle hook;
D pull the lever outwards (Fig. 1, ref. 2) and
at the same time raise the lever (Fig. 1, ref.
3) so as to lower the hook (Fig. 1, ref. 1);
D connect the trailer to the hook (Fig. 2, ref.
1) checking that the safety lever (Fig. 2, ref.
2 2) has entered into its housing.
1-202 HHD9 Euro3
1 NORMS FOR TOWING TRAILER / SEMI-

TRAILER
Before hitching-up
Before reversing with the tractor, make sure
no people are standing in the immediate
area
After hitching-up
228NUR61
Engage the parking brake.
Check that the coupling has been made cor-
rectly.
Connect the air lines and electrical cables.
Check the brakes and lights.
Check correct function of the safety device.
When driving
Proceed with care while towing a trailer/
semi-trailer. Never exceed the maximum
admissible weight.
In case of stops on hill, check that the park-
ing brake functions correctly. It must be
capable of holding the vehicle stopped.
HHD9 Euro3 1-203
1 TRAILER COUPLING
4 3
Pneumatic coupling (Fig. 1)
1. Automatic (red)
2. Adjustable (yellow)
Electric coupling (Fig. 1)

3. 15 pin coupling (ISO 12098)
2 1 4. ABS
228NUR60
SEMI-TRAILER COUPLING
2
Pneumatic coupling (Fig. 2)
1. Automatic (red)
2. Adjustable (yellow)
Electric coupling (Fig. 2)

3. 15 pin coupling (ISO 12098)
4. ABS
272NU107X
LADDER
3 Use the specific ladder (Fig. 3, ref. 1) to
access the electric and pneumatic connec-
tions of the tractor.
Keep the steps clean at all times to avoid

slipping.
1 272NU108X
1-204 HHD9 Euro3
1 TOWING THE VEHICLE

The towing of the vehicle is to be carried out
using the specific hook for this purpose (see
arrow).
Proceed as follows:
D free the split pin and withdraw the locking
pin;
D insert the end of the towbar into the seat;
228NUR72 D insert the locking pin and fasten it with the
cotter pin.
If present, remove the protection hood

before starting towing operations.
Always use a suitably anchored rigid bar.

Do not use cables or chains.
Insert the key into the ignition switch to
release the steering lock.
The towing vehicle must have:
D a total weight comparable to that of the
vehicle being towed;
D traction power sufficient to tow the
convoy up the hills along the way;
D braking power sufficient to slow the
convoy down the hills along the way.
HHD9 Euro3 1-205
1 Operating instructions
Proceed as follows:
D release the parking brake spring cylinders
operating as described in the relevant sec-
tion.
If there is suspicion of internal transmis-
sion failures, or when driving long dis-
tances, it is necessary to remove the pro-
peller shaft.
228NUR61
Manual transmission vehicles
D Check that the gears high range is inserted
(5th --- 8th ratio).
D Bring the lever to idle position.
D Start towing keeping MAXIMUM SPEED at
40 KM/H.
It is advised not to exceed a maximum
distance of 200 km.
Automated transmission vehicles
D Insert the gears high range proceeding as
follows:
--- check the gear pneumatic and electrical
supply;
--- move the ignition switch to position 1;
--- check there are no error messages on the
display.
D Select Neutral position.
D Start towing, maintaining a MAXIMUM
SPEED of 25 km/h for a MAXIMUM DIS-
TANCE of 100 km.
Vehicles with automatic Allison transmission
Remove the propeller shaft.

1-206 HHD9 Euro3
1 Propeller shaft removal

To remove (Fig. 1, version 6x4) proceed as
follows:
D for the moment, fasten the shaft to the
chassis;
D make a reference mark on the coupling
flange to be able to refit in the same posi-
tion;
357ANU110L
D unscrew the fastening bolts and place
them in the cab;
D retract the end of the shaft and secure it to
the chassis so as to avoid interference with
the axle flange and other moving parts.
Flanges to be removed to avoid dragging of
the transmission (splitter unit and gearbox)
(Fig. next page).
To lift the front of the vehicle, remove the

rear flange.
A. 2-axle vehicles
B. 3-axle vehicles
If the steering does not have hydraulic

servo control (engine off) much more
force is required on the steering wheel.
C. 4 axle vehicles
If the steering does not have hydraulic

servo control (engine off), steering is
almost impossible. In this case the front
of the vehicle has to be lifted.
HHD9 Euro3 1-207
Fig. 1 - Flanges to be removed
357ANU113L
1-208 HHD9 Euro3
1 Spring cylinder emergency braking

device
In the event that compressed air does not
reach the parking brake circuit, the vehicle is
automatically braked by the spring cylin-
ders.
To enable the vehicle to be towed, the brake
must be released with the mechanical re-
lease device.
Mechanical disengagement
To do this, proceed as follows OPERATING
ON BOTH CYLINDERS:
D place chocks under the wheels;
D engage the hand brake;
D turn the central screw located on the rear
part of the cylinder (Fig. 1) anticlockwise
from position 1 to position 2.
238NU56 After intervention of the emergency

release device, the vehicle must only be
towed and must under no circumstances
circulate autonomously.
Before using the vehicle normally again,
return both the spring cylinders to posi-
tion 1.
HHD9 Euro3 1-209
1 Compressed air discharged

If the vehicle has not been used for a long
period and the comprssed air system is dis-
charged, it can be re-charged from an exter-
nal source through the connector (Fig. 1, see
arrow).
This operation also releases the spring cylin-
ders.
228NUR62
1-210 HHD9 Euro3
1 WHEEL CHANGE
Jacking up the vehicle
To use the jack:
D remove the cab jack (Fig. 1, ref. 1) from its
housing behind the passenger seat by
loosening the retainer screw (Fig. 1, ref. 2)
from the bracket;
D take the rod supplied;
D check, that the hydraulic valve (Fig. 2,
285ANU038L ref. 1) of the jack is rotated clockwise
(hydraulic circuit under pressure);
D position the jack at the raising points
2 specified in the following page;
D insert the rod into the bush (Fig. 3, ref. 2)
and work the pump until lifting the wheel;
D after replacement, SLOWLY turn the jack
control hydraulic valve anticlockwise;
D remove the jack and press the top part of
1 2 jack cylinder with your foot to fit it back into
seat.
Strictly comply with instructions indi-
178NU91 cated on the label attached to the jack to
use it correctly.
The wheels should be changed when the
vehicle is on level ground and unloaded
with the hand brake engaged and chocks
placed against the wheels which remain
on the ground.
HHD9 Euro3 1-211
1 4 Changing a wheel
To change a wheel:
D use the wheel brace provided to loosen
the wheel bolts on the wheel to be
changed;
D raise the vehicle until the wheel is off the
ground and set the jack at the following
points:
Figure 1: axle;
272NU006MY 272NU008MY Figure 2: front axle;
Figure 3: intermediate axle;
Figure 4: rear axle.
2
272NU007MY
272NU008MY
1-212 HHD9 Euro3
1 The vehicle may be provided with

spacers in some cases:
D between rim and hub (Fig. 1);
D between rim and fastening nuts (Fig. 2).
Take note of the position if the spacer is

removed to refit it correctly.
Do not eliminate the spacer.
309FNU008L
HHD9 Euro3 1-213
1 D unlock the fastening nuts completely and

remove them, then withdraw the wheel,
taking care not to damage the stud bolt
threads;
D clean the threads of the screws and the
nuts and the rim and hub stops;
D fit the spare wheel or the repaired wheel;
D fasten the nuts slightly until the wheel is
correctly coupled to the hub;
272NU010MY
D lower the vehicle;
D tighten the wheel fastening nuts to the
specified torque (see TECHNICAL DATA
section) in the order indicated (Fig. 1).
Putting the weight of the body (approx 70

daN) on the end of the lever supplied,
obtain a torque that is approximately
equal to the specified value.
Check the torque of the wheel fastening

nuts after travelling about 20-40 km and
then again after travelling 100 km.
Do NOT lubricate the contact zones
between nut and rim.
A torque that is too tight could cause
damage: therefore do not use pipes or
extensions that have not been specifi-
cally supplied
Do not use wheels and fastening devices
different to the originals.
1-214 HHD9 Euro3
1 Handling the spare wheel

Replacing a front or rear wheel with a spare
does not create problems even if the profile
of the thread is different.
A tyre with the same profile should however
be reintegrated as soon as possible.
To remove the wheel proceed as follows:
D unscrew the nuts (Fig. 1, ref. 1) fastening
the wheel to the support bracket;
178NU96
D free the handle (Fig. 1, ref. 2) and take it in
job position;
D turn the crank until sufficiently lowered to
remove the wheel.
To replace the wheel, reverse the above pro-
cedure.
HHD9 Euro3 1-215
1 DIAGNOSTICS
The odometer display shows errors present
in the vehicle control system memory.
The warning light related to the concerned
system will appear to indicate that errors are
present. The control systems are indicated
by four letters (Fig. 1, see table).
Proceed as follows if one or more warning
lights come on (see table, Fig. 1):
D Turn the ignition switch to MAR;
D Hold the button pressed for at least 5 se-
conds (Fig. 2, ref. 1). The error situation
2 when the request was made will appear on
the display (Fig. 2, detail).
a error sequential number
b total number of errors present
c error code
d ECU type (Fig. 1, see table).
The errors present at the time of the re-

quest are displayed. The displayed error
list is not refreshed. Each error is di-
splayed for 5 seconds: the display goes
back to the basic function after the last er-
ror.
307ANU100L
1-216 HHD9 Euro3
1 DIAGNOSTICS --- CONNECTIONS FOR

CONTROL SYSTEMS
Use of jack
1 30---pole connector
For connection with the specific IVECO diag-
nostics tool.
There are the following diagnostics systems:
D ECM (engine control unit);
357ANU240L D ABS (brakes/traction control unit);
D UDS (AdBlue additive dosing unit);
D VCM (vehicle control unit);
2 D IBC (body computer control unit);
D ETC (automated transmission control
unit);
D EST (intarder control unit).
2 ALLISON connector
For connection with the specific Allison auto-
matic transmission diagnostics tool.
356ANU102L
HHD9 Euro3 1-217
Maintenance Instructions
1-218 HHD9 Euro3

HHD9 Euro3 1-219
INTRODUCTION
Properly dispose of replaced material (brake pads, filters, etc.) and materials resulting from maintenance operations and
repairs (material soaked in fuel, oil, powder, etc.) according to the laws in force, diversified from normal waste.
Collect and dispose of used lubricants and fluids, according to the laws in force.
Collect and dispose of used batteries according to the laws in force.
Drain and recharge the air conditioning system using the specific devices, according to the laws in force.
All level checks must be carried out with vehicle parked on flat and handbrake engaged.
Wait a few minutes for the level to stabilise before checking.
Observe scrupulous cleanness of oil and fluid containers when refilling.
Before injecting grease, or checking levels, carefully clean the pressure fittings and the areas around the level and filling
caps.
Use oil and fluid of the same type used before in the various assemblies when topping up.
Never tamper with valves, regulators or other devices, unless specified in the handbook, to prevent damage to vehicle
components and consequent hazards for persons.
Technical information on maintenance (intervals, type and number) is given in TABLES AND DIAGRAMS.
1-220 HHD9 Euro3
1 OPENING RADIATOR GRILL

To open the radiator grill, lift it (Fig. 1, see
arrow): two gas springs hold it open.
To close the radiator grill, lower it until flush.
342BNM001L
HHD9 Euro3 1-221
1 TILTING THE CAB

The vehicle’s cab can be tilted forward via a
hydraulic cylinder driven by the oil pressure
supplied by a manually operated pump.
Always apply the parking brake and set
the shift lever to neutral before starting
any job.
Before tipping open the front grill to pre-
272NM001MY vent damage.
Lifting the cab

2
Proceed as follows:
D take the rod supplied;
D using the lever (Fig. 1, ref. 1) turn the pawl
to the circuit pressure position (to right);
D insert the lever into the seat provided
(Fig. 2, ref. 1) and pump until the cabin is
fully tipped.
272NM002MY Never leave the cab in a partially tilted

position. Never work under a partially
tilted cab. Do not stand in front or behind
the cab when it is being tilted.
Keep the front grill fully open throughout

the operations.
If there is an anomaly affecting the

hydraulic system, the cab can be tilted
with mechanical means (e.g. with a
crane).
1-222 HHD9 Euro3
1 Lowering the cab

Proceed as follows:
D using lever (Fig. 1, ref. 1) turn the pawl
(Fig. 1, ref. 2) to the circuit decompression
position (to the left);
D insert the lever provided into the appropri-
ate seating (Fig. 2, ref.1) and down until
the cab has been tilted;
D check that the cab is fully lowered and
272NM003MY
warning light and cluster (Fig. 3) is off.
Tipping can be interrupted by turning the

2 pawl (Fig. 1 ref. 2).
Leave the pawl (Fig. 1, ref. 2) in decom-
pression position until the next tipping
operation.
272NM002MY
272GNM001
HHD9 Euro3 1-223

1-224 HHD9 Euro3
1 MAIN LEVELS CHECK
All the fluids indicated have a level sen-

sor.
However it is a good rule to periodically
check the levels visually, also to ensure
the correct functioning of the sensor.
Check engine oil level

342BNM002L
Proceed as follows:
D open the cowl;
D with the engine off and cold, remove the oil
2 dipstick (Fig. 1, see arrow) and check that
the level is included between the refer-
ences on the dipstick (Fig. 2). Reposition
the dipstick;
If the engine is warm, stop the engine and

wait for 10 minutes for the oil to drain into
the sump.
Do not use the vehicle if the oil level is
156NM11 either under or over the limits. Lack of
lubricant or excessive lubricant can dam-
age the engine.
D if required, top up using oil of the same

type contained in the oil sump.
HHD9 Euro3 1-225
1 Check engine coolant level

Proceed as follows:
D open the cowl;
D with engine cold check that the liquid level
is at a distance of 1-2 (cm) from the cap
(Fig. 1, see arrow);
D top up using fluid of the same type con-
tained in the reservoir, if required;
342BNM003L Check windshield washer level
Proceed as follows:
D open the cowl;
2 D check that the liquid level is at a distance
of 2-3 (cm) from the cap (Fig. 2, see arrow);
D if necessary top up the level, using an
appropriate mixture of water and deter-
gent.
342BNM004L
1-226 HHD9 Euro3
1 ENGINE
Changing engine oil
Proceed as follows:
D stop the warm engine and wait for the cool-
ant temperature to drop to 60 ˚C;
D tilt the cab;
D arrange a suitable sized container and re-
move the dipstick;
178NM10
D clean the cap area, loosen the drain cap
(Fig. 1) and drain all the oil for the time re-
quired;
D clean the drain plug, check that the thread
is in good condition, replace the O-ring
and close it;
HHD9 Euro3 1-227
1 D clean the filler area and pour in the specific

amount of lubricant through the filler
D close the filler and arrange the dipstick in
the housing;
D start the engine and warm it up. Stop the
engine and wait for a few minutes;
D remove the oil dipstick and check that the
level is included between references on
178NM11 the dipstick (Fig. 2);
D top-up the level if necessary.
2 Do not use the vehicle if the oil level is

either under or over the limits.
Lack of lubricant or excessive lubricant
can damage the engine.
156NM11
1-228 HHD9 Euro3
1 Replacing engine oil filter F3B
Replace the oil filter at the frequency

shown. If the filter is clogged up, the
bypass valve will permit lubrication of the
engine, but the circulating lubricant will
not be filtered.
Proceed as follows:
178NM12 D stop the warm engine and wait for the cool-
ant temperature to drop to 60 ˚C;
D loosen the filtering cartridge (Fig. 1, see
2 arrow) using the specific tool and accu-
rately clean the housing;
D fasten the cartridge by hand until the seal
comes into contact with the housing, then
turn by another 3/4 of a turn (Fig. 2).
Do not fasten the cartridge excessively.

This could damage the seal. Observe the
specifications provided by the supplier.
178NM13
D start the engine for a few minutes and
check for leakage of lubricant;
D check engine oil level and top up, if
required.
HHD9 Euro3 1-229
1 Engine oil vapour filter change

Proceed as follows:
D loosen the screws of the cover (Fig. 1) and
remove it;
D remove the filter (Fig. 2, ref. 1);
When refitting, position the filter with the

support brackets (Fig. 2, see arrow)
pointing toward the cover.
228NM221
D replace the cover;

D check that the breather pipe (Fig. 3, see
1 2 arrow) is not kinked or bent.
228NM222
228NM223
1-230 HHD9 Euro3
1 Accessory drive belts check

The engine has two accessory drive belts
(Fig. 1):
1. alternator/fan/water pump drive belt
2. climate control compressor drive belt
(only clima-version).
Each belt has an automatic take-up device
and does not require adjustment.
Proceed as follows:
D tilt the cab;
D when the engine is cold, check that the belt
(Fig. 2) is not frayed or cracked (small
crosswise cracks are allowed);
178NM14 D otherwise replace the belt;
This operation must be carried out by

2 adequately trained personnel. For further
information contact your Dealer.
D press with the hand on the longer branch

to check the take-up device is functioning
properly.
178NM05
HHD9 Euro3 1-231
1 Intake-exhaust valve play adjustment

(Fig. 1)
adequately trained personnel. For further
Play is adjusted by means of the screw with

lock nut, at the head of each rocker.
178NM18 Injector-pump pre-load adjustment
(Fig. 2)
2 This operation must be carried out by

Adjust the pre-load by means of the screw

with lock nut on the head of each rocker arm
(contact the dealership for further informa-
tion).
VGT actuator grease application pro-
178NM19 cedure
Proceed as follows:
D tilt the cab;
3 D clean the concerned fitting (Fig. 3, see
arrow);
D inject grease of the specified type in the fit-
ting.
Inject lubricant until it pours out of the

lubricated points to ensure efficient
lubrication.
Use a manual grease dispenser only.
284CNM001L
Never use a high pressure grease dis-
penser.
1-232 HHD9 Euro3
1 FUEL FEED SYSTEM

Bleed fuel tank condensation water
Proceed as follows:
D loosen the drain cap (Fig. 1, see arrow)
and let a little fuel out to drain the residues
and condense which normally is formed in
the tank.
272CNU099
Keep the fuel tank as full as possible. Use
fuels of the specified types supplied by
petroleum companies. Do not use other
than specified fuels.
Use of other than specified fuels can
cause severe engine damage.
HHD9 Euro3 1-233
1 Fuel tank water drain

Proceed as follows:
D with engine off disconnect the electric
connector (Fig. 1, ref. 1);
D loosen the filter ring a few turns (Fig. 1, ref.
2) and drain the fuel;
D tighten the ring nut without excessive tor-
que when water-free fuel flows out;
357ANM100L D connect the electric connector.
This operation must be carried out if the

fuel filter water warning light comes on
2 (Fig. 2).
Purging water from fuel decanter

Proceed as follows:
D fasten on end of a rubber pipe to the con-
nector (Fig. 3, ref. 1);
D insert the other end of the pipe into a con-
tainer;
272NU007MY
D loosen the vent screw (Fig. 3, ref. 3);
D open the valve (Fig. 3, ref. 2) and drain off
the water and any impurities trapped in the
3 decanter;
D close the valve and remove the pipe.
285ANM002L
1-234 HHD9 Euro3
1 Replacing fuel filters

The vehicle has two groups of fuel filtration:
D fuel prefilter (on chassis; Fig. 1, see arrow);
D fuel filter (on engine; Fig. 2, see arrow).
Proceed as follows:
D with engine off disconnect the electric
connector (Fig. 1, ref. 1);
D with the engine stopped, loosen the filter-
357ANM101L ing cartridge using the specific tool and
carefully clean housing and engine;
2 Do not fill the new filter with fuel to pre-

vent foreign matter entering the injection
system.
D hand-tighten the cartridge until the seal

comes into contact with the support, then
tighten it by ¾ of a turn;

206NM08
D connect the electric connector (Fig. 1, ref.

1);
D bleed the air from the fuel circuit as
indicated in the following pages;
D start the engine for a few minutes and
check for leakage of lubricant.
HHD9 Euro3 1-235
1 Replacing fuel decanter filter

Proceed as follows to replace the fuel sepa-
rator filter cartridge:
D Stop the engine.
D Close the on-off valve (if present).
1 D Loosen the securing screws and remove
2 the cover (Fig. 1, ref. 1).
D Remove the spring (Fig. 1, ref. 2).
D Remove the cartridge (Fig. 1, ref. 3) and re-
3 place it.
D Refit the spring.
D Refit the lid and check that the seal is intact
and correctly positioned: replace it re-
quired.
D Open the on-off valve (if present).
D Start the engine and check for leakage.
Bleed the feed system, if required.
285ANM003L
1-236 HHD9 Euro3
1 Fuel circuit bleeding

Proceed as follows:
D tip the cabin;
D fit suitable pipes to the bleed nipples and
lead them to a container;
D loosen the bleed nipples by a few turns.
Prefilter
D Pump the priming pump (Fig. 1, see
272NM006MY
arrow) until fuel flows out from the nipple
(Fig. 1, ref. 1) without air bubbles, then
tighten the nipple.
1 2
Filter
D Repeat the operation for this nipple (Fig. 2,
ref. 1);
Cylinder head bleed nipple
D Remove the soundproofed cover;
D Repeat the operation for this nipple (Fig. 3,
ref. 1).
206NM03
Absolutely avoid smearing fuel on the
accessory drive belts to prevent damage.
3
Use suitable receptacles to prevent fuel
leakage into the environment.
1
178NM119
HHD9 Euro3 1-237

1-238 HHD9 Euro3
1 INTAKE SYSTEM
Intake system seal check
Proceed as follows:
D tip the cabin;
D check the intake system seals and con-
nectors (Fig. 1, see arrow).
Turbocompressor lubrication check
Proceed as follows:
D tip the cabin;
D inspect the delivery pipes (Fig. 2, ref. 1)
and return pipes (Fig. 2, ref. 2) to check
absence of leaks or faults that could cause
decreased oil flow to the turbo.
Given the high turbocompressor operat-

ing speed, any reduction in oil supply will
result in damage.
Intercooler external cleaning

272NM007MY Clean the radiator using compressed air to
remove accumulated debris (leaves,
insects).
2 To remove hardened debris, brush the radi-
ator with a water/detergent solution then use
steam to remove any residue.
1
269NM193
HHD9 Euro3 1-239
1 Main filter element cleaning/change
Clean the main filter element at most 6

times, after which it must be changed.
Proceed as follows:
D release the retainer springs (Fig. 1, see
arrow) and remove and thoroughly clean
the cover;
174NM26 D extract the primary cartridge (Fig. 2, see
arrow);
D dust removal using compressed air at
2 maximum 3 bar pressure, blowing air from
inside filter element outwards (Fig. 3);
Keep the air jet at a few centimeters from

the filter pack to prevent damage.
Never clean the filter by beating on a hard
surface.
D thoroughly clean the inside of the filter box

174NM27A with a vacuum cleaner.
Take care not to allow the dust enter the

intake hose.
3 Do not start the engine without the air
filter.
156NM52
1-240 HHD9 Euro3
1 Carry out the following checks before refit-

ting the filtering element:
D check conditions of O-rings and plastic
tabs. Replace the filtering element, if
required;
D check integrity of filtering element by plac-
ing a source of light inside (Fig. 1); light will
filter from even the smallest cracks, indi-
cating that the filter must be replaced;
156NM53
Make sure the temperature does not
exceed 60˚C if a light source outputting
heat (e.g. a lamp bulb) is used.
2
D clean the rubber drain valve, check integ-
rity and replace it if required.
Safety secondary filter element replace-
ment
Proceed as follows:
D remove the main filter;
174NM29A D remove the element (Fig. 2, see arrow).
The secondary element cannot be

cleaned. It can only be replaced.
HHD9 Euro3 1-241
1 Replacing the VGT piloting hoses filtering

element
Proceed as follows:
D with a cold engine, loosen the filtering car-
tridge (see arrow) using the specific tool
and accurately clean housing and engine;
D fasten the cartridge by hand until the seal
comes into contact with the housing, then
turn by another 3/4th of a turn.
178NM88
1-242 HHD9 Euro3
1 COOLING SYSTEM
Never remove the cap (Fig. 1, ref. 1) when

coolant is hot to avoid:
D scalding;
D damage to the engine, in that the sys-
tem comes under pressure only with cool-
ant heating from engine cold.
Always top up the system with engine off
342BNM007L and cold.
HHD9 Euro3 1-243
1 Replacing engine coolant
The system pressure regulator valve (Fig.

1, ref. 2) is sealed and must not be
removed for any reason.
Proceed as follows:
D turn the cab heater cock to maximum heat;
D position a container with adequate capac-
342BNM007L ity then remove the cap (Fig. 1, ref. 1) on
the expansion chamber (Fig. 1, ref. 2);
D disconnect the radiator hose (Fig. 2, see
2 arrow), then wait for coolant to fully drain
off;
D refit the hose;
D pour the coolant very slowly into the
expansion tank until full;
D start the engine and run it slightly faster
than idle speed for about 5 minutes;
D stop the engine and top-up expansion
chamber coolant level;
D start the engine, warm it up and allow it to
run until the coolant in the chamber does
not produce air bubbles;
D check that the system pressure regulator
228NMR01 valve opens at the specified pressure
value: otherwise replace it.
1-244 HHD9 Euro3
1 Checking antifreeze concentration

A 50-50 mixture of water and specific anti-
freeze is required to protect the system from
corrosion.
The minimum concentration of antifreeze
depends on the temperature where the
vehicle is in use (Fig. 1).
antifreeze
156NM61
water
Check the concentration of antifreeze in the

engine coolant.
Always respect the supplier’s mixing

specifications if particular additives are
used.
HHD9 Euro3 1-245
1 CLUTCH
Check clutch disengagement
Proceed as follows:
D run the engine at idle and depress the
clutch;
D after approx. 10/12 seconds, slowly
engage reverse gear. If the toothing
“grates” (grating noise of engagement of
342BNM008L front teeth) the clutch must be checked
and/or bled.
Oil level check
Proceed as follows:
D open the radiator grill;
D visually check that oil level (Fig. 1, see
arrow) is not below the minimum level;
D if necessary, top-up the level as shown in
the following paragraph.
The fluid is corrosive: always wear pro-

tective gloves.
Use only the specified type of fluid for

topping up.
The fluid will corrode any paintwork it
comes into contact with.
1-246 HHD9 Euro3
1 Changing the hydraulic fluid

Proceed as follows:
D prepare a suitable container, unscrew tank
cap (Fig. 1, see arrow) and unscrew drain
pipe (Fig. 2, ref. A), draining off oil com-
pletely;
D seal drain pipe and fill tank with oil to the
max. level;
D bleed out air from the system.
342BNM008L
Air bleeding
Proceed as follows:
2 D check whether reservoir is full;
D use a transparent tubing and insert one
end into the drain valve union (Fig. 2, ref.
B) and the other end into a clean container;
D press clutch pedal and keep it in position;
D open the drain valve a little to allow oil and
air bubbles to come out and close it after
a few seconds;
272NM004X D release clutch pedal completely;
D repeat operation until oil without air
bubbles comes out of the drain valve.
HHD9 Euro3 1-247
1 MULTIPOWER PTO
Oil level check
Proceed as follows:
D with the engine off remove the dipstick
(Fig. 1, ref. 1) and check that oil level is
between the notches on the dipstick, then
replace it;
285ANM001L the following paragraph.
1-248 HHD9 Euro3
1 Oil change
Proceed as follows:
D place a suitable container, clean the area
around the level plug and remove it (Fig. 1,
ref. 1);
D remove the drain plug (Fig. 2, ref. 1) fully
drain off the oil;
285ANM002L
and close it;
D fill with the required quantity of fluid as
shown on the cap (Fig. 1, ref. 1);
2 D clean the filler cap, check that the thread is
in good condition, replace the O-ring and
close it;
D test drive then check level again, removing
the screw (Fig. 2, ref. 2) waiting for oil to
stop draining then replacing the screw;
D top-up the level if necessary.
228NM226 Clean the filter on the intake pipe after the

first 25 hours of use, proceeding as fol-
lows:
D remove the filter unscrewing the
retaining cap (Fig. 2, ref. 3), clean it
with diesel oil and dry with com-
pressed air. If exhausted, replace it;
D check gaskets and replace them if
necessary.
HHD9 Euro3 1-249
1 ZF NMV 221 POWER TAKE OFF --- TYPE

I
Oil level check/change
The power take off uses the same oil as

the gearbox.
For further information regarding oil level
checks and oil replacement, see the
following pages.
228NMR32 For oil level check/oil change operations
refer to the instructions for the gearbox.
The quantity of oil required in addition to
2 that of the gearbox is circa 2 litres.
Oil filter change (Fig. 1)

2
Change the filter only after having
1 drained off oil.
3 Oil may leak during these operations.
Proceed as follows:
228NMR02
D position a suitable container then remove
the cover (Fig. 2, ref. 1);
D remove the filter (Fig. 2, ref. 2) and recover
the seal (Fig. 2, ref. 3);
D refit the filter following above instructions
in reverse order.
1-250 HHD9 Euro3
1 TRANSMISSION
Versions with power take-off NMV 221 ---

type I only.
Oil level check

Proceed as follows:
D clean the area around the cap and and
open the level cap (Fig. 1, ref. 1): oil should
228NM227
drip from the hole;
the following paragraph;
D close the level plug.
Check that the breather is perfectly clean
and functioning.
HHD9 Euro3 1-251
1 Oil change
Proceed as follows:
around the level plug and remove it (Fig. 1,
ref. 1);
D remove the drain plug (Fig. 2, ref. 1) fully
drain off the oil;
228NM227
and close it;
D fill with the specified oil until it flows from
the plug hole (Fig. 1, ref. 1);
2 D clean the level plug, check that the thread
and close it;
D carry out a test drive then re-check level at
plug (Fig. 1, ref. 1);
D if necessary, top-up with specified oil until
it flows from the hole, repeat the test drive
and check the level again.
228NM228
1-252 HHD9 Euro3
1 GEARBOX
Oil level check
If transmission is fitted with retarder, do

not use it just before stopping the vehicle.
The check is to be made with transmis-
sion cold (< 40 ˚C).
Proceed as follows:
342BNM009L D clean the area around the cap; then open
the level/filler cap (Fig. 1, ref. 1): oil should
drip from the hole;
D replace the cap.
HHD9 Euro3 1-253
1 Oil change
Version without retarder
Proceed as follows:
D clean the level/filler cap zone (Fig. 1, ref. 1)
then remove the cap;
D prepare an appropriate container and
remove the drain cap (Fig. 2, ref. 1) ;
D clean the drain cap, check that the thread-
342BMM009L ing is in good condition, replace the seal-
ing ring with a new one and close the drain
cap;
2 D fill with prescribed lubricant through the
level/filler cap (Fig. 1, ref. 1) until it over-
flows;
D clean the level/filler cap, check that the
thread is in good condition, replace the
o-ring and close the cap;
D run a road test, check the level through the
cap (Fig. 1, ref. 1);
D if required, top up oil of the specified type
342BMM011L until it spills out of the hole. Repeat the
road test and check the level again.
1-254 HHD9 Euro3
1 Version with retarder

Proceed as follows:
D clean the level cap zone (Fig. 1, ref. 1) then
remove the cap;
D prepare an appropriate container, remove
the drain caps (Fig. 2, ref. 1) and (Fig. 2,
ref. 2) emptying out all the lubricant;
D clean the drain caps, check that the
threading is in good condition, replace the
342BMM009L
o-ring with a new one and close the drain
caps;
D fill with prescribed lubricant through the
2 filler cap (Fig. 3, ref. 1) until it overflows
from the level cap (Fig. 1, ref. 1);
It is also possible to fill through the level

cap (Fig. 1, ref. 1) except in the case of a
first filling after an overhaul.
D clean the level and filler cap, check that the

357ANM102L o-ring and close the caps;
3 D if required, top up oil of the specified type
until it spills out of the hole. Repeat the
357ANM103L
HHD9 Euro3 1-255
1 Replacing the oil filter

Empty the oil before this oper-
ation.
During this operation further oil
may spill out.
Proceed as follows:
D prepare an appropriate container;
D unscrew the fastening screws (Fig. 1, ref.
1) and remove the cover (Fig. 1, ref. 2);
D remove the filter (Fig. 1, ref. 3) from the
cover;
When refitting, lubricate the
O-rings (Fig. 1, ref. 4) of the filter.
D refit the filter following the operations in

reverse.
357ANM104L
1-256 HHD9 Euro3
1 AUTOMATED TRANSMISSION
Checking oil level
If the transmission is equipped with

retarder do not use it prior to stopping the
vehicle.
The test is to be carried out with trans-
mission cold (< 40 ˚C).
357ANM105L
Proceed as follows:
D clean the area around the cap; then open
the level/filler cap (Fig. 1, ref. 1): oil should
drip from the hole;
D if necessary, top up the oil level as shown
in the following paragraph;
D close the cap.
HHD9 Euro3 1-257
1 Changing oil
Version without retarder
Proceed as follows:
D clean the level/filler cap zone (Fig. 1, ref. 1)
then remove the cap;
remove the drain caps (Fig. 1, ref. 2) and
(Fig. 2, ref. 1) emptying out all the lubric-
357ANM105L ant;
2 o-ring with a new one and close the drain
caps;
the level/filler cap (Fig. 1, ref. 1);
D clean the cap, check that the threading is
in good condition, replace the O-ring with
a new one and close the cap;
357ANM107L D if required, top up oil of the specified type
1-258 HHD9 Euro3
1 Version with retarder

Proceed as follows:
D clean the level cap zone (Fig. 1, ref. 1) then
remove the cap;
remove the drain caps (Fig. 1, ref. 1) and
(Fig. 2, ref. 1 and ref. 2) ;
357ANM106L
o-ring with a new one and close the drain
caps;
2 filler cap (Fig.3, ref. 1) until it spills out from
the level cap (Fig. 1, ref. 1);
It is also possible to fill through the level

cap (Fig. 1, ref. 1) except in the case of a
first filling after an overhaul.
D clean the level and filler cap, check that the

357ANM102L o-ring and close the caps;
3 D if required, top up oil of the specified type
357ANM103L
HHD9 Euro3 1-259

Empty the oil before this oper-
ation.
During this operation further oil
may spill out.
Proceed as follows:
D prepare an appropriate container;
D unscrew the fastening screws (Fig. 1, ref.
1) and remove the cover (Fig. 1, ref. 2);
D remove the filter (Fig. 1, ref. 3) from the
cover;
When refitting lubricate the
O-rings (Fig. 1, ref. 4) of the filter.
D refit the filter following the operations in

reverse.
357ANM104L
1-260 HHD9 Euro3
1 AUTOMATIC TRANSMISSION
Checking oil level
The correct oil level is essential for good

operation of the transmission. Insuffi-
cient oil can cause irregular operation
and damage the converter. Excessive oil
can cause the formation of foam and over-
heat the transmission.
Hot check (80-100 ˚C) on display

Proceed as follows:
D let the engine idle with the gearshift in Neu-
tral position for a few minutes;
D apply the parking brake;
D press the DIAGNOSTIC button (Fig. 1, ref.
1);
D carefully observe the display (Fig. 1, ref.
2): the information are shown on pages in
sequence, two characters at a time.
357ANM201L
HHD9 Euro3 1-261
1 The following cases may occur:

D Correct oil level: oL oK appears on the dis-
play
D Low oil level: oL Lo XX will appear on the
display, where xx is the missing amount of
oil expressed in quarters of a gallon
D High oil level: oL Hi XX will appear on the
display, where xx is the amount of oil in
excess expressed in quarters of a gallon
D Procedure error: oL --- xx will appear
where xx shows the error code
The errors are:
D oL --- --- 0X : insufficient waiting time
D oL --- --- EL : engine speed too low
D oL --- --- EH : engine speed too high
D oL --- --- SN : selector not in neutral
D oL --- --- TL : low oil temperature
D oL --- --- TH : high oil temperature
D oL --- --- SH : vehicle moving
357ANM201L D oL --- --- FL : faulty level sensor
1-262 HHD9 Euro3
1 Cold check (15-45 ˚C)

Proceed as follows:
D start the engine and let it idle with trans-
mission in Neutral for approximately one
minute; engage reverse once or twice and
then Drive to bleed the hydraulic circuit;
D clean the filler zone, then release the grip
by one or two turns and remove the dip-
stick inserted in the filler (Fig. 1), clean it
274NM0D1 and re-introduce it;
D remove the dipstick and check that the oil
level is comprised between the COLD
ADD and the COLD FULL notches;
D then top up or empty to the required level;
then reposition the dipstick and refasten
the grip;
D do a hot check as soon as possible.
HHD9 Euro3 1-263
1 Hot check (80-100 ˚C)

Proceed as follows:
D let the engine idle with the gearshift in Neu-
tral position;
D clean the filler zone, then release the grip
by one or two turns and remove the dip-
stick inserted in the filler (Fig. 1), clean it
and re-introduce it;
D remove the dipstick and check that the oil
274NM1B2
level is comprised between the HOT ADD
and the HOT FULL notches;
D top up or empty as required; then reposi-
2 tion the dipstick and fasten the grip;
Repeat the level check at least twice to

make sure that the value is correct: check
the correct operation of the breather if
this does not occur.
D check the breather (Fig. 2, see arrow)

which must be perfectly clean and func-
274NM1B3 tioning.
1-264 HHD9 Euro3
1 Changing the oil

Proceed as follows:
D take a suitably sized container, clean the
filler area, loosen the handle by two or
three turns and remove the dipstick;
D remove both drain cap (Fig. 1, arrow) and
drain all the oil;
D clean the drain cap, check that the thread-
ing is in good conditions and close;
274NM1C1
D pour in the specified amount of lubricant
through the filler and reposition the dip-
stick by screwing back the handle;
D check the level after a test run.
HHD9 Euro3 1-265

The filters may be replaced after draining
the lubricant oil.
Proceed as follows:
D arrange a container of appropriately
capacity, clean the area around the
flanges and then loosen the fasten screws
274NM1C2 (Fig. 1, ref. 1) and remove the flange (Fig.
1, ref. 2) and the seals (Fig. 1, ref. 3);
D remove the cartridge (Fig. 1, ref. 4);
Oil may leak out during these operations.
D insert the new cartridge in the housing, fit

the new seal and the corresponding flange
and then fasten the screws;
D fill will lubricant as described above;
D at the end, start the vehicle and check for
leakages of lubricant.
1-266 HHD9 Euro3
1 DISTRIBUTOR-TRANSFER (TRANSFER)
Checking oil level
Proceed as follows:
D Clean the area around the filler/level plug
then open it (Fig. 1, ref. 1): oil should arrive
at the edge of the hole;
D Top up with the specified lubricant, if
necessary, through the same hole;
D Close the plug;
D Check that the breather (Fig. 1, see arrow)
is perfectly clean and functional.
272CNU101
HHD9 Euro3 1-267
1 Changing oil
Proceed as follows:
D Place a suitably sized container, clean the
area around the plug then remove the level
D Remove the drain plug (Fig. 1, ref. 2) and
fully drain the oil;
D Clean the drain plug, check that the thread
is in good condition, replace the o-ring and
close it.
D Fill with the specified oil until it flows from
D Clean the level plug, check that the thread
is in good condition, replace the o-ring and
close it;
D Carry out a test drive then re-check level at
D If required, top up with oil of the specified
type, repeat the road test and check the
level again.
272CNU101
1-268 HHD9 Euro3
1 TRANSMISSION SHAFTS
Greasing
Proceed as follows:
D clean the joint concerned;
D Inject grease into the universal joint grease
nipples (Fig. 1, see arrow) each trans-
mission shaft has two or three greasing
points.
178NM46
Inject grease until it seeps from the
grease nipples to ensure efficient lubrica-
tion
A hand pump must be used for greasing,
and never a high pressure grease gun.
HHD9 Euro3 1-269
1 AXLES
Front axle
Check differential oil level
Proceed as follows:
D clean the area around the level plug and
1 remove it (Fig. 1, ref. 1): oil should drip
from the hole;
285BNM001L D if necessary, top-up the level as shown in
2 Check the breather which must be clean and
functioning.
Changing differential oil
Proceed as follows:
around the level plug (Fig. 1, ref. 1) and
remove it; (Fig. 1, ref. 1);
1 D remove the drain cap (Fig. 2, ref. 1) and
285BNM002L drain all the oil;
and close it;
D clean the level plug, check that the thread
and close it;
D carry out a test drive then re-check level at
1-270 HHD9 Euro3
1 Hub oil level check
This must be checked separately on both

hubs.
Proceed as follows:
D turn the plug (Fig. 1, ref. 1) such that the
reference mark is horizontal;
D clean the plug zone and open the plug
276NM019T (Fig. 1, ref. 1): oil should drip from the hole;
HHD9 Euro3 1-271
1 Hub oil change
This must be checked separately on both

hubs.
Proceed as follows:
D turn any of the screws (Fig. 1, ref. 2) in the
lowest position, until the cap is situated
aloft;
276NM019T D clean the area around the cap, then open
it (Fig. 1, ref. 1);
D place a suitably sized container, clean the
area around the level plug (Fig. 1, ref. 2)
and remove it fully draining off the oil;
D tighten the screw;
D position cap hole (Fig. 1, ref. 1) in horizon-
tal position;
D fill up with new oil until it overflows from
hole (Fig. 1, ref. 1);
and close it;
D repeat operation for the other hub;
D carry out a test drive, then re-check the
level at plug (Fig. 1, ref. 1);
1-272 HHD9 Euro3
1 Front intermediate axle

Checking oil level
Proceed as follows:
the cap (Fig. 1, ref. 1): oil should drip from
the hole;
D if necessary top ---up the level until it over-
flows from the cap;
341CNM001L D replace the filler cap.
Oil drainage
D prepare an adequate container, clean the
caps area then remove the level (Fig. 2, ref.
1) and filling caps (Fig. 2, ref. 2);
D remove the axle (Fig. 2, ref. 3) and splitter
unit drain caps (Fig. 2, ref. 4) emptying out
all the lubricant;
D clean the caps, check that the threading is
in good condition, replace the O ---ring with
341CNM002L a new one and close the drain caps;
HHD9 Euro3 1-273
1 Oil refill
Proceed as follows:
filler cap hole (Fig. 1, ref. 1) until lubricant
flows out from the axle filler cap hole (Fig.
1, ref. 2);
Fill slowly.
The operation is complete when the level
341CNM003L at hole level does not lower for some min-
utes.
D replace the o---ring and close the cap;

D run a road test, then check both levels (1);
D if required, top up with lubricant of the
specified type until it spills out of the hole.
Repeat the road test and check the levels
again.
1-274 HHD9 Euro3
1 Hub oil level check
The operation is to be carried out separ-

ately on both hubs.
Proceed as follows:
D position the cap (Fig. 1, ref. 1) so that the
reference marking is in horizontal position;
276NM019T the cap (Fig. 1, ref. 1): oil should drip from
the hole;
D if necessary, top up the oil level as shown
in the following paragraph;
D close the level cap.
HHD9 Euro3 1-275
1 Changing hub oil
The operation is to be carried out separ-

ately on both hubs.
Proceed as follows:
D bring one of the screws (Fig. 1, ref. 2) to the
lowest position , so that the cap (Fig. 1, ref.
1) is in high position;
276NM019T D clean the area around the cap; then open
the cap (Fig. 1, ref. 1);
D arrange a container of appropriate capac-
ity, clean the area around the screw (Fig. 1,
ref. 2) then remove it and drain off all the
lubricant;
D tighten the screw;
D position the cap (Fig. 1, ref. 1) so that the
reference marking is in horizontal position;
D fill with the specified lubricant until it flows
from the cap hole (Fig. 1, ref. 1);
D clean the cap, check that the threading is
in good condition, replace the o---ring with
a new one and close the cap;
D repeat the operation for the other hub;
D run a road test, check the cap level (Fig. 1,
ref. 1);
1-276 HHD9 Euro3
1 Rear intermediate axle
The splitter oil level is higher than the axle

oil level.
Consequently, the oil check/change pro-
cedures of the splitter must be carried out
in addition to the axle procedures.
Check axle oil level
276NM019T The oil level can be checked on the hubs
or the differential.
Top up if required from the differential.
2
Proceed as follows:
D take the reference on the hub to horizontal
position (Fig. 1, see arrow);
D clean the cap area and open the level cap
(Fig.1, ref. 1): lubricant should drip out of
1 the hole;
D close the cap.
285BNM003L or
(Fig.2, ref. 1): lubricant should drip out of
the hole;
D if required, top up through the same cap
until oil spills out;
D close the cap.
HHD9 Euro3 1-277
1 Check transfer oil level

Proceed as follows:
D clean the cap area and open the cap (Fig.
1, ref. 1): lubricant should drip out of the
hole;
D if required, top up through the same cap
until oil spills out;
D close the cap.
356DNM001L
1-278 HHD9 Euro3
1 Axle oil drain

Proceed as follows:
D Hubs: take the reference on the hub to
horizontal position (Fig. 1, see arrow);
D arrange a suitably sized container, clean
the cap areas and remove the level cap
(Fig. 1, ref. 1) and the drain cap (Fig. 1, ref.
2); drain all the lubricant;
D clean the caps; check that the threading is
276NM019T
in good condition, replace the o-ring and
close the drain cap;
D repeat the procedure on the other hub;
2 D Axle: arrange a container of appropriately
capacity, clean the area around the caps
and then remove the filler cap (Fig. 2, ref.
1);
D remove the drain cap (Fig. 3, ref.1) and
drain out all the oil;
1
285BNM003L close the drain cap.
285BNM004L
HHD9 Euro3 1-279
1 Transfer oil drain

Proceed as follows:
D arrange a container of appropriately
1);
D remove the drain cap (Fig. 1, ref. 2) and
307ANM002L
close the drain cap.
1-280 HHD9 Euro3
1 Axle oil filling

Proceed as follows:
D Hubs: fill until oil spills out the of the hole
on the hub level cap (Fig. 1, ref. 1);
D remove the o-ring and close the cap;
D Axle: fill until oil spills out the of the axle
filler hole (Fig. 2, ref. 1);
276NM019T
Fill slowly.
The operation ends when the level at the
hole does not decrease for several min-
2 utes.
285BNM003L
HHD9 Euro3 1-281
1 Transfer oil filling

Proceed as follows:
D fill until oil spills out the of the hole on the
splitter level cap (Fig. 1, ref. 1);
Fill slowly.
Specifically, avoid oil from pouring from
the transfer to the axle because the
splitter oil level is higher than the axle oil
356DNM001L level.
utes.
D remove the o---ring and close the cap;
D run a road test, then check both levels;
D if required, top up with lubricant of the
specified type until it spills out of the hole.
Repeat the road test and check the levels
again.
1-282 HHD9 Euro3
1 Rear axle
Checking oil level
The oil level can be checked on the hubs

or the differential.
Top up if required from the differential.
Proceed as follows:
D take the reference on the hub to horizontal
276NM019T position (Fig. 1, see arrow);
(Fig. 1, ref. 1): the lubricant must flow out
of the hole;
2
or
(Fig. 2, ref. 1): the lubricant must flow out
of the hole;
D top up the level as shown below, if
1 required;
D close the filler cap.
285BNM001L Check the breather (Fig. 1, see arrow) which
must be clean and functioning.
HHD9 Euro3 1-283
1 Draining oil
Proceed as follows:
D Hubs: take the reference on the hub to
horizontal position (Fig. 1, see arrow);
D arrange a suitably sized container, clean
the cap areas and remove the level cap
(Fig. 1, ref. 1) and the drain cap (Fig. 1, ref.
2); drain all the lubricant;
276NM019T
close the drain cap;
2 D Axle: arrange a container of appropriately
1);
D remove the drain cap (Fig. 3, ref.1) and
1
285BNM001L close the drain cap.
1
285BNM002L
1-284 HHD9 Euro3
1 Filling oil
Proceed as follows:
D Hubs: fill until oil spills out the of the hole
on the hub level cap (Fig. 1, ref. 1);
D Axle: fill until oil spills out the of the axle
filler hole (Fig. 2, ref. 1);
276NM019T
Fill slowly.
2 utes.

D check again the level after a test run;
1 until it spills out of the hole. Repeat the
285BNM001L
HHD9 Euro3 1-285

1-286 HHD9 Euro3
1 SUSPENSIONS
Leaf spring pins greasing
Fig. 1: Support pin
Fig. 2: Support plate
Proceed as follows:
D clean the relevant union;
D inject grease in the pressure unions of leaf
342BNM012L spring joints (see arrow).
To ensure efficient lubrication, inject

2 lubricant until it pours out of the lubri-
cated points.
penser.
342BNM013L
HHD9 Euro3 1-287
1 Carriage pin greasing on 3 and

4-axle vehicles
Proceed as follows:
D open the cover (Fig.1) remove grease and
fill the cover with prescribed lubricant ;
D clean union (Fig. 2, see arrow);
D inject grease in pressure union until it flows
out from the bearing (fig.3);
342BNM014L D close the cover.
To ensure efficient lubrication, inject

lubricant until it pours out of the lubri-
2 cated points.
penser.
342BNM015L
342BNM016L
1-288 HHD9 Euro3
1 STEERING SYSTEM
Oil level check
This check is optional, since there is an oil

level warning light.
The system has two inter-connected

228NM236 tanks. The following operations are to be
carried out on one tank only.
Proceed as follows:
2
D park the vehicle with the engine off and
wheels straight;
D clean the area around the plug, then
unscrew the plug and check that the reser-
voir oil level is between the two notches
(Fig. 2) on the dipstick;
D if necessary top-up the level and close the
plug.
228NM237
HHD9 Euro3 1-289
1 Changing the hydraulic oil

Proceed as follows:
Dumping
D raise the vehicle until the front wheels are
off the ground;
D prepare a suitable container, remove drain
plug (Fig. 1, see arrow) from the power
steering casing and remove the oil reser-
228NM238 voir cap;
D with engine off, turn the steering wheel
from lock to lock until the oil stops flowing
out;
D close the plug.
Filling
D fill completely reservoir with oil;
D with engine off, turn the steering wheel
from lock to lock topping up reservoir with
oil, at the same time, until oil level is stabi-
lised;
D start the engine to fill the system with oil:
since the level drops rapidly, continue
pouring oil into the tank while PREVENT-
ING AIR BEING DRAWN INTO THE SYS-
TEM;
D proceed until the level is steady.
1-290 HHD9 Euro3
1 Bleeding off air

D with the engine running at idle, turn the
steering wheel from lock to lock until the
residual air bubbles are eliminated;
During this operation the oil level should

be constantly checked. If the above
indications are followed strictly, oil
should not exceed the upper notch on the
228NM238 dipstick by more than 0.5 cm when the
engine is stopped, nor suddenly emul-
sify. This phenomenon would denote a
remarkable presence of air in the circuit
due to incorrect operations during the fill-
ing phase.
D run a road test of approx. 10 km, then top

up the level.
HHD9 Euro3 1-291
1 Replacing oil filter

Proceed as follows:
2 4 D loosen the retaining screws (Fig. 1, ref. 2);
D remove the cover (Fig. 1, ref. 3), gasket
(Fig. 1, ref. 4) and the spring (Fig. 1, ref. 5);
3 D replace the filter cartridge (Fig. 1, ref. 1);
D check the cover seal. If damaged, replace
it;
5 D replace the cover.
178NM60
1-292 HHD9 Euro3
1 Stub axle greasing

Proceed as follows:
D inject grease into the axle stub grease
nipples (see arrow).

tion.
272NM005X
HHD9 Euro3 1-293
1 Steering linkage grease application

Fig. 1: 3-axle vehicles
Fig. 2: 4-axle vehicles
Proceed as follows:
D inject grease into the joint pressure
nipples (see arrow).
342BNM017L
tion.
228NMR11
1-294 HHD9 Euro3
Front wheel toe-in check

Before starting the check, make sure:

D the vehicle is on a level surface and
empty
D the tyres are inflated to the correct
pressure.
Proceed as follows:
D set the wheels so that they are pointing forwards;
D check that the distances A and B measured along the centreline of the rims at the same
height from the ground, correspond to the specified values.
Fore-carriage Measurement
1st axle B = A --- (1 / 3 mm)
2nd axle B=A
If this is not the case, adjust as follows:

D loosen the bolts fastening the heads (see figures on next page, ref. 1) to the coupling
bar (see figures on next page, ref. 2);
D rotate the bar itself right and left by enough to obtain the required measurement;
D tighten the head clamp bolts;
D move the vehicle straight forwards or backwards by at least one turn of wheels and
check toe-in again.
The entire steering mechanism must be

checked if adjustments require more than
5 mm from the indicated measurements.
For further information contact your
Dealer.
HHD9 Euro3 1-295
A Front wheel toe-in check

A: 6x6 vehicles
B: 8x6 vehicles
C: 8x8 vehicles
B C
1 2
1 2
1-296 HHD9 Euro3
1 COMPRESSED AIR SYSTEM

Tank visual inspection
Visually inspect tank external condition.
Under no circumstances should any form

of heat treatment or welding be carried
out on the outside of the tank.
If the reservoir is dented, have it
178NM66
replaced.
The conditions for use of the compressed
air tank (pressure and temperature) are
given on the label applied to the tank
itself (Fig. 1).
Application should conform to these
indications.
During operation the tank must not be
subject to stresses in addition to those
deriving from the normal conditions of
use and by its weight.
The tank is only designed for use with
compressed air systems.
The tank is maintenance-free. The following

precautions should however be taken:
D any painting should be preceded by a pre-
paratory coat;
D surface treating of the bolts and screws
with passivation;
D clean with products which do not contain
alcohol.
HHD9 Euro3 1-297
1 Air dryer functionality check

Proceed as follows:
D check that the air drier functions correctly
by operating the drain valve (Fig. 1, see
arrow), in this case the air should come out
of the tank with no traces of condensation.
As soon as a small amount of moisture is no-
ticed, carry out a number of inspections at
shorter intervals to check whether this fact is
178NM67
only due to temporary overloading of the
drier or (Fig. 2, ref. 1) whether its efficiency is
permanently impaired.
2 In the second case it will be necessary to
renew the cartridge as the dampness ab-
sorption capacity of the granulate is greatly
reduced due to the action of oils, dirt, etc.
If a mixture of oil and water comes out of the
tanks during this check, this means that the
compressor is not working correctly as it is
discharging oil.
In this case in addition to replacing the car-
356DNM002L tridge, the compressor must also be over-
hauled.
1-298 HHD9 Euro3
1 Air dryer filter change

Proceed as follows:
D with the engine off unscrew the cartridge
(Fig. 1, ref. 2) with the correct spanner if
necessary, then thoroughly clean the sup-
port seat;
D hand-tighten the cartridge until the washer
comes into contact with the support, then
tighten it by ¾ of a turn;
356DNM002L
Do not overtighten the cartridge to avoid
damaging the washer. Always follow the
manufacturer’s recommendations.
D run the engine for a few minutes to check

for the absence of air leaks.
HHD9 Euro3 1-299
1 BRAKING SYSTEM
Shoe-drum play check
This check must be made separately on

both the shoes of each wheel.
Front wheels (Fig. 1)

Rear wheels (Fig. 2)
228NMR17
Proceed as follows:
D remove the caps (see arrow) through the
inspection slots;
2
D measure the play between the shoes and
drums; this must be between 0.8 and 1.5
mm;
D if not, remove and overhaul the automatic
play take-up device;
D check the condition of the brake linings;
D measure brake lining thickness: if less
than 8 mm, replace the linings.
228NMR18
After completing the hecks, replace the
plugs in the corresponding holes.
Check pedal distributors

Check that there are no leaks from the drain
holes of the two distributors.
A leak in the rest position indicates that

the air inlet valve is worn while the ex-
haust valve is worn if the leak occurs dur-
ing braking.
1-300 HHD9 Euro3
1 TYRES AND WHEELS

Checking wheels and tyres
Proceed as follows:
D check the inflation pressure of the tyres
(Fig. 1) is within the specified values;
otherwise adjust to correct pressure;
Check pressure and inflate the tyres

178NM70 when cold.
D check the condition of the rims and the

wear on the tyres;
D check that bolts are fastened at the speci-
fied torque (see TECHNICAL SPECIFICA-
TIONS section);
D check tyres for evident cuts; check
whether the tyres touch the vehicle.
If anomalous wear is found on the front

tyres, check the front wheel toe-in.
Never exceed the maximum load per axle
if the vehicle is fully loaded.
Inflating tyres
Proceed as follows:
D remove the protective cap and connect
the inflation device fitting to the valve
D take to specified pressure;
D disconnect the fitting and close the protec-
tive cap.
HHD9 Euro3 1-301
1 CAB TIPPING SYSTEM

Oil level check / fluid change
To check level, check through the filler cap
(Fig. 1, see arrow) that the oil level with cab
tilted is 1 - 1.5 cm from the cap. Top-up if
necessary.
To change the fluid, proceed as follows:
D clean the area around the cap and remove
272NM009MY it;
D using a syringe and flexible pipe, draw-out
the fluid in the reservoir;
D fill with the required quantity of fluid then
close the cap.
1-302 HHD9 Euro3
1 Greasing
Proceed as follows:
D tip the cab;
D grease the mechanism of both cab stop
hooks (Fig. 1, ref. 1);
D grease the telescopic manual trans-
mission control rod (Fig. 1, ref. 2).
357ANM001L
HHD9 Euro3 1-303
1 TOWING SYSTEMS
Greasing the fifth wheel
Fig. 1: fixed fifth wheel
Fig. 2: pivoting fifth wheel
Proceed as follows:
D release the semi-trailer from the tractor;
D clean the surface of the fifth wheel plate
307FNM002L and the semi-trailer hitching plate;
D apply plenty of grease the fifth wheel plate,
the locking mechanism for the fifth wheel,
2 the coupling pin and semi-trailer attach-
ment plate;
D the rubber buffers require no mainten-
ance;
D clean the concerned fitting;
D inject grease in the pressure fittings of the
fifth wheel (Fig. 2, see arrow).
307FNM003L
Inject lubricant until it pours out of the
lubricated points to ensure efficient
lubrication.
penser.
The grease nipple of the fifth wheel plate

(ref. 1) is to be used for lubrication
between services without needing to
uncouple the semi-trailer.
1-304 HHD9 Euro3
1 Tow hook greasing --- Type I

Proceed as follows:
D release the trailer from the tractor;
D clean the internal surface of the bell head
(Fig. 1);
D grease the hooking pin;
D clean the coupling involved;
D inject grease in the hook pressure fittings
307HNM002L (Fig. 1, see arrow).
To ensure efficient lubrication, continue
to inject lubricant until it flows out from
2 the lubricated points.
To grease, use a hand pump only, never
use a high pressure greasing device.
This operation should be carried out with
the lever raised.
Tow hook greasing --- Type II

Proceed as follows:
D release the trailer from the vehicle and
leave the hook in open position;
D carefully clean the hook with a jet of com-
pressed air;
D lubricate the zone in contact with the trailer
towing eye;
D clean the coupling involved;
D inject grease in the hook pressure fittings
(Fig. 2, see arrow).
To ensure efficient lubrication, continue
to inject lubricant until it flows out from
the lubricated points.
To grease, use a hand pump only, never
use a high pressure greasing device.
HHD9 Euro3 1-305
1 AIR CONDITIONER
Air-conditioner system maintenance
Proceed as follows:
D remove the cover (Fig. 1, see arrow) and
replace dust filter;
D inspect and clean the condenser with
compressed air (max 5 bar).
342BNM018L
1-306 HHD9 Euro3
1 System charge check

Check system charge once a year or when
reduced cooling effect is noticed (Fig. 1).
1. system checking and charging equip-
ment
2. high pressure circuit valve
3. low pressure circuit valve
Checking and charging must be carried

out by specialist personnel using specific
equipment.
R134a (tetrafluoroethane) coolant is
used. This coolant is classified as an
environmentally-friendly product by law.
Do not use this fluid in systems working
with the previous fluid R12 (Freon 12).
For reasons of incompatibility between
compressor oil and fluid, do not use R12
in systems designed to use R134a.
Do not discharge R134a into the

atmosphere. Although the product has a
342BNM019L zero ozone depletion potential it has a
global warming potential.
Always use type-approved coolant
recovery and recharging devices.
Do not mix different coolants in the same
device.
HHD9 Euro3 1-307
11 SUPPLEMENTARY HEATER
Replacing the supplementary heater fuel
filter
Proceed as follows:
D arrange a container of appropriate capac-
ity and clean the filter area;
D unscrew the cup (Fig. 1, see arrow) using
the wrench if necessary, and remove it
357ANM108L from its seat;
D replace the filter cartridge;
Do not fill the new filter with fuel to pre-

vent introducing impurities.
D fasten the cup;

D run the heater for a few minutes and check
for leakage of fuel.
1-308 HHD9 Euro3
1 BODYWORK
Replacing front windscreen wiper blade
(Fig. 1)
Proceed as follows:
D lift the arm and blade;
D push the blade backwards, disengaging it
from the stop and removing it;
D fit the correct adapter on the new blade
357ANM109L and approach the blade to the clip to
fasten it in the adapter;
D pull the blade fastening the adapter clip.
2
Observe the specifications provided by
Temperature Product Water
the supplier.
---35 ˚C 1 0
---20 ˚C 1 1 Windscreen washer reservoir
---10 ˚C 1 2 You are advised to use a specific antifreeze
0 ˚C 1 6 product mixed with water as shown in the
summer 1 10 table (Fig. 2).
178NM80 Proceed as follows:
D unscrew the plug (Fig. 3, see arrow) and fill
3 until completely full;
D replace the cap and close the grill.
Use the proportion of detergent recom-

mended by the manufacturer.
342BNM004L
HHD9 Euro3 1-309
Bodywork maintenance
Periodically wash the vehicle with neutral detergent and water to remove any corrosive ag-
ents (salt, sand, etc.).
Dry accurately with compressed air to fully eliminate any stagnating water.
Do not use products containing aromatic solvents, methanol or hydrocarbons for cleaning
paintwork.
Do not wash inside the cab with a jet of water or steam.
Cleaning plastic parts
Plastic parts should be cleaned using the same procedure as for normal washing.
For any remaining traces of dirt use specific products, carefully following the manufacturer’s
recommendations.
Do not use products containing aromatic solvents, methanol or hydrocarbons for ceaning
paintwork.
Fabric panels cleaning
Upholstery may be cleaned with dry foam

and general solvents. Exercise caution
when using these products as they are
flammable and give off fumes.
Ventilate the cabin until they are com-
pletely dry. Never use chloride solvents
(trichloroethylene, hypochlorite, etc.).
Cleaning seat belts
Seat belts may be washed by hand with hot water and neutral soap, then rinsed and left to
dry in the shade. Never use strong detergents, bleach or dyes. Avoid any chemical sub-
stance that may weaken the fibres.
1-310 HHD9 Euro3
1 LIGHTING SYSTEM
Headlight/front sidelight bulb replace-
ment
Proceed as follows:
D unhook the guard grill by rotating it toward
the outside (Fig. 1, see arrow);
D unscrew the screws (Fig. 2, see arrow) on
the inside of the fenders and rotate the
228NMR21 complete headlight group toward the out-
side;
D remove the corresponding cover (Fig. 3):
2 1. headlight
2. side light
3. high beams
D disconnect the electrical connector;
D release the bulb retaining spring and
remove the halogen bulb
or
D remove the sidelight bulb;
228NMR22 Never touch a halogen bulb with fingers,
to avoid damage.
3 D check that bulb is correctly fitted.

D for replacement, follow the removal
instructions in reverse order.
228NMR23
HHD9 Euro3 1-311
1 Headlight alignment
After dismantling the headlights or following
crash damage, the headlights have to be
realigned.
It is advisable to use specific equipment for
this operation.
However, a sufficiently correct alignment can
be achieved proceeding as follows:
D park the unladen vehicle, with tyres at cor-
178NM103
rect pressure, on flat ground nearly up
against a light coloured wall;
D mark two crosses on the wall, correspon-
2 ding to the two headlights (Fig. 1);
D back the vehicle up 10 m and shine the
headlights (Fig. 1) on the wall. The dis-
tance between the crosses and reference
points P-P must be equal to the percen-
tage of the distance between the vehicle
and the wall indicated on the specific plate
(Fig. 2);
D if necessary, use the adjuster screws
238NM51 (Fig. 3):
1. vertical adjustment
2. horizontal adjustment
3
For vehicles fitted with adjustable head-
lights, turn the adjuster knob to position
0.
228NMR24
1-312 HHD9 Euro3
1 Front direction indicator light bulb

replacement
Proceed as follows:
D working from the inside of the fenders, dis-
connect the connector (Fig. 1, see arrow);
D rotate and extract the fitting with bulb;
D press and turn the bulb anti-clockwise;
D check that bulb is correctly fitted;
228NMR25 D for replacement, follow the removal
2 Side direction indicator bulb replacement

Proceed as follows:
D remove the cover fastening screws (Fig. 2,
see arrow) and remove it;
D press and turn the bulb anti-clockwise;
D check that bulb is correctly fitted;
228NMR26
HHD9 Euro3 1-313
1 2
228NMR27 228NMR28
Rear light bulb replacement

Proceed as follows:
D remove the cover fastening screws (Fig. 1) and remove it;
D press and turn the bulb to replace (Fig. 2) anti-clockwise:
1. position (double)
2. stop
3. direction indicator
4. clearance
5. rear fog lamp
6. reversing light
D check that the replaced bulb is correctly fitted.
D for replacement, follow the removal instructions in reverse order.
1-314 HHD9 Euro3
1 1
Front clearance light bulb replacement
Proceed as follows:
D remove the fastening screws and remove
the complete light (Fig. 1, ref. 1);
Rotary warning light bulb replacement
Proceed as follows:
228NMR29
D remove the screws and the cover (Fig. 2,
ref. 1);
D replace the bulb;
2
Ceiling light bulb replacement
Proceed as follows:
D insert a screwdriver between the light fit-
ting and cabin interior lining (Fig. 3, ref. 1);
lever off the fitting and replace the bulb.
228NMR30 D for replacement, follow the removal
Replacing cab step light
D press and turn the bulb anti-clockwise
(Fig. 3, ref. 2).
D For replacement, follow the removal
228NMR31
HHD9 Euro3 1-315
List of bulbs
Use Type Watt
Lights:
--- main beam and dipped beam light Double filament halogen 75/70
--- position Round 4
Front direction indicator Round 21
Side direction indicator Round 21
Rear lights:
--- position/brake (stop) Round double filament 5/21
--- turn Round 21
--- reverse Round 21
--- rear foglight Round 21
Number plate light Round 10
Overall light Round 5
Rotating light Round 21
Rear light Round 21
Cabin ceiling light Round/cylindrical 5/5
Instrument panel/warning lights All glass 1.2
Warning lights All glass 1.2
1-316 HHD9 Euro3
1 ELECTRICAL SYSTEM
Precautions
Make absolutely sure that the electrical
power is disconnected before working di-
rectly or indirectly on electrical system parts
by operating the battery disconnect switch
(Fig. 1).
A: power off
B: power on
272CNU093
The vehicle electrical system should work
even if the fitted battery is flat.
In order to avoid incorrect interventions
which may irreversibly damage the elec-
tronic control units installed on board the ve-
hicle the following recommendations should
be followed:
D when work on the chassis requires arc
welding the connector should be removed
from the control units: when welding is to
be carried out near the control units,
remove the units;
D after a service operation requiring battery
disconnection, make sure that the ter-
minals are well connected;
D never use a battery charger to start the
engine;
D disconnect the batteries to recharge them;
D do not disconnect or connect the con-
nectors to the electronic control unit when
the engine is running or control units are
powered;
D do not disconnect the batteries when the
engine is running;
D remove the electronic control units in the
event of operations at temperatures
exceeding 80˚C (oven painting, etc.).
HHD9 Euro3 1-317
1 Battery maintenance (unsealed bat-

teries)
Sealed batteries (maintenance free) do

not require topping up with water in nor-
mal working conditions and mild climate.
The electrolyte should be checked
approximately once a year in tropical cli-
mates.
274CNU102
Proceed as follows:
D open the access cover (Fig. 1):
2 D carefully clean the batteries, the cables
and the case, removing rust and dirt which
can cause voltage drops;
D check through the caps that the distance
between the electrolyte (Fig. 2) and the
upper edge of the plate of each element is
as specified:
level-plate distance 10-12 mm
(0.4-0.5 in)
174NM43 D if required, top up with distilled water when
the batteries are cold and rested, through
the specific filler holes;
3 D check the battery charge with a densi-
Tempera- Electrolyte density meter (Fig. 3).
ture (100% of charge)
˚C ˚F g/dm3
40 1.265
20 1.285
0 1.300
-20 1.365
178NM84
1-318 HHD9 Euro3
1 Always take the following precautions when

working:
D devices that require current draw from
accumulators (Fig. 1) must only be used
for the time strictly necessary for the
checks to perform on the vehicle.
D carry out function checks requiring current
draw from accumulators with the engine
running, if possible and in compliance with
274CNU102 safety standards.
D do not use the installed batteries to power
tools when fitting-out.
D always disconnect the batteries when
carrying out any kind of welding operation.
HHD9 Euro3 1-319
1 Recharge with external devices

Recharge should usually be performed with
batteries disassembled from vehicle.If this is
not possible, the batteries can also be re-
charged using an external source (battery
charger) connected directly to the battery
terminals.
The vehicle is equipped with a 24 volt

electrical system with negative and earth.
Proceed as follows:
D lay the cables on the ground ensuring that
the terminals do not touch metal parts or
each other. Connect the red cable (Fig. 1,
ref. a) to the POSITIVE terminal of the flat
battery;
D connect the black cable (Fig. 1, ref. b) to
174NM44 the NEGATIVE terminal of the flat battery;
D set the recharge time and current. Start re-
charging.
Respect the instructions provided by the

battery charger supplier.
Respect the sequence of the operation.
Do not reverse the polarity when making
the connection.
1-320 HHD9 Euro3
1 Changing the battery
Follow all safety precautions when handl-

ing the battery.
D cut---out electric power supply acting on

the battery master switch;
D remove the battery compartment cover
(Fig. 1):
274CNU102 D disconnect the battery as follows:
--- disconnect the negative terminal;
--- disconnect the positive terminal.
D remove the flat batteries;
D thoroughly clean the battery compart-
ment, removing oxides and grime;
D install the new batteries;
D connect the battery leads as follows:
--- connect the positive terminal;
--- connect the negative terminal.
D smear pure Vaseline on the terminals;
D replace the battery compartment cover.
D activate electric power supply.
Always follow the battery manufacturer’s

instructions.
Observe the sequence of operations.
When connecting, never invert polarity.
HHD9 Euro3 1-321
1 Interconnection control unit (fuses and

relays)
Fuses that protect electrical system equip-
ment and relays are arranged in a special
compartment (Fig.1, see arrow) inside the
cab.
If a fuse valve blows more than once, look

for the cause in the electrical system.
342BNM020L
The control unit has two types of fuses:
D type A (AMP unival) (Fig.2, ref. 1)
2 D type A0 (AMP minival) (Fig.2, ref. 2)
To remove fuses type A0, use the special

pliers provided (Fig.3, see arrow).
Fuse replacement
Proceed as follows:
342BNM021L D disconnect the batteries from the battery
master switch;
D remove the compartment lid;
3 D remove the blown fuse from its housing;
D fit a new fuse WITH THE SAME AMPERES
as the blown fuse;
D refit the compartment lid;
342BNM022L
1-322 HHD9 Euro3
FUSE / RELAYS HOLDER PLATE
342BNM023L
HHD9 Euro3 1-323
FUSES
Fuse holder (70005)
POSITION FUNCTION CAPACITY (A)

1 DTCO --- Cluster 3
2 DTCO --- Cluster 5
3 IBC2 5
4 Left low beam, right main beam headlights and cab IBC2 10
5 Right low beam, left main beam headlights and symbol panel IBC2 10
6 Right side position lights and rear fog light IBC2 10
7 Left position side lights --- braking lights IBC2 10
8 Turn indicators IBC2 10
9 Windshield wiper IBC2 10
10 Fog light --- work headlight --- day lighting 10
11 Reverse gear 10
12 Pivotable headlights --- horn --- air horns 15
13 Alternator --- Vehicle service equipment 5
14 Solenoid valves VGT --- Synchro protection --- differential locks --- solenoid valves PTO 10
15 Heated fuel pre-filter 15
16 Brakes air drier --- fuel filter water detector sensor 5
17 Ignition key --- PTO solenoid valve 3
18 Climate control --- Heater 20
19 Cigar lighter --- 24V/12V voltage reducer --- MC net 20
20 Electric window risers 20
1-324 HHD9 Euro3
Fuse holder (70601)

1 Trailers ABS 30
2 ABS control unit 15
3 ABS control unit 5
4 OBD socket --- refrigerator . 30-pole diagnostics socket 10
5 Centralised closure 10
6 Centralised closure --- heated mirrors 10
Fuse holder (70602)

1 ECM control unit 15
2 ECM control unit 5
3 Heated seats 7,5
4 Heated mirrors 10
5 + 30 outfitters 15
6 + 30 outfitters 10
HHD9 Euro3 1-325
Fuse holder (70401)

1 AsTronic/Allison control unit 10/15
2 AsTronic/Allison control unit 10/15
3 --- ---
4 + 30 trailer 20
Fuse holder (70402)

1 Preparation 15
2 Intarder 10
3 Intarder 10
4 Heated diesel water separator 20
Fuse holder (70403) not used

1-326 HHD9 Euro3
RELAYS
CODE
REF. DESCRIPTION
COMPONENT
001 Relay for climate control 25332
002 Resistor holder for PTO parameter setting 61125
003 Synchro protection engagement relay 25611
004 Power steering failure warning light control relay 25868
005 Horn relay 25805
006 Lights on relay 25806
007 Flywheel PTO engagement enable relay 25701
008 PTO1 engagement relay 25704
011 PTO1 parameter setting recall relay (outfitters)
014 SET adjustment relay +( outfitters) (outfitters)
015 SET adjustment relay --- ( outfitters) (outfitters)
016 PTO engaged confirmation relay (outfitters)
017 Idle gear confirmation relay (outfitters)
018 External cruise activation relay (outfitters)
019 Reverse light relay for vehicle with automatic or automated transmission 25030
HHD9 Euro3 1-327
RELAYS
CODE
REF. DESCRIPTION
COMPONENT
A Diodes holder EV PTO outfitter wiring (outfitters)
B Vehicle doors open locking relay 25500
C --- ---
D --- ---
E --- ---
F Terminal 15a/50A relay 25213A
G Window washer level delay relay 25907
H 40A engeine start relay 25200
I Fuel pre-filter heating relay 25825
L Terminal 15b/50A relay 25213B
1-328 HHD9 Euro3
Additional relays board
356ANM001L
CODE
REF. DESCRIPTION
COMPONENT
1---A Emergency stop relay 25205
1---B ECM deactivation relay 25903
2---A Set + relay 25914 A
2---B Set --- relay 25914 B
3---A Off relay 25914 C
3---B Resume relay 25914 D
HHD9 Euro3 1-329
Supplementary flying fuse
A. Fuse holder (20A)
272NM009X
There is a flying fuse holder near to the batteries, which contains a 20A fuse.
1-330 HHD9 Euro3

HHD9 Euro3 1-331
Table and diagrams

1-332 HHD9 Euro3

HHD9 Euro3 1-333
INTRODUCTION
Scheduled maintenance intervals refer to normal operating conditions. They may vary according to the type of use, road
and environmental conditions.
If in doubt or faults not possible to correct with normal maintenance, contact the Dealer.
1-334 HHD9 Euro3
LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM

3-axle vehicles
342BTB006L
HHD9 Euro3 1-335
Key (see diagram on previous page)
1. semi-trailer fifth wheel/tow hook greaser 19. transmission oil

2. cardan joint greaser 20. transmission oil filter
3. rear carriage articulation greaser 21. transfer oil (only 6x6 version)
4. leaf spring articulation greaser 22. front axle final reductions oil (only 6x6 version)
5. stub axle greaser 23. front axle oil (only 6x6 version)
6. not used 24. not used
8. VGT actuator grease application procedure 26. intermediate axle and transfer case oil
9. engine oil vapour filter 27. rear axle and transfer case oil
10. engine oil 28. power steeling oil
11. engine oil filters 29. power steeling filter
12. VGT filter 30. no used
13. clutch control system oil 31. air conditioning fluid
14. fuel filters 32. air cleaner of air conditioning
15. main/secondary air cleaner 33. compressed air drier filter
16. engine coolant 34. not used
17. not used 35. cabin tilting oil
18. oil/power take off oil filter 36. supplementary fan system oil/oil filter
Service frequency is expressed in:

[h] vehicle working hours
[m] months
1-336 HHD9 Euro3
LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM

4-axle vehicles
342BTD005L
HHD9 Euro3 1-337
1. semi-trailer fifth wheel/tow hook greaser 18. oil/power take off oil filter
2. cardan joint greaser 19. transmission oil
3. rear carriage articulation greaser 20. transmission oil filter
4. leaf spring articulation greaser 21. transfer oil
5. stub axle greaser 22. front axle final reductions oil
6. steering linkages greaser 23. front axle oil
7. not used 24. second axle final reductions oil (8x8 only)
8. VGT actuator grease application procedure 25. second axle oil (8x8 only)
9. engine oil vapour filter 26. intermediate axle and transfer case oil
10. engine oil 27. rear axle and final reductions oil
11. engine oil filters 28. power steeling oil
12. VGT filter 29. power steeling filter
13. clutch control system oil 30. not used
14. fuel filters 31. air conditioning fluid
15. main/secondary air cleaner 32. air cleaner of air conditioning
16. engine coolant 33. compressed air drier filter
35. cabin tilting oil
Service frequency is expressed in:

[h] vehicle working hours
[m] months
1-338 HHD9 Euro3
LOCATION OF COMPONENTS
Engine F3B
342BTB001L
HHD9 Euro3 1-339
Engine F3B
8. VGT actuator grease application procedure

9. engine oil vapour recirculation filter
10. engine oil
11. engine oil filter
12. VGT system filter
14. fuel filter
15. main/secondary air filter
16. engine coolant fluid
1-340 HHD9 Euro3
Manual transmission
357ATB001L
HHD9 Euro3 1-341
Manual transmission
13. clutch control system oil

19. manual transmission
20. manual transmission oil filter (intarder equipped vehicles only)
1-342 HHD9 Euro3
Automated/automatic transmission
357ATB201L
HHD9 Euro3 1-343
Automated/automatic transmission
19(A). automated transmission oil

19(B). automatic transmission oil
20(A). automated transmission oil filter
20(B). automatic transmission oil filter
1-344 HHD9 Euro3
Multipower/NMV 221 power take off
272CNM005
HHD9 Euro3 1-345
Multipower/NMV 221 power take off

17(A). Multipower power take off oil
17(B). Multipower power take off oil filter
18. NMV 221 power take off oil filter
1-346 HHD9 Euro3
Drive-line
272CNM007
HHD9 Euro3 1-347
Drive-line
21. reducer-distributor oil
22. final transfer case oil of 1st front axle
23. 1st front axle oil
24. final transfer case oil of 2nd front axle
25. 2nd front axle oil
26. intermediate axle and final transfer case oil
27. rear axle and final transfer case oil
1-348 HHD9 Euro3
Greasing transmission shafts
272CNM008
HHD9 Euro3 1-349
Greasing transmission shafts

2. universal joint greaser
1-350 HHD9 Euro3
Suspension greasing
356DTB001L
HHD9 Euro3 1-351
Suspension greasing
3. rear carriage articulation greaser
4. leaf spring joint greaser
1-352 HHD9 Euro3
Steering linkages, semi-trailer fifth wheel, tow hook greasing
272CNM010
HHD9 Euro3 1-353
Steering linkages, semi-trailer fifth wheel, tow hook greasing

1(A). semi-trailer fifth wheel greaser
1(B). trailer pintle greaser
5. stub axle greaser
6. steering linkages greaser
1-354 HHD9 Euro3
Systems
342BTB004L
HHD9 Euro3 1-355
Systems
Key (see figure on previous page)
28. power steering oil
29. power steering oil filter
31. air conditioner system fluid
32. air conditioner filter
33. compressed air dryer filter
35. cab tipper oil
1-356 HHD9 Euro3
SERVICE SCHEDULE
Checking, adjusting and cleaning operations
hours
OPERATION day year
400 800 1600
Check engine oil level X
Check engine coolant level X
Check service brake and parking brake X
Check external lights, dashboard warning lights and windscreen wiper X
Windscreen washer fluid level check X
Check trailer pintle /semi-trailer fifth wheel condition X
Bleed compressed air tank X
Check tyre pressure/conditions X
Fuel filter check/water drain (1) X
Check tightness of wheel fasteners (2) X
Turbocompressor intake/lubrication system seal check X
Check clutch control oil level X
Check gearbox oil level X
Check transfer oil level X
Check transfer case oil level X
Check axle oil level X
Pedal distributors check X
Tow hook/thrust washer functioning check X
Check compressed oil dryer function/if necessary bleed off condensation from
X
tank(s)/visual inspection of tanks
Battery maintenance (unsealed batteries) X
(1) or when respective warning light comes
(2) after 20-40 km and again after 100 km when the vehicle is new or after changing the wheel.
The table indicates the time interval
between two consecutive operations.
HHD9 Euro3 1-357
Checking, adjusting and cleaning operations (contd.)

hours
OPERATION day year
400 800 1600
Check cab tilting system oil X
Check accessory belt X
Check conditioner compressor belts X
Bleed fuel tank condensation water X
Check power steering system oil level (^^) X
Intercooler external cleaning (1) X
Front wheel toe-in check (˚) X
Brake shoe-drum play check X
Check EDC engine control system with diagnosis equipment (˚) X
Adjust tappet /injector-pump play (˚) X
Clean conditioner condenser X
Check antifreeze concentration X
Check headlight alignment X
(˚) For further information contact your Dealer
(^^) This check is optional, since there is an oil level warning light.
(1) according to working environment

1-358 HHD9 Euro3
Lubrication and replacement operations --- Engine

hours
OPERATION year
100 400 800 1600 2400 3200
Replace engine oil/filter with ACEA E2 or equivalent (*) (1) X
Replace engine oil/filter with ACEA E5/E7 or equivalent (*) X
Engine oil vapour recirculation filter replacement X
Replace fuel pre-filter/filter X
Replace main air cleaner element (2) (*) X
Replace air cleaner main element (3) X
Replace VGT circuit air filter X
Change engine coolant (**) X
Replace accessory belt (˚) X
Replace air conditioner compressor belts (˚) X
Replace AdBlue filter (˚) X
(˚) for further information contact your Dealer
(*) yearly for shorter periods of use than foreseen

(**) every two years for periods of use less than envisaged interval
(1) with a NEW vehicle, change engine oil the first time after 800 hours of operation
(2) or when respective warning light comes on
(3) or after every three main filter replacements

HHD9 Euro3 1-359
Lubrication and replacement operations --- Vehicle

hours
OPERATION year
100 400 800 1600 2400 3200
Grease lubrication points X
Change clutch control oil X
Change power hitch oil (*) X
Transmission oil change (*) (***) X
Manual transmission oil filter change with intarder/automatized (*) (***) X
Transmission oil filter change (*) X
Change transfer oil (*) X
Change axle transfer case oil X
Change power steering system oil (**) X
Replace power steering system oil filter X
Replace compressed air dryer filter (*) X
Change oil in cab tilting system (**) X
Recharge conditioner system fluid (˚) X
Replace air conditioner filter X
(˚) for further information contact your Dealer
(*) yearly for shorter periods of use than foreseen

(**) every two years for periods of use less than envisaged interval
(***) every two years or 240,000 km if reached before the foreseen time (automatized transmission only)

1-360 HHD9 Euro3
LUBRICANT AND HYDRAULIC FLUID TABLES

Astra Hhd9 Euro 3 Use and Maintenance Handbook

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Astra Hhd9 Euro 3 Use and Maintenance Handbook

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USE AND MAINTENANCE

ASTRA Veicoli Industriali

Prepared by SIPAL S.p.A. --- Torino (Italy)

--- INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX --- TRANSFER DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . 1-11

--- EXTERNAL LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 S 12Volt current socket . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

--- HATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81 S Automatic transmission warning lights . . . . . . . . . . 1-97

S Climate controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 --- EUROTRONIC TRANSMISSION . . . . . . . . . . . . . . . . . . 1-150

--- ALL VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-181 S Electric coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-203

S Fuel tank water drain . . . . . . . . . . . . . . . . . . . . . . . . . 1-233 S Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-256

S Steering linkages, semi-trailer fifth wheel,

Failure to heed and/or correctly carry out

Procedures, technical information and

Failure to heed and/or correctly carry out

AFTER SALES SERVICE

The handbook contains use and mainten-

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POSITION OF VEHICLE IDENTIFICATION

b 1 Chassis punching (Fig. 1)

Vehicle registration number (Fig. 2)

1 3 Vehicle identification plate (Fig. 3)

R.G. = Reverse Gear

Tandem rear drive axles (Fig. 1)

1 BRAKES (simplex without ABS)

1 BRAKES (duplex with ABS)

(*) (**) (*) (**)

The characteristics of accumulators and

D Standard warning triangle (Fig. 1, ref. 1).

D Tool box (Fig. 1, ref. 2).

357ADT003L According to the outfitting the chocks

Instructions for use

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GENERAL INSTRUCTIONS FOR CORRECT USE OF THE VEHICLE

Driving in rain, fog and snow

Engage a high gear whenever traffic and road conditions permit.

1 Range of use of the engine

The best performance/consumption ratio

c yellow sector: maximum engine speed

NEVER USE RED SECTOR.

Tachometer sector (RPM)

1 LEFT HAND DRIVE VEHICLES

Always keep handles and foot-boards

1 1 Rear lights (Fig. 1)

1 1 Rear lights --- Version with LED taillights

The vehicle has two doors symetrically

1 The inner side of the door has the following

Central locking remote control

Replacing remote control battery

A reduction in range of the remote control

Exhausted batteries are harmful to the

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DRIVER’S SEAT (Fig. 1 previous page)

1 1 INTERNAL LIGHTING DEVICE

2. Access step lighting

1 EXTERNAL REAR VIEW MIRRORS

1 Mirror selection and handling

This adjustment must be made with ve-

Using the mirror selection control (Fig. 1, ref.

Without remote control the driver has to

The selected mirror is identified by the num-

The mirrors controlled by the system are

2 Press the mirror heater button (Fig. 1, ref. 3)

Release the lever and ensure the mech-

Cushion angle adjustment