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INDEX MAINTENANCE……………………………………………………………………………………2 Nameplate………………………………………………………………………………………..3-4 Engine block marking……………………………………………………………………………..5 Technical data……………………………………………………………………………………...6 Engine……………………………………………………………………………………………….6 Transmission and torque divider………………………………………………………………….6 Axle transmissions…………………………………………………………………………………7 Max speed for all versions ………………………………………………………………………..7 Suspensions ………………………………………………………………………………………..7 Brakes……………………………………………………………………………………………….7 Rims and tires………………………………………………………………………………………8 Adjustment of front wheel toe-in………………………………………………………………….8 Table of tire air pressure…………………………………………………………………………..9 Tire air pressure for off-road driving…………………………………………………………….11 Use conditions…………………………………………………………………………………….11 Electric equipment………………………………………………………………………………..13 Battery maintenance……………………………………………………………………………..13 Lamps………………………………………………………………………………………………14 Fuses ………………………………………………………………………………………………15 Fuses position……………………………………………………………………………………..16 T-REX on road overall dimensions……………………………………………………………..19 Total weight allowable……………………………………………………………………………18 Allowable loads per axle…………………………………………………………………………18 Net weights hauled……………………………………………………………………………….18 T-REX off road overall dimensions……………………………………………………………..18 Total weight allowable……………………………………………………………………………20 Allowable loads per axle…………………………………………………………………………20 Net weights hauled……………………………………………………………………………….20 Vehicle control…………………………………………………………………………………….21 Vehicle key………………………………………………………………………………………...21 Door lock…………………………………………………………………………………………..21 Doors……………………………………………………………………………………………….22 Side mirrors………………………………………………………………………………………..22 Fuel tank…………………………………………………………………………………………...23 Bonnet……………………………………………………………………………………………...23 Driver seat, passenger and central seats………………………………………………………24 Seat regulation…………………………………………………………………………………….24 Further seat regulations………………………………………………………………………….24 Seat cleaning……………………………………………………………………………………...24 Warning lights……………………………………………………………………………………..28 Combined selection switch………………………………………………………………………30 Heating and ventilation system………………………………………………………………….31 ABS…………………………………………………………………………………………………31 On-Board diagnostics plug (OBD2)……………………………………………………………..31 Selectors…………………………………………………………………………………………...32 Torque distributor control………………………………………………………………………...32 Selecting lever for power take-off / shift………………………………………………………..34 Handbrake…………………………………………………………………………………………35 Start and drive…………………………………………………………………………………….36

High temperature starting………………………………………………………………………..38 Engine shut-off…………………………………………………………………………………….38 Checks before starting……………………………………………………………………………38 Ordinary recommended checks…………………………………………………………………39 Fault check through the EDC/OBD pilot lights (Diagnostics)………………………………...45 Lighting system……………………………………………………………………………………46 Headlights………………………………………………………………………………………….46 Replacing bulbs in position lights (A).…………………………………………………………..46 Replacing halogen dipped-headlights / headlights (B)………………………………………..46 Replacing bulbs in direction indicators (C)……………………………………………………..47 Internal lighting system…………………………………………………………………………..48 Reading light (optional)…………………………………………………………………………..48 Rear light left / right ………………………………………………………………………………49 Wheel replacing…………………………………………………………………………………...50 Towing……………………………………………………………………………………………..51 Using a trailer……………………………………………………………………………………..52 Towing hook……………………………………………………………………………………….52 Maintenance……………………………………………………………………………………….52 Engine……………………………………………………………………………………………...52 Particle filter (FAP)………………………………………………………………………………..54 Air filter……………………………………………………………………………………………..54 Air filter cleaning and replacing………………………………………………………………….55 Coolant……………………………………………………………………………………………..55 Check of the coolant……………………………………………………………………………...55 Gearbox……………………………………………………………………………………………55 Clutch ………………………………………………………………………………………………54 Torque distributor BK 20 (central differential)………………………………………………….57 Fuel filter…………………………………………………………………………………………...58 SEPAR fuel pre-filter (optional)………………………………………………………………….58 Filter’s cartridge replacing………………………………………………………………………..59 Fuel standards…………………………………………………………………………………….60 Fuel additives……………………………………………………………………………………...60 Winter diesel ………………………………………………………………………………………60 Power steering…………………………………………………………………………………….61 Driving universal joints……………………………………………………………………………62 Universal joints……………………………………………………………………………………62 Front wheel hub…………………………………………………………………………………..63 King pin bolt and front driving universal joints…………………………………………………63 Hydraulic system with power transfer unit (optional)………………………………………….63 Brakes……………………………………………………………………………………………...64 Air bleed……………………………………………………………………………………………64 Handbrake clearance…………………………………………………………………………….64 Service brake clearance on front and rear axle ……………………………………………….64 Braking system + ABS diagram…………………………………………………………………65 Recommended maintenance for off-road use…………………………………………………66 Lubrication schedule……………………………………………………………………………..66 Water stream crossing……………………………………………………………………………67 Table of recommended oils and lubricants…………………………………………………….67 Table of approved oil viscosity values………………………………………………………….68 What you should know about your BREMACH vehicle……………………………………….69 Precautionary measures for off-road vehicles…………………………………………………69

Running-in…………………………………………………………………………………………69 Vehicle take care………………………………………………………………………………….69 Onboard tools……………………………………………………………………………………..72 Spare wheel……………………………………………………………………………………….73 Removing………………………………………………………………………………………….74 Spare wheel assembling…………………………………………………………………………75 Off-road driving……………………………………………………………………………………77 In general…………………………………………………………………………………………..77 Recommendations for off-road driving depending on vehicle type………………………….77 Using permanent four-wheel drive………………………………………………………………77 Using engageable four-wheel drive……………………………………………………………..77 Using off-road gear……………………………………………………………………………….77 Off road vehicle characteristics………………………………………………………………….78 Technical data of 4x4s vehicles………………………………………………………………...78 Power take-off………………………..……………………………………………………………79 Engine (crankshaft) PTO…………………………………………………………………………80 Transfer box PTO…………………………………………………………………………………81 Off-road drive speed ……………………………………………………………………………..82 Driving on a slope…………………………………………………………………………………82 Side roll-over………………………………………………………………………………………82 Driving along trenches and rolling terrain………………………………………………………83 Driving over cat's backs………………………………………………………………………….83 Travelling over ruts in the road surface………………………………………………………...83 Crossing the water………………………………………………………………………………..84 Driving on muddy soil…………………………………………………………………………….84 Driving on sandy soil …………………………………………………………………………….85 Driving on snow and ice………………………………………………………………………….86

Dear Customer,

Thank you for preferring a BREMACH vehicle. The purpose of this Manual is to introduce you to every individual detail about your BREMACH vehicle and to teach you how to control it correctly. Please read this Manual carefully before using the vehicle for the first time. This Manual contains important information, advice and recommendations for using the vehicle, which will help you make the best possible use of all the technical features of your BREMACH vehicle. User Manual and Maintenance Guide are important documents that you should always have available on your vehicle. We recommend that you follow the maintenance schedule reported in this Manual strictly so as not to jeopardize driving safety and vehicle durability. This manual applies to several models, that on the whole have the same characteristics. It also deals with special optionals. Even so your vehicle may differ from the reported descriptions and illustrations.

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Maintenance To safeguard the value of the vehicle and its warrantee, revisions and maintenance should be carried out by qualified persons belonging to the following service networks:

BREMACH service network for all vehicle components and details; FPT (FIAT Powertrain Technologies) service network for engine and gearbox parts and general service.

For the vehicles used in countries where there are no BREMACH and/or FPT service points, please contact the manufacturer’s or importer’s network. All maintenance instructions for revisions are reported in BREMACH maintenance manual that you receive together with End User Manual. BREMACH manufacture’s guarantee as well as FPT engine’s guarantee are valid only if original spare parts are used. MODEL :

CHASSIS IDENTIFICATION NUMBER :

IMPORTANT: please write down model and identification number indicated in car license

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Vehicle identification for all versions

Nameplate Inside the bonnet

1. Final test number 2. Vehicle identification number 3. Vehicle total weight allowable 4. Vehicle + trailer total weight allowable 5. Total weight allowable on the front axle 6. Total weight allowable on the rear axle 7. Body - Frame - Load floor - Truck with loading container that can be tipped on 3 sides - Van

8. Type description 9. wheelbase (expressed in mm)

10. fuel gas coefficient

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Chassis number Nameplate

on right side member Under passenger

rain-flap, inside bonnet

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ENGINE BLOCK MARKING

F1 engine number (EURO4) A: Manufacturer B: Engine type and version C: Engine serial number D: 1st figure Main journal No. 1 (Engine front side) E: Selection class main bearing diameters F: Selection class Cylinder liners G: 1st figure Cylinder No. 1 (Engine front side)

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Technical data: Engine

Engine type IVECO F1A E4 IVECO F1C E4 with FAP* Capacity (cm³) 2287 2998

Bore (mm) 88 95,8 Stroke (mm) 94 104

Number of cylinders 4 4 max. power (kW/Ps) 85/116 at 3900 rpm 107/146 at 3500 rpm

max. torque (Nm/kgm) 270/27,5 at 1800 rpm 350/35,6 at 1400 rpm *FAP: particle filter GEARBOX AND TORQUE DIVIDER

Clutch With F1A engine version All versions with permanent four-wheel drive

With F1C engine version

Dry single plate clutch ZF gearbox type 6S300 BREMACH BK 20P torque divider

ZF gearbox type 6S380

Mechanically or hydraulically operated

Transmission gear ratio With power distribution 35%:65% (front; rear axle) Transmission gear ration

Transmission gear ratio

1st (gear) 1 : 6.727 Road (R) 1 : 1.028 1st (gear) 1 : 5.375 2nd 1 : 3.47 Road (S) 1 : 1.298 2ª 1 : 3.154 3rd 1 : 2.555 Off-road (Rapid) 1 : 3.086 3ª 1 : 2.041 4th 1 : 1.778 Off-road (Slow) 1 : 3.894 4ª 1 : 1.365 5th 1 : 1.289 5ª 1 : 1.000 6th 1 : 1.000 6ª 1 : 0.791 Reverse gear 1 : 6.055 Reverse gear 1 : 4.838

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AXLE TRANSMISSIONS T-REX on road T-REX off road

Front axle Rear axle Front axle Rear axle 9/46 (1:5.11) 9/46 (1:5.11) 9/46 (1:5.11) 9/46 (1:5.11) 10/45 (1:4.5) 10/45 (1:4.5 ) 10/45 (1:4.5) 10/45 (1:4.5)

Standard equipment: Differential locking device on rear axle, with mechanical control. Optional equipment: Differential locking device on front axle, with mechanical control.

Max speed for all versions Max. speed with nominal rpm (3900 rpm) Min. speed at 1800 rpm (max. torque) 115-140 km/h (depending on tire and ratio

type) BK 20 reducer BK 20P reducer

In the case of T-REX 60 limited to 90 km/h 2-2.3 km/h 2-2.3 km/h

SUSPENSIONS Wheel axle’s suspensions Stiff axles with parabolic leafsprings, double effect shock absorbers and front and rear stabilizers. BRAKES Hydraulic braking system with two circuits, vacuum brake and ABS. Front self-ventilated disk brake, rear disk brake. Mechanical parking brake acting on rear wheels. Rear break splitter.

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RIMS AND TIRES T-REX Steel rims Tire dimension

35 tons off road version 16 - 6.50 H SDC 255/100 R16 (126/124K) 35 tons road version 17.5 x 6.00 225/75 R17.5 (129/127M) 60 tons road version 17.5 x 6.75 245/70 R17.5 (136/134M)

OPT. 60 tons off road version 16 – 6.50 H SDC 255/100 R16 (126/124K)

ADJUSTMENT OF FRONT WHEEL TOE-IN Toe-in (with static load): 0-3 mm

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TABLE OF TIRE AIR PRESSURE

Air pressure in bar (kg/cm²) for road drive

under max load allowable per axle Version Tire dimension

Front axle Rear axle

T-REX 35 off road 255/100 R16 2.7 3.5

T-REX 35 road version 225/75 R17.5 3.5 4.5

T-REX 60 road version

245/70 R17.5 3.5 7.75

T-REX 60 off road 255/100 R16 3.0 5.5

The air pressure in the spare wheel corresponds to the value of rear wheels.

IMPORTANT WARNING Please note the loads allowable per axle and tire manufacturer’s instructions about tire air pressure.

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Please only use tire types reported in car license. Tires other than the ones listed in mentioned document can be used only upon written authorization of rim and tire manufacturers. Otherwise driving safety and vehicle running license as well as your personal safety will be not assured. Please make periodical checks (every two weeks) for correct air pressure in the tires, including spare wheel. The check must be carried out when tires are cold; please do not reduce air pressure of warm tires. We recommend changing tire position after approx. 25,000 km from front axle to rear axle to allow regular tire wear.

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TIRE AIR PRESSURE FOR OFF-ROAD DRIVING Air pressure: According to conditions of use and depending on stress per axle, three different air pressure values

are reported: road - track - sand Road drive: Air pressure values mentioned here apply to drive on roads in good conditions with hard road surface

(asphalt or compacted). Off-road drive: Track: These air pressure values are meant for driving on road surface under bad conditions, tracks and

hamadas. They allow driving on most of the low sand dunes. Max. speed 65 km/h. Sand/mud: These air pressure values allow using the vehicle on difficult grounds with grip problems or the risk of

becoming blocked. In this case constant speed must be limited to 20 km/h. Use conditions: The following tables contain, according to usage conditions, two different stress limits:

A lower limit (underlined) for usage on difficult grounds and tracks. This limit is the results of several tests and should not be exceeded to obtain good performance.

A higher limit (bold) for usage on roads. In this case the air pressure value for road use is to be applied.

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Capacity: air pression tyre/bar (kg/cm2) To know exactly the right tyres pressure for on road use, please, make reference to the tyres table.

Example: Tire air pressure/bar (kg/cm²)

Model Tire dimension Capacity per axle Road Sand Mud 1400 1.7 1.0 1600 2.0 1.2 0.6 255/100 XZL 1800 2.0 1.4 0.7 2000 2.3 1.6 0.8 2200 2.6 1.8 1.0 2400 3.0 2.0 1.1 2600 3.25 2.2 1.2 2800 3.6 2.3 1.4 3000 3.9 2.5 1.5 3200 4.25 2.7 1.6 3400 4.5 2.9 1.7

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ELECTRIC EQUIPMENT Battery 12V/100 Ah, min. 450 CCA Starter 2.7 kW Dynamo 14V 140A/1960W Starter battery may be found on frame on the right or left side. Open the two hinges to remove the battery cover, then the battery is accessible and maintenance can be carried out.

BATTERY MAINTENANCE Battery needs little maintenance: In areas with temperate climate check for fluid level every 2 years, in areas with hot climate check for level every 6 months. To check fluid level remove the cover of the battery elements (arrow). Fluid level in every cell must be at least 5 mm above the battery plates. Top up only with distilled water. Please, keep battery terminals clean and free of corrosion, applying from time to time acid protection grease.

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LAMPS

Lamps

Type Watt

Headlights Halogen H7 55 Front sidelamp Spherical 5

Front direction indicators Spherical 21 Rear lamps Spherical 5

Rear direction indicators Spherical 21 Brake lamp Spherical 21

Number plate lighting Spherical 5 Reverse gear lamp Spherical 21

Fog lamp Spherical 21 Inside lighting Cylindrical 5

Roof reading lamp Spherical 5

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Fuses The fuses are of coupling type and so-called „Mini“-fuses. Fuses position Open the driver door and remove the side cover of fuses on the dashboard. Behind this cover you will find fuses and relays. Fuses’ position can be inferred from the following page.

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Vehicle Single Cab Wheel base 2600 3100 3450 Total length 4380 4880 5230

All values are in mm. All measurements are only representative and therefore are not binding.

Total weight allowable Serie Road/off-road

T-REX 35 3,500 kg T-REX 60 6,000 kg

Road/off-road: applies to vehicles that are mainly used on-road and only sometimes off-road (such as construction site vehicles, winter vehicles, forest vehicles etc..). Off-road: applies to vehicles that are mainly used on critical grounds.

Allowable loads per axle Serie Front axle Rear axle

T-REX 35 2,000 kg 2,500 kg T-REX 60 2,300 kg 4,450 kg

Please infer the dead weight of your vehicle from your car license. Net weights hauled All road models: 3500 kg with inertia brake and 750 kg not braked. Max. drawbar load: 120 kg All off-road models: 1750 kg with inertia brake and 750 kg not braked. Max drawbar load: 120 kg

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Vehicle Single cab Wheel base 2600 3100 3450 Total length 4380 4880 5230

All values are in mm. All measurements are only representative and therefore are not binding.

Total weight allowable Serie Road/off-road

T-REX 35 3,500 kg T-REX 60 6,000 kg

Road/off-road: applies to vehicles that are mainly used on-road and only sometimes off-road (such as construction site vehicles, winter vehicles, forest vehicles etc..). Off-road: applies to vehicles that are mainly used on critical grounds (as for example for long trips etc), considering

the ratio load per axle / tire size to reach optimal adaptability off-road.

Allowable loads per axle Serie Front axle Rear axle

T-REX 35 2,000 kg 2,500 kg T-REX 60 2,300 kg 4,200 kg

Net weights hauled All road models: 3500 kg with inertia brake and 750 kg not braked. Max. drawbar load: 120 kg All off-road models: 1750 kg with inertia brake and 750 kg not braked. Max drawbar load: 120 kg

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VEHICLE CONTROL Vehicle key Your vehicle has 2 bunches of keys, both for open the doors (or with remote control) and for ignition. If remote control does not work, use the key to open the door.

Door lock Driver door is provided with its own key lock, lockable with key.

1. lock 2. door handle

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Doors

When opening, internal door-lamp lights-up automatically.

1. Door opener 2. Door handle

Side mirrors Side mirrors are adjusted by hand, with slight pressure on the mirror body. Mirror supports are hinged, they can be turned completely inwards towards the cab, if necessary (narrow spaces).

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Fuel tank Standard fuel tank has a volume of 70 liters and is placed on left side of the vehicle. Upon request, an additional tank can be mounted with 140 liters of capacity. Additional tank (optional) is mounted on right side of the vehicle. Fuel is pumped from right tank to the left one by means of an electric pump Upon request a fuel tank plug with key lock can be installed. Use only DIESEL FUEL (Minimum cetane number 48).

Bonnet Bonnet can be opened upwards using the hexagonal key.

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DRIVER SEAT, PASSENGER AND CENTRAL SEATS Seat regulation Lift the handle to unlock the seat and move it forward and backward. Release the handle to fix the seat in the required position.

Further seat regulations Lift first lever to change the height/angle of the front part of the seat. Lift second lever to change the height/angle of the back part of the seat. Use third lever to adjust the backrest. Rotate the knob to adjust seat suspension according to driver’s weight (upon request for the passenger seat). Seat cleaning The seats should be cleaned with dry foams or other suitable products.

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DASHBOARD INSTRUMENTS AND CONTROL SWITCHES

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A. Rev counter B. Control lights C. Cronotachograph, odometer, fuel level and engine temperature D. Air vents E. Air-conditioner controls module F. Voltage socket 12V (lighter) G. Switches (see following explanations) H. Lightning lights (see following explanations) I. Switch for ABS diselection L. tipping body switch M. Headlight height adjustment

Headlight height adjustment By means of selector (M) main headlights can be adjusted according to vehicle’s load conditions. Position 0: Normal position Position 1-3: Headlight downward adjustment according to load conditions, to avoid blinding traffic moving in the

opposite direction.

A. Slow speed engage/disingage control B. Half speed engage control C. Locks control D. Lightening lights (see following explanation) E. Emergency flash light system F. Yellow rotating lamp G. Work lamp H. Fog lamps I. PTO switch L. Dinsingage securities switch

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WARNING LIGHTS

1. direction indicators 2. engine EDC 3. low pression of engine oil 4. no charge of alternator 5. hand brake 6. oil brakes level and wear of brakes tabs 7. headlights 8. breakdown

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9. position light 10. fog light 11. ABS breakdown 13. tow direction indicators 14. electromagnetic PTO 15. reducer PTO 16. gear PTO 17. low speed 18. fast speed 20. tipping body 21. neutral slow speeds 22. rear differential lock 23. 3rd differential lock

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Combined selector switch: Left lights drive: klaxon is activated by pressing the A knob. By turning the B knob, at the first click, parking lights are engaged; at the second one, dipped headlights are activated. Push forward to switch on high beams. Use the lever for engage indication lights. Right lights drive: for engage different speeds of the windshield and if pushed, engage sprinklers.

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HEATING AND VENTILATION SYSTEM The temperature set to the temperature controller is measured by a sensor, which automatically adjusts the heating valve. For temperature automatic adjustement, fan selector switch must be turned on. Close the directional air outlets to increase the air flow in windshield direction, this favors the demisting effect. ABS All BREMACH models are equipped with a standard ABS system. Sometimes (for example with deep snow) the ABS system should be deactivated to reduce the braking distance. To deactivate the ABS follow these instructions: - Engage the front axle (for permanent four-wheel drive vehicles, engage the central locking device); - Engage the rear differential locking device; - Press the ABS selector (A).

When the ABS system is deactivated a red flashing light is on. To engage the ABS press again the selector. (Note: ABS warning light turning on when you are driving your vehicle indicates a fault in the system. In that case immediately look for the nearest BOSCH service point).

On-Board Diagnostics plug (OBD2) Plug for On-boards Diagnosis is near to the lighter. You can find the corresponding interface, the connecting cable or the software to read the error codes of the engine guide box by your nearest dealer.

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Selectors

A. slow speeds selector B. half speeds selector C. III differential and rear differential selector

Torque distributor control The torque distributor has 2 switching steps: a „Split unit“ not synchronized with the Quick/Slow lever positions (A) and a level that is synchronized with the Road/Off-road (B) (half speed).

You can switch the „Split unit“ when driving, after pressing the clutch pedal, to modify every shift gear, regardless of whether you have just engaged the road or off-road gear. If you have a heavy load or if you have a trailer, we always suggest starting with the „Split unit“ in Slow position, to safeguard your clutch. This allows reducing stress to the vehicle clutch.

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Note: To avoid difficult shifting when temperatures are low, switch the Split Unit only after 5-10 km trip. Note: half and slow speedd must be engaged pushing to the end the clutch pedal. The Road/Off-road gear (A) has to be engaged only when the vehicle is at a standstill ! It is used to reduce the speed of the vehicle off-road and to simultaneously increase the tractive effort. You can engage the Road/Off-road gear (D) after pressing the clutch pedal, but only when the vehicle is at a standstill. Note: The use of (A) may cause some problems when the driving bar is subject to excessive stress. If so move the vehicle a back a short distance to reduce traction or release the clutch pedal before trying again. The vehicle is equipped with permanent four-wheel drive. This means that the four wheels are always activated. The rpm compensation between front axle and rear axle when cornering is allowed by a planetary differential integrated in the torque distributor. When it is “unlocked” it transmits 35% of the whole torque to the front axle and 65% to the rear axle. If the planetary differential is “unlocked” and one wheel loses the entire traction force (because either it lifts off the ground or it can not gain grip on ice or snow, etc.) the vehicle stops. To avoid this situation, the planetary differential is fitted with a (central) locking device. The selector (C) allows engaging this central locking device to the torque distributor. The front axle is so stiffly connected to the rear axle and the torque is equally distributed among the four wheels. However when cornering there is no rpm compensation between the front axle and the rear axle, which when driving on solid ground or turning a tight bend causes excessive stresses to the driving bar. For this reason the central locking device should be engaged only when the ground is slippery (for example snow, ice) and/or we are driving on a bumpy road. The central locking device must be engaged only when the vehicle is at a standstill, when it is engaged the relevant pilot lamp “Central locking device” on the dashboard lights up. Note: Releasing the central locking device may cause some problems if the driving bar is subject to excessive stress. If so move the vehicle back a short distance to reduce traction or drive “straight ahead” for a long time and simultaneously engage the locking device.

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Rear axle differential unit locking device (C) The differential locking device has to be engaged only when the vehicle is at a standstill, when it is engaged the pilot light “Rear axle locking device” on the dashboard lights up and an audible alarm is triggered. By engaging the differential locking device the rear axle traction is increased, but no rpm compensation occurs between the two wheels of the locked axle when cornering, so that steering is quite impossible. It’s suitable to engage the rear axle locking device only for the necessary time in order to resolve the stalemate. Further explanation for gear and torque distributor control engagement, and also for differential locking device, into our “Instruction for use the off-road”.

Selecting lever for power take-off /shift The power take-off has to be engaged only when the vehicle is at a standstill. Press the clutch pedal, set the shift lever to neutral and move the selecting lever. Note: The lever is provided with a lock; lift it with your fingers and shift the lever. The pilot light “Power take-off” on the dashboard lights up. Release the clutch pedal. By changing the engine rpm also the power take-off rpm rpm is modified. The explained selectors control an oil-pressure switchboard, with allows to engage half and slow speeds, rear and front differential locking device.

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Handbrake To engage the handbrake, pull the lever, untill the vehicle stops as per slope and charge condition. To disingage the handbrake, press the bottom and take down totally. Note: engage the handbrake only when the vehicle is at a standstill. Note: when handbrake is engaged, “handbrake” lamp is on.

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Start and drive Engine start Put the ignition key in the ignition lock. Note: After removing the key and turning the steering wheel, the ignition lock is locked. To unlock it put the key in the ignition lock, slightly turn the steering wheel and turn the key). After turning the ignition key to position (1) „MAR (DRIVE)“ of the ignition lock the following pilot lights turn on:

Combined instrumentation: „Oil pressure“ and „Charge control“ Dashboard: The pilot light „Water in diesel oil“ lights up for approx. 5 sec. (The pilot light „Water in diesel oil“ indicates its function).

The „Pre-heating“ light lights up for approx. 2 sec. The “OBD and EDC pilot light“ turns on for approx. 5 sec. and performs a system control.

Note: The electric fuel delivery pump starts for approx. 10 seconds, on condition that you keep the ignition key in position (1) „MAR (DRIVE)“ for at least that time. At the end of the pre-heating process and/or system control, the lights „Pre-heating“, „OBD and EDC pilot light“ remain on low, indicating their operational stand-by condition. Press the clutch pedal firmly.

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When turning the ignition key to position (2) „AVV (START)“ the engine starts. When the engine has started release the key that will automatically return to position (1) „MAR“. Note: The ignition lock is provided with a start lock which prevents you from “restarting” the engine when it is already running. To „restart“ you must return the key to position (0)). When doing this operation never press the accelerator pedal! (if you press the accelerator pedal, when the engine starts a black cloud of smoke is emitted). If engine does not start immediately, never activate the starter for more than 30 seconds. Once the engine has started, move slowly and keep the engine at intermediate rpm range, so that it can rapidly reach the optimal running temperature. This procedure allows obtaining the following: Regular oil flow inside the lubrication circuit. The flue gas values are within the limit values allowed. Low fuel consumption.

Warning: When the engine is cold you are advised to idle it for quite a long time in order to reach a better “regular running. Otherwise you only increase the emission of noxious substances in the flue gas!

Low temperature starting If temperature is over 10 °C you can start the engine immediately. If temperature is below 10 °C the light “Pre-heating” turns on the dashboard. Wait until the light goes off and then start the engine. After the engine has started the light may turn on again, this reduces the formation of „white smoke“ when temperature is very low outside.

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High temperature starting If temperature is over 10 °C or at a normal running value you can start the engine immediately.

Engine shutoff To shut down the engine turn the ignition key to position (0) (Note: If the engine has been significantly stressed, run it for approx. 30 seconds at a standstill with minimum rpm before shutting it down).

Checks before starting Carry out the following checks: (Q): daily (S): weekly

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Ordinary recommended checks: F1A E4 engine type Oil level in the engine (Q)

Check with the oil plunger (4). The oil level must be between the „MIN“ and „MAX“ marks. Top up from the filling plug (1)

Coolant In the compensation tank (2). Top up with coolant, if necessary (see also Page 28)

Brake fluid (S) in the tank (3) Power steering fluid in the tank (5) State and air pressure in the tires (S) Braking system and handbrake (S) Lighting system, indicators, direction indicators and

windshield wipers function (S)

Note: To drive off-road the oil level in the engine must always be at „MAX“ mark of the plunger, to ensure a sufficient engine lubrication when driving on very rapid slopes.

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F1C E4 engine type

Oil level in the engine Check with the oil plunger (4). The oil level must be between the „MIN“ and „MAX“ marks. Top up from the filling plug (1)

Coolant In the compensation tank (2). Top up with coolant, if necessary (see also Page 28)

Brake fluid (S) in the tank (3) Power steering fluid in the tank (5) State and air pressure in the tires (S) Braking system and handbrake (S) Lighting system, indicators, direction indicators and windshield

wipers function (S)

Note: To drive off-road the oil level in the engine must always be at „MAX“ mark of the plunger, to ensure a sufficient engine lubrication when driving on very rapid slopes. The oil level in the power steering tank (5) must be between the „MIN” and „MAX” marks of the oil plunger included in the closure plug.

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Warning: Check oil level only when the engine is not running. To replace the air filter open the 3 release latches of the air filter body, remove the cover and then the filter cartridge. The replacement schedule is reported in the maintenance manual. Warning: When positioning the cover make sure the gasket is in the correct position! To replace the pollen filter of the heating/ventilation system, unscrew the two screws of the filter cover plateand remove the filter. We suggest replacing the filter every year.

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In vehicles with centrifugal pre-filer the separation tank (1) must be periodically emptied and/or according to the dust pollution conditions. Windshield wiper system tank (1): It should always be filled with approx. 50% antifreeze and 50% water.

Notes:

a) The coolant temperature under normal running conditions is about 85-90 °C. Depending on the external temperature and the driving stress the temperature may rise up to 95 °C. When the cooling fluid reaches approx. 95 °C the radiator fan starts automatically and the coolant temperature is reduced to 85-90 °C. (In suitably equipped vehicles this operation may also be manual, in order to keep the coolant at a constant temperature of 85 °C). If the coolant temperature is too high (> 100 °C) a pilot lamp „Coolant temperature too high“ turns on in the combined instrumentation. In this case stop your vehicle immediately and run the engine for 2-3 minutes idle, then shut it down and investigate the cause.

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b) The „oil pressure“ indicator light turns on when the ignition system starts and turns off only when ignition is completed. If it turns on when you are driving, shut down the engine immediately and contact an authorized repair shop to have the fault identified and removed, before continuing the journey. c) The „Brake fluid“ pilot light indicates a lack of brake fluid due to wear of brake linings or a damage in the braking system, (for example a leak of brake fluid connected with a very long pedal stroke). In this case look for an authorized repair shop immediately. The double circuit braking system allows you to continue your journey, but consider that the braking effect is significantly reduced and the pedal stroke is much longer than usual. d) The „Hand brake“ pilot light turns on when the handbrake is put on and turns off when the handbrake is released. e) The „Charge check “ indicator turns on when the ignition system starts and turns off when the ignition is completed and with an rpm ratio higher than rpm at idle speed. If it turns on while you are driving, it warns that the battery is not charged (for example a V-belt is broken). Have the fault investigated by an authorized repair shop. f) If the „Water in diesel oil“ pilot light turns on when the engine is running, you should discharge the water in the diesel oil filter immediately from the discharge screw under the filter. Before doing this operation remember to disconnect the plug of the water sensor. Note: The plug is provided with a safety anti-shale system that is released by pressing the metal bar.

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g) The „Low fuel“ pilot light turns on when about 15 liters (70 l tank) and/or 25-30 liters (130-150 l tank) respectively are left in the tank. When driving along slopes with over 20% slope the fuel indicator should be at least in the green sector to prevent fuel feeding from stopping.

Warning: If the vehicle remains at a standstill for long time (at least for 2 weeks) the fuel tank and/or tanks should be left full in order to avoid the formation of water condensation.

h) If you have to “empty” the fuel tank or the entire fuel system (for example when you have to replace the filter), you must first of all bleed the system: start the ignition, the ignition key is in position (1) „MAR (DRIVE)“. The electric fuel delivery pump starts and then turns off again after approx. 10 sec. Turn off the ignition and wait for about 10 seconds (during this time data are saved in the engine control equipment). Start the ignition again and repeat the entire procedure twice. Then you can start the engine. Warning!: Never try to start the engine without following this procedure. The fuel present in the system may damage the high pressure pump because of lack of lubrication. Also never “drag” the vehicle because of lack of current.

i) The „OBD and EDC pilot lights“ , after starting the ignition system check the flue gas system and injection for about 5 seconds. If one or both pilot lights turn on when you are driving, look for the closest IVECO service point. Note: The pilot light may turn on also because of a power drop in the engine.

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FAULT CHECK THROUGH THE EDC/OBD PILOT LIGHTS (DIAGNOSTICS)

The EDC pilot light (1) displays information about the injection system faults. If the pilot light turns on during normal running, it means that there is a fault, such as:

Pilot light off Normal running

Pilot light on Fault The system function may be reduced

Proceed with caution and find a customer service shop as soon as possible

Flashing pilot light

Serious fault The injection system is running at reduced rate and/or one or more safety functions are not working , the engine may run only with the emergency power (60%)

Park your vehicle along the roadside. Contact your BREMACH sale point and have the vehicle towed to a customer service shop

Diagnosis: Upon request you may receive an OBD Tester for your vehicle, that allows you to read through the OBD2 connector mounted on the vehicle the error messages displayed in the injection system. It allows you:

1. to identify the fault displayed; 2. to send it to a customer service point of FPT or IVECO, to be helped with the elimination of the fault; 3. to eliminate on your own the fault displayed by means of the shop manual available.

Lighting system

Headlights Front light system includes position lights A, dipped headlights B, high beams C.

Position lights bulbs replacement (A): Loosen fixing screws of metal support. Remove rubber cover behind lights. Remove the lamp and replace with a new one. Assemble again components previously dismantled. Halogen dipped headlights (B) / high beams (C) replacement:

Projectors and ignition must be turned off Loosen fixing screws of lightening group, remove it and replace bulb with a new one.

WARNING: do not touch glass of lamp to avoid damaging it.

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Direction indicators bulbs replacement:

Make sure that direction indicator and ignition are off. Remove carefully lamp with its cover. Separate lamp from its support and replace with a new one.

Insert again support with new lamp and pay take care protrusion matches the corresponding seating; then screw the support clockwise.

Front turn indicator Side turn indicator

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Internal lighting system 1. Side internal light with pressing support (cylindrical bulb, 5 Watt Roof) 2. Switch: press the transparent acrylic glass to turn light on/off. Internal light turns on every time driver and/or passenger door is opened.

Reading lights (optional) 3. Central internal light 1 with pressing support (2 x 5 W Roof); to replace bulbs apply a slight pressure on glass perimeter with a screwdriver and remove it from its frame 4. Reading light (bayonet bulb, 4 W), to replace, push reading bulb counterclockwise and remove it; mount the new bulb following the reverse sequence.

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Rear lights left / right 1- Brake light, 21 W bayonet bulb 2- Turn indicator, 21 W bayonet bulb 3- Rear light, 10 W bayonet bulb 4- Fog rear light, 21 W bayonet bulb 5- Reverse gear light, 21 W bayonet bulb Replacing: Loosen glass fixing screws. Replace baked bulb with a new one of same model. Place again glass in its seating and fasten with scews. Plate side lightening: 5 W lamp.

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Wheel replacing Onboard equipment and jack are under the passenger seat. Lift vehicle only with jack positioned in specified points, under axle bodies. (In case of soft ground place jack on a solid support, such as a wooden panel or equivalent). Strictly follow instructions for the use of the jack, reported on it and on end user manual. Before lifting the vehicle: Pull hand brake and/or make sure that vehicle cannot move (for example by placing a drop-type sprag) Release slightly wheel bolts. Then lift the vehicle until the wheel is free to rotate. Remove the wheel releasing the 6 bolts and replace the wheel. Lower the jack until the wheel reaches the ground and tighten the nuts following a cross sequence. (as shown in picture) Tightening torque required for wheel nuts: 200 Nm (20 kgm) Advice: You may obtain the correct tightening torque also by inserting the jack lever on the bar of the box spanner SW27 Included in the onboard equipment and tightening the nuts with it.

Important note: Periodically check the tightening torques of the wheel nuts and after changing a wheel check them again after max. 50 km.

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Towing Your BREMACH vehicle is provided with a towing hook respectively placed on front side and rear side of the frame. On vehicles provided with towing device, it can be used as a hitch itself. Front towing hook Rear towing hook

Hole for towing

hook Rear towing hook

WARNING : if your vehicle needs to be towed, please follow these instructions: Engine failure: Turn the ignition key to position (1) „MAR (DRIVE)“, to prevent the steering wheel locking device from triggering when steering.

Warning: When the engine is off, both power brake and power steering do not work, which means that braking and steering forces increase significantly.

Drawbar failure: to allow power brake and power steering to work, you can run the engine. (WARNING: To do this put the shift into neutral). Clutch failure: Put the shift into neutral. Shift failure: Do not run the engine and put the shift lever Road/Off-road into neutral so that no parts of the torque distributor are moved and the

shift remains at a standstill during towing operations. Torque distributor: Put shift lever Road/Off-road into neutral. Torque distributor won’t move during towing operation.

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Central differential failure: Remove propeller shaft from torque distributor on both sides, i.e. front and rear axle. Rear axle failure: Remove propeller shaft from torque distributor to rear axle. Remove right and left driving axle and close openings in wheels’ hubs

(using for example rubber round plates, etc.) Front axle failure: Remove propeller shaft from torque distributor to front axle.

Using a trailer Before using a trailer check values of max. allowable trailing load, vehicle’s overall weight, max allowable load per axle and drawbar load. When using a trailer comply with following instructions:

Trailer’s overall weight (trailer weight + load) must not exceed allowable trailing load.

Trailing load has to be divided so as the drawbar load is at least 25 kg. Drawbar’s load must not exceed the max. value of 120 kg.

Total amount of vehicle dead weight, vehicle’s weight (including passengers), towing hook weight and drawbar load must not exceed the max. allowable weight of the vehicle.

Before starting any trip check that the lights on the trailer work properly.

Towing hook Rear crossbar is provided with holes to add a towing hook (ULPYO or spheric hook) with screws. Whenever is needed to add a towing hook after purchase of the vehicle, it must be added registered on vehicle’s license. Maintenance Engine

Engine type IVECO F1A E4 IVECO F1C E4 Oil R every 20.000 km R every 20.000 km** Oil filter R every 20.000 km R every 20.000 km Air filter C/R every 20.000 km C/R every 20.000 km Fuel filter R every 10.000 km * R every 10.000 km * Fuel pre-filter C/R every 20.000 km C/R every 20.000 km Toothed belt R every 120.000 km R every 350.000 (chain)

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* Every 5000 km: Bleed fuel filter to eliminate condensation water. Outside the EU customer service network discharge the condensation water every week.

C = Check R = Replacement C/R = depending on dust pollution and/or soiling level S** = set at zero the particle filter counter (see Page 28) WARNING: if use of the vehicle is in harsh conditions (mainly off-road) all maintenance times indicated are to be halved! You can find further information in the user guide or ask your BREMACH partner. If the annual kilometric performances are below the parameters specified, fuel and oil must be replaced every year.

Min. level Max. level Check of oil level in the engine: remove the oil dipstick and clean it with a cloth, then put it again inside its guide.

Extract again the oil dipstick and read the oil level. (Note: engine should have been switched-off for a few minutes, before doing this check).

Oil level should always reach the „MAX“ mark. Oil quantity between the two marks is about 1.5 liters.

fill up with oil OK too much oil Oil specifications: SAE 10W/40 or 15W/40 at least B3/E2-96 or API CH4/CG4 (see also Page 37) F1A oil change quantity: approx. 5.5 liters (including oil filter) and/or 4.8 liters (without oil filter) F1C oil change quantity: approx. 7.0 liters (including oil filter) and/or 6.5 liters (without oil filter) Drain plug: 12 mm hexagonal-head screw F1A oil filter type: IVECO 2995811 F1C oil filter type: IVECO 2995655 Air filter type: IVECO 1903669 or Mann/Hummel C 17337 F1A engine oil filter position F1C engine oil filter position

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1: Oil filter Particle filter F1C engine type is provided with a self-cleaning particle filter. The particle filter system requires no maintenance; however after every engine oil change the electronic control unit counter has to be set to zero. If no computer aided equipment of FPT – IVECO service network is available, proceed as follows:

1. Switch-off the engine and turn the ignition key to position (1) „MAR (DRIVE)“ (see Page 18) 2. Press accelerator pedal firmly for at least 15 seconds. Simultaneously press 10 times the brake pedal and then release it. 3. Turn the ignition key back to position 0).

If the counter is not cleared to zero, the electronic control unit reduces the engine power after reaching the max. limit hours set. Note: If the vehicle is to be used in countries where the diesel oil is expected to contain more than 0.5% sulphur, please contact the manufacturer service network or the producer before starting the use. AIR FILTER Air filter replacement and cleaning: Remove filter box cover (1) after opening the 3 spring clamps (2). Remove filter cartridge. While this operation is done, please prevent 1 dust from entering the filter body. Check that the body gasket is in good condition. Apply a new filter cartridge and make sure that the box is correctly closed.

2 Filter cartridge can be cleaned by blowing compressed air from inside to outside (max. 3 bar). In this case avoid using detergents or naphta.

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Coolant Coolant check: When the engine is cold, the coolant level should be between the „MIN“ and „MAX“ marks on the compensation tank. To fill up, unscrew the screw plug (arrow). WARNING: If the engine is hot the cooling system is under pressure. Open the screw plug only when the engine is cold to avoid being injured! To fill up use a mix of 50% radiator antifreeze (in compliance with Spec. SAE J1034) and 50% water, able to resist up to -35 °C. To avoid corrosion this mix is to be used throughout the year. Coolant must be anyway replaced every 3 years. Approx quantity: 11 liters Note: If liquid level has significantly sensibly decreased, a leak or overheating condition is to be assumed. Gearbox 6 + R speed synchronized gearbox type ZF 6S-300/380. Every 20,000 km (400 h) – Check oil level; oil must reach the lower edge of the screw plug (A). Every 40,000 km (800 h) – Change oil. First discharge all exhaust oil through drain outlet (B). A

Oil specifications: SAE 75W/90 GL 4/5 or 85W/90 GL4 Oil change quantity: ca. 3.0 liters Drain or screw plug: SW 17 mm WARNING: please deliver exhaust oil to authorized workshops and do not throw it into the environment.

B

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Clutch Clutch does not require maintenance and clutch control must not be bled. In the event of a fault the entire clutch control has to be replaced with a spare unit. Clutch wear may be checked as follows: a = Max disengagement position in case of a new clutch (121.8 mm) b = Max engagement position in case of a new clutch (99.29 mm) c = Min position in case of worn clutch (73.3 mm) When wear on the clutch disc is over 90%, the servo cylinder compensates for such wear by increasing pedal load during the declutching phase.

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Torque distributor BK 20 Every 10,000 km (400 h): Check for oil sealing and the height and longitudinal clearance of the propeller shaft flanges. Every 20,000 km (400 h): Check for oil level, the oil should reach the lower edge of the screw plug (A). Every 40,000 km (800 h): Change oil. First discharge all exhaust oil from drain outlet (B). A Oil specifications: SAE 75W/90 GL 4/5 or 85W/90 GL4 Oil change quantity: approx. 3.0 liters Drain plug: SW 24 mm B Screw plug: SW 24 mm Differential unit for front or rear axle Every 10,000 km (200 h): Check oil seal and height and longitudinal clearance of propeller shaft flanges. Every 20,000 km (400 h): Check oil level, it should reach bottom edge of the screw plug (A). Every 40,000 km (800 h): Change oil. First discharge all exhaust oil from the drain outlet (B). (Note: on vehicles provided with a protection plate on front axle differential, unscrew the plate first to access the filling screw (A)). Every 80,000 km (1600 h): Check the gear ring/ pinion clearance in the differential (max. tooth side clearance approx. 0.2 mm).

A Oil specifications: SAE 75W/90 GL 4/5 o 85W/90 GL4 Oil change quantity: approx. 2.0 liters Drain plug: 10 mm hexagonal-head screw Screw plug: SW 27 mm B

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Fuel filter Position inside the vehicle Filter type Fuel filter under vehicle frame IVECO 2992300 or Mann+Hummel WK 854/2 IVECO fuel pre-filter IVECO 500318246 Every 10,000 km (200 h): Replace filtering unit Every 5,000 km (100 h): Drain fuel from filter from drain plug (1)

(= water sensor), to remove condensation water. First remove plug form water sensor. (Note: The plug is provided with a safety anti-shake system that is released by pressing on the metal bar). 1 When fuel filter has been replaced or condensation water has been removed, fuel system must be bled. Proceed as follows: Start the ignition, turn the ignition key to position (1) „MAR (DRIVE)“. Fuel delivery electric pump starts and then stops after approx. 10 sec. Turn off ignition and wait for about 10 seconds (meantime some data are saved in the engine control equipment). Start ignition again and repeat entire procedure twice more. Then you can start the engine. WARNING: If the vehicle is used out of EU service network, maintenance schedule about employment under harsh conditions must to be applied (Service Group I). Vehicles which are presumed to run with low quality fuel (such as diesel oil mixed with water) and/or clearly polluted fuel (for example from drums, cans etc.) the schedule for diesel oil filter replacement should reduced to 5000 km. (This provision does not apply to vehicles provided with SEPAR pre-filter). When fuel is taken from drums, these drums should not have been moved for at least 6 hours before taking the fuel and the fuel should be drawn at least at 25 cm from the drum bottom.

1Note: The schedule of filter maintenance is to be strictly followed. Any damages due to lack in filter maintenance are not covered by FPT engine guarantee. Fuel pre-filter type SEPAR (optional) Pre-filter must be checked daily for the presence of water and dirt in the gauge glass (visual control). According to contamination, filter must be emptied weekly or monthly.

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For that purpose open the drain screw (1) on the top of the cover, press the drain plug in (2), turn it by 90° and drain the filter completely. Close the drain plug and screw, bleed the fuel system. Every 40,000 km (800 h) or annually: Replace the filtering element. Max. allowable water level must be at least 15 mm below the guide blade! When reaching max. water level, drain water from the drain plug. Filter’s cartridge replacing 1. Shut down the engine and empty the filter (see above) 2. Unscrew the cover screws (hexagonal-head M5, SW 8), remove the cover 3. Draw the spring box and remove the filtering cartridge on the bracket 4. Insert the new cartridge and position the spring box on the cartridge 5. Check that it has been correctly housed in the cover and verify any damages in the cover seal 6. Put on the cover, make sure that it is correctly positioned and tighten the screws in cross sequence 7. Bleed fuel system. Note: in event SEPAR filter blocks in winter due to the presence of water crystals in diesel oil (oil diesel with paraffin), filtering cartridge can be removed to allow diesel oil to flow through again. Note: If the vehicle is used in cold countries, we suggest using a SEPAR filter with integrated resistance.

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Fuel type Standard fuel must be used according to EN 590:1993, with a minimum cetane number of 48 and a maximum sulphur content of 0.5%. If used fuels have a sulphur content higher than 0.5% the engine oil change time has to be halved. In addition, failures may occur in the engine due to a reduced regeneration of the diesel fuel particle filter (DPF). Note: if the vehicle is used in countries where the sulphur content is expected to be much higher, contact the manufacturer’s network or the producer before using the vehicle. Fuel additives We recommend not using any fuel additives; it may not be covered by the FPT engine guarantee. The use of BIODIESEL, according to EN 14214, is allowed as an addition to the standard fuel up to 5% only. Note: In certain EU countries, such as Germany and Austria, law provides for a 5% addition of BIODIESEL to the fuel sold in petrol stations. Winter diesel Generally, it is responsibility of the individual oil companies to sell fuel with characteristics suitable for use under low external temperature conditions. In cold countries, such as Scandinavia, winter diesel has got necessary characteristics to be employed with Common-Rail engines and allows them to run at -30 °C. The use of common diesel additives available on the market to improve cold characteristics is not recommended. These additives generate a non-homogeneous mix in the tank, which causes the additive to deposit on the bottom of the tank. This increases the diesel fuel fluency for a short time, but, since the fuel intake system is at the bottom of the tank, it first of all intakes diesel mixed with the additive and this mix may cause damages to high pressure pump or to injectors. If you drive through countries where no winter diesel is available, then you can exceptionally proceed as follows: Every time you fill up the tank, add max. 5% kerosene or petroleum, as well as oil for 2-stroke engines in a 1:300 ratio (1 liter oil for 2-stroke engines every 300 liters diesel fuel). Use only high quality oil for 2-stroke engines, preferably if it burns without producing ash. Kerosene or petroleum, as well as oil for 2-stroke engines, must be added before the tank is filled up with diesel oil, to help the mixing process. WARNING: This note applies exclusively to emergency running conditions of your vehicle in very cold countries where good quality winter diesel oil is not available (such as Russia, etc.). However, in the long run, damages to the high pressure pump or to the injectors may occur. The use of the above mentioned mix is therefore at your own risk and is not covered by the FPT engine guarantee.

Power steering Every 10,000 km – Check all steering elements, especially the propeller shaft and the shaft universal joints of the

steering control arm, in particular the locked tighten coupling of the lower universal joint (A) on the steering box. Grease the universal joints (A,B) with a grease gun. Stop greasing when grease comes out of the universal joint. Check that the protection collar of the universal joint sliding part is free of rust and dirt.

Every 20,000 km – Check the oil level in the storage tank (A). „Minimum – Maximum“ marks on the cover. Every 60,000 km – Replace oil and filter. After replacenet, to bleed the steering system start the engine and steer from

one limit stop to the other, until the steering wheel becomes easy to move. Hydraulic fluid: ATF Dexron.

WARNING: If a hose of power steering system breaks and consequently oil leaks, shut down the engine immediately. In fact in this case the pump is no longer lubricated and may lock, damaging the engine toothed driving belt.

A

B

A

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Driving universal joints Universal joints Every 10,000 km: Grease universal joints with a grease gun. Stop greasing when grease comes out of the universal joint. Sliding elements Every 60,000 Km: Grease the sliding element toothing. Disconnect the propeller shaft on one side from the universal flange and separate them. Warning: Two arrows indicate the point where the two propeller shaft halves are connected. If this indication is no longer visible, first mark a new sign with a color and then divide the shaft. Lubricant: Lithium-soap grease available on the market.

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Front and rear leaf springs (no maintenance type) Every 10,000 km – Check the wear of the Silent blocks in the elastic studs of the leaf springs. WARNING: if you drive on track check for wear of Silent blocks every week. Front wheel hub A Every 20,000 km – Grease the lubrication nipple of the front wheel hub (A) using a grease gun, until grease comes

out of the innermost point of the bearing of the front driving universal joints! Grease: Molybdenum disulphide lithium soap grease. Every 40,000 km – Check the clearance of the wheel bearing. The wheel bearings require no maintenance and are

not adjustable. In the presence of axial clearance whole bearing unit must be replaced. We recommend this work to be carried out by an authorized repair shop.

A King pin bolt and front driving universal joints Every 20,000 km – Grease the lubrication nipple of the front king pin bolt (A) by means of a grease gun, until grease comes

out of the overflow holes. To grease the universal joints (B) of the two-hinge propeller shaft the vehicle must be lifted at the front by means of a jack, the wheels must be completely steered to the left and/or completely to the right; this is the only way to have access to the lubrication nipples (two on each side respectively) in the universal joints of the front driving universal joints.

Grease: Molybdenum disulphide lithium soap grease. WARNING: If the vehicle is used on muddy soil or after water stream crossing, the king pin bolts and the two-hinge

propeller shafts must be greased at least daily. In this case the wheel hubs must be greased at least weekly. Hydraulic system with power transfer unit (optional) In the case of irregular use: replace the hydraulic fluid every 2 years. Clean the oil return filter and the oil radiator. Check all

A

B

B

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connections of the hose for any damages. In the case of regular use or continuous running: the operations described above are to be carried out annually. Brakes Weekly – Check the fluid level in the storage tank in the engine compartment. The fluid level decreases when the

brake linings wear. When the fluid level reaches the „MIN“ mark the pilot light „Check of brake linings“ on the combined instrumentation lights up.

Change the brake fluid at least every 2 years. Brake fluid: DOT4 Air bleed We suggest having these jobs carried out by an authorized repair shop. A : Rear brake cylinder bleed screw B : Front brake cylinder bleed screw B Handbrake clearance Weekly – Check braking efficiency of handbrake; adjust it, if necessary.

We suggest having this job carried out only by an authorized repair shop.

Service brake clearance on front and rear axle It is automatically adjusted, further adjustment is not required. Periodically check the wear condition of the brake linings.

A

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Braking system + ABS diagram 1 – Vacuum power brake . Dwg…… 2 – 2-section master hydraulic cylinder. Dwg. …… 3 – Brake fluid storage tank with level indicator 4 – Front/rear wheel brake control hydraulic cylinders

2 Front Ø52 Braking area 157 cm per wheel 2 Rear Ø46 Braking area 139 cm per wheel

5 – Engine air pump 6 – Stop light indicator 7 – Drum in hot Ø190. Re. Dwg. …… 8 – Air tank. Dwg. …. 9 – BOSCH – ABS controller code …….

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Recommended maintenance for off-road use If your vehicle is used under critical conditions (off-road) make regular checks (daily/weekly) of the perfect state and function of the following parts and components:

All mechanical parts and components (Visual control) All connection of hoses, ducts and bushings (Visual control to identify any damages) Radiator fan to verify any damages due to a break of the engine suspension Engine suspension Shift suspension Air suction and exhaust pipe Leaf spring suspension, shock absorbers, axle suspension, stabilizers Driving box and steering linkage Transmission universal joints, propeller shafts, universal joints, suspension of the reducer shift Fuel and oil tanks Cab suspension

Lubrication schedule Strictly follow this lubrication schedule to ensure that the relevant parts function properly. Warning: Carry out lubrication operation only by means of a manual grease gun. The following parts are to be lubricated: Every 20,000 Km: The universal joints of the torque distributor drive shafts (6 pcs., see Page 33) (Every 10,000 Km The front king pin bolts (2 pcs. on each side, see Page 34) if used under critical The universal joints of the front cardan drives (2 pcs. on each side, see Page 34) conditions) The wheel hubs (2 pcs. see Page 34), the shaft of the steering control arm (2

pcs., see Page 33) The support of the handbrake lever on the frame (1 pc.)

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If used on muddy soil or after water stream crossing Daily: The front king pin bolts (2 pcs. on each side, see Page 34) The universal joints of the front cardan drives (2 pcs. on each side, see Page 34) Weekly: The universal joints of the torque distributor cardan drives (6 pcs, see Page 33) The shaft of the steering control arm (2 pcs., see Page 33) The front wheel hubs (2 pcs., see Page 34) Water stream crossing Warning! When you come out of water remember that the brakes of your vehicle must “dry when braking”, otherwise they would have a very long braking stroke and the risk of accidents would significantly increase. If the vehicle has drum brakes, at the end of the trip they should be open to eliminate mud and pebbles. If you drove for a long time in water streams or your vehicle remained for a long time inside deep water because it got bogged down, then check engine oil, shift oil and axle oil to make sure that no water has infiltrated and replace them, if necessary, and follow the instructions of the lubrication plan. Further information are given on Page 48. Table of recommended oils and lubricants Engine SAE 10W/40 or 15W/40

at least B3/E2 ACEA and/or API CH4/CG4 Shift – torque distributor – drive axle SAE 85W/90 GL4 or

SAE 75W/90 GL4/5 Power steering Oil for hydraulic automatic drives

ATF Dexron II D Braking system Brake fluid

DOT 4 3-side dumper hydraulic system Hydraulic fluid

HLP 46 Hydraulic system with power take off Hydraulic fluid

HLP 46 Water radiator Radiator antifreeze available on the market mixed with water 50:50 for limit

temperatures of -35 °C Greasing points Molybdenum disulphide lithium soap grease

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Table of approved oil viscosity values:

Oil quality: at least B3/E2 ACEA and/or CH4/CG4

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What you should know about your BREMACH vehicle Precautionary measures for off-road vehicles: This vehicle is an off-road class vehicle. When used off-road this type of vehicle has a higher ground clearance. Compared to normal road vehicles this means not only a higher vehicle barycenter, but also a narrower toe-in compared to the barycenter height. In off-road vehicles this causes a stronger overturning and slip moment. The higher ground clearance makes the vehicle suitable for off-road drive and also gives the advantage of a higher driving position with consequent better visual field: this allows the advance identification of any problems. On the other hand off-road vehicles are not designed to corner at the same speed as normal cars – just as sport cars are not designed to be used off-road. For this reason it is important to bear in mind that if you drive narrow bends at high speed or you have to change lane rapidly, you risk overturning or rolling over. Running in Drive smoothly and avoid running the engine with high rpm rates. The running in of your vehicle does not need any complex operations. If you follow some simple advice during the first 1000 kilometers, you will achieve cost effectiveness and long life for your vehicle.

Do not drive over 110 km/h speed. Run the engine only in the intermediate range of 2000 - 3000 rpm. Do not start by pressing the accelerator pedal firmly („Start at full speed“). Do not brake suddenly during the first 300 kilometers, if possible. Drive by changing speed. Do not tow a trailer for the first 800 kilometers.

Vehicle take care Off-road vehicles are subject to higher corrosion due to off-road use and to the different climates in which they are driven. In this case the salt spread on the European roads damages all vehicle parts as well as the mineral salts contained in the desert sand. Therefore, in addition to the anticorrosion measures adopted by the manufactures, looking after your BREMACH vehicle is important to protect it against rust in the long term.

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The most frequent causes for the formation of rust on your vehicle are:

Salt, dirt and humidity accumulation in points under your vehicle that are difficult to reach. Paint or prime detachment due to minor accidents or impacts by pebbles, gravel etc.

Taking care of your vehicle is particularly important if you live or drive your vehicle under special environmental conditions.

Spread salt or chemical products that bind dust accelerate the formation of rust, as well as air reach in salts in seaside areas, in desert regions or polluted air in industrial zones.

High air humidity accelerates the formation of rust, especially when temperature is just over the freezing point. Humidity in certain points of your vehicle, which stays for long time, may cause the formation of rust although other parts of the vehicle are perfectly dry. High ambient temperatures may cause the formation of rust on some parts of the vehicle, which due to insufficient air circulation do not dry in quite a

short time. The above mentioned points highlight the need that your vehicle to be kept as clean as possible, mainly the lower side, and that any paint or underbody protection damages are repaired as soon as possible. To avoid the formation of rust on your vehicle operate as follows: Wash your vehicle frequently. Of course you have to keep your vehicle clean, washing it regularly, but to avoid the formation of rust and corrosion you should follow these points:

If in winter you drive on roads where salt has been spread, if you live near the sea or if you drive through desert regions, you should clean the lower part of your vehicle at least monthly, to reduce the formation of rust as much as possible.

Water or steam blast appliances are recommended for cleaning the lower part of your vehicle and the wheel guards. Pay particular attention to these points since they are not well visible. If you just wet the dirt and stone fragments without removing them, damages may be worse. The sill boards and frame parts are provided with apertures that must not be clogged by dirt, otherwise they may cause the formation of rust.

After the winter season, carefully wash the lower part of the vehicle. Check the painted part of your vehicle Immediately repair paint scratches or damages caused by stone impacts, to avoid the formation of rust. If scratches or lamination penetrate down to bare metal, the damage has to be repaired by a qualified repair shop.

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Check the inside of your BREMACH vehicle Water and dirt may accumulate under the mats and cause the formation of rust. For this reason control under the mats from time to time to make sure that the bottom is dry. When transporting chemical products, detergents and cleaning products, fertilizers, salts etc. may sure you carry these product in suitable containers. If anything slops out or leaks, clean immediately and dry the area concerned. Park your vehicle in a well ventilated garage or under-cover parking. Do not park your vehicle in a humid or badly ventilated garage. If you wash your vehicle inside the garage or you leave the vehicle wet and/or covered with snow, the humidity deriving from this condition may cause corrosion. A wet vehicle may be subject to corrosion even when parked in a heated garage, if air circulation is not enough. Washing and waxing your vehicle Washing your BREMACH vehicle Keep your vehicle clean by washing it regularly. The following cases may cause damages to the paint or corrosion to the body. Wash the vehicle as soon as possible in the following cases:

Driving through coastal areas Driving along roads with presence of salt or sand Staining from tar, resin, bird excrements and insect remains Driving in areas with strong air pollution due to smoke, soot, dust, iron dust or chemical compounds Excessive staining from mud and dust Long trips, mainly after driving through desert regions, salted lakes etc.

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Onboard tools Onboard tools and jack are under and/or behind the passenger seat. Equipment with onboard tools:

Universal pliers Round pliers Screwdriver Cross screwdriver Double ended spanner 8x10 Double ended spanner 12x13 Double ended spanner 14x17 Socket spanner 19x22 Socket spanner 27 mm Hammer Separately: Hydraulic jack Grip wedge (on request)

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Spare wheel The spare wheel is found either on the right side of the chassis or on the rear protrusion of the chassis (in the case of single or double cab) depending on the vehicle model. The wheel is fixed to a support with integrated lift. Unscrew the two screws in the rim (SW27) to lower the lift with extension included. In the van model the spare wheel is fixed to a rotary support on the rear side of the chassis. To open the rear door overturn the support. Open the hinge lock. Spare wheel assembling Rim with elastic ring: including rim, joint ring, side ring and closure ring (elastic ring). To remove the tire you need the following tools: Wood block approx. 20x20x20 cm Tire drift, spanner 2 kg hammer (and/or in the case of old tires, 5 kg hammer with round pliers) 1-2 screwdrivers with blade width approx. 8-10 mm.

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Removing the tire: Put the removed tire on the wood block with the valve side turned upward (Note: If the floor is dirty or muddy we suggest laying a covering sheet under the wheel). Unscrew the valve using the suitable spanner and let air bleed out of the tire. By means of a chalk, felt tip or equivalent mark the position of the counterweights on the side ring with reference to the rim/closing ring/tire, to obtain the correct counterweight position when reassembling. By means of the hammer and tire drift remove the tire from the rim on the valve side, until the tire bead is approx. 20 mm below the side ring. By means of the hammer separate the side ring from the rim, until it is approx. 10 mm below the closing ring. (Note: To avoid damaging the rim paint, interpose the wood block between hammer and the side ring).

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Put a screwdriver in the slot of the closing ring and exert a light pressure to diverge the ring. The closing ring detaches from the rim, with a second screwdriver (or by hand) exert a light pressure and remove the closing ring from the rim by hand. Remove the side ring from the rim and then remove the L-shape seal ring. Overturn the wheel, lean it on the wood block and by means of the hammer and drift separate the tire from the rim. Assembling the tire: Rest the rim on the wood block. Before mounting the tire brush the bead and rim with mounting paste. (Note: In alternative also suds can be used).

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Push the tire on the rim. Brush the tire upper bead and the rim with mounting paste. Position the seal ring and push it through the slot between tire and rim, so that the L-shape part is turned downwards. Brush the rim and bead with mounting paste. Position the side ring and closing ring. You can push by hand and/or hammer the closing ring in the relevant rim groove using a wooden block. Make sure that the closing ring completely fits the rim groove. Screw the valve device on the tire valve and inflate the tire (to know the correct tire pressure see page 4-5). Make sure that the tire bead and the side ring lift homogeneously. If you used insufficient lubricant, when the tire is inflated the side may rise, because there is too much friction on the rim. The seal ring may become entangled between tire bead and rim and may be displaced and therefore the seal effect is not ensured. In this case remove the closing ring and the side ring again, remove the seal ring, apply more mounting paste and repeat the entire mounting sequence. Note: If the closing ring has been correctly assembled, the ring can not detach during tire inflation. Make sure that:

1. The closing ring groove is clean and free of rust. 2. The two ends of the closing ring are close, not bent and not detached, when it is disassembled, otherwise its pre-tensioning would be insufficient. 3. The closing ring after assembly and before the tire is inflated is in the correct position inside the relevant rim groove.

If after inflating the tire the closing ring is not correctly positioned in the rim groove, it is possible to hammer it in the rim groove by means of a wooden block in the corresponding points.

Off-road driving In general: Recommendations for off-road driving depending on the vehicle type: The high off-road adaptability of our 4x4s vehicles is ensured by its centre of gravity that is higher than a regular car, but it reduces stability when cornering. This means that cornering at high speed is not allowed, as we are used to doing with regular cars, also because the standard tires of 4x4s vehicles have less road holding than regular car tires. Using permanent four-wheel drive Generally permanent four-wheel drive allows safe driving both on-road and off-road, since the central differential unit compensates for the different tracks of the front and rear axles when cornering. If the central differential unit is “open” (not locked) and the thrust on a wheel axle collapses, because for example a wheel lifts off the ground and loses traction on ice or snow, in that case there is no more traction force on the other wheels and the vehicle stops (or remain blocked). The central differential unit should be locked in this case, to increase traction. Lock the central differential unit only when the vehicle is at a standstill. On dry, consolidated (asphalted/concrete) roads the central locking device must not be locked. Otherwise it may distort the tow bar (Lack of RPM compensation between front and rear axle). Using engageable four-wheel drive On consolidated roads: on ice or snow the front axle must be engaged to increase vehicle traction. This operation is possible even when the vehicle is running (wheels straight and forward), so your vehicle can rapidly adapt to any road conditions (dry/snowy or icy). On dry and consolidated roads (asphalted/concrete) the front axle (four-wheel drive) must be engaged. Otherwise damages may occur to the tow bar due to distortions (Lack of RPM compensation between front and rear axle). On rough ground: to increase traction the front axle must be engaged in all circumstances. Using off-road gear The off-road gear is used to increase the traction force and/or to reduce the running speed on rough ground. Too high a speed may cause a lack of grip, thus increasing the risk of accidents; in addition the frame could be excessively stressed. The off-road gear can be used with or without the “central locking device” (or four-wheel drive) engaged. WARNING: When using the off-road gear to increase the traction force without engaging the front axle (as in the version with “engageable four-wheel drive”) the mechanical drive elements, and particularly the rear drive shafts and rear differential may be excessively stressed.

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OFF-ROAD VEHICLE CHARACTERISTICS

The ground adaptability of an off-road vehicle is obtained through very special technical and geometrical characteristics, that often conflict with the characteristics of regular cars. These special characteristics are:

- Four-wheel drive for optimal traction - Off-road reduction for low speed and high traction force - Big wheels for increased ground clearance, high thrust horsepower and reduced ground pressure, if possible - Possibly high front and rear angle of slide, to run along slopes - Big ramp angle (ground clearance on cat’s back), if possible, to drive over cat’s backs

On the other hand all these characteristics make the normal drive characteristics of these vehicles on regular roads worse compared to regular cars, and this is important to take care for your own safety. Technical data of 4x4s vehicles

T-REX ON ROAD OFF ROAD

Allowable Slope 100% 100% Max. side inclination* 65% (31°) 60% (28°) Front slide angle 40° 45° Rear slide angle 35° short overhang 40°

25° long overhang 30° Ramp angle 35° axle spacing 2600 45° 30° axle spacing 3000 40°

25° axle spacing 3400 35° Min. ground clearance 215-235 mm 265-280 mm Shallow recess depth 750 mm 900 mm Steering diameter 11 m axle spacing 2600 11 m 13 m axle spacing 3000 13 m

15 m axle spacing 3400 15 m

* The max. side inclination data have been determined under realistic driving conditions, for this reason they are lower than the values determined by calculation (theoretical values). You should not exceed these values, for your own safety.

WARNING: Inappropriate usage of the vehicle and/or any of its components (external transformations included) leads to immediate loss of guarantee of the vehicle itself.

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POWER TAKE-OFF

For auxiliary groups control such as tipper, crane and municipal vehicles, different types of power take-offs can be fitted. Depending on required performances and use, the application can be fitted on:

Gearbox Transfer box Engine On the vehicle rear

Specifications and performances are indicated on power take-off sheet attached. For defining the necessary power for instruments control, especially if high values are required, it is appropriate to consider also assimilated losses during the power transmission phase ( 5-10% for mechanical transmissions, belts and gears and higher values for hydraulic controls). Selection of power take-off ratio has to be made in such a way the power absorption occurs in the engine constant torque reving range: low speeds (lower than 1000 revs/1’) have to be avoid for no irregularities and pulls. Transmission kinematic mechanism (angles, revs, torque) has to be carefuly considerated, from the power take-off to the device, during the designing step, and the dinamic behaviour in working situation, as prescripted by the trasmission manufacturer. In calculating process, features in max power and max torque, have to be considered. To get a good constant-speed behaviour, angles with the same value at the extremities, avoiding too high values, have to be made; Z solution is normally prefered to the W one, for lower charges, both on the PTO and on the group to be controlled bearings

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Engine (crankshaft) PTO PTO is front applied on the crankshaft, can be used both with standing and driving vehicle. This PTO drives an hydraulic pump throgh poly-V rubber belt Max withdrawn power = 14.7 KW Engine rpm/feed pump rpm = 1 : 0.605

Gearbox PTO The gear box PTO has to be used only “in neutral position” and it has to be engaged / disengaged when the clutch is disconnected Characteristics of feed pumps usually applied are as follows (due to gearbox installed):

Motore - Cambio Rpm Motore Rpm Out Pto F1A – S300 1 0,910 F1C – S380 1 1,044

PTO Lat. L.d. Zf 6s-300 PTO Lat. L.s. Zf 6s-380 vo

Coppia (Nm) 180 180 Rapp. Int. 1,27 1,45 N denti 28 32

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Transfer box PTO Transfer box PTO is normally used when the vehicle is stopped. If the application requires the vehicle to be running, no change of gear has to be done. This PTO, thanks to universal joint, can have the drive on rear chassis crossbar. Depending on the usage, the suitable no. of revs can be chosen, selecting the suitable gearbox speed. Max withdrawn power can be of 55 KW.

For further explanations and specifications or to install systems with particular characteristics, please refer to BREMACH’s Technical Office. It will be on behalf of transformation’s furnisher presentation and approval of transformation by Qualified Authority, when expected by National law in force.

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1. Off-road drive speed The less even and the more indented the ground, the lower the speed must be. Slopes that end with a flat plane must not be driven over at high speed, in order to avoid an undesired jump when the vehicle reaches the horizontal level. If the shifting and speed change are correct, you can drive safely on every ground type without declutching too often. Do not slip in the clutch to overcome difficult drive situations due to ground unevenness, just change down. 2. Driving on a slope The high position of the vehicle’s centre of gravity requires special care when driving off-road. All up and down slopes are to be travelled over at right angles only, i.e. along the slope line. To avoid the risk of overturning, when you get down a slope, and particularly when the ground is soft and slippery, you must only use low gears and drive at low speed, avoiding sudden braking and wide steering angles. Never tackle a slope at an angle, since in this case there is the risk not only of overturning along the longitudinal axis, but also and primarily of tilting sideways, along the transversal axis . If when driving up a steep hill the engine of your vehicle “stalls” because you selected too high a gear, you should try not to let your vehicle slip down the hill, since this operation requires that you control the speed only with the brake pedal and the risk of accident increases! To reach the original start point drive as follows, for your own safety:

1. Stop your vehicle on the slope using the brake pedal. 2. Simultaneously declutch and engage the reverse gear. 3. Engage the gear and release the brake pedal. 4. With the reverse gear engaged activate the starter. If the speed increases too much, use the brake pedal with caution without locking the wheels.

When driving down a hill you must use the same gear you would use if you were driving up the hill. If the speed increases too much despite the engine braking effect, you can use the brake pedal. However you must prevent tires from locking, because in that case you can not steer. 3. Side roll-over The side roll-over moment of a fully loaded vehicle in driving conditions is approx. 65% (31°) for the JOBX4 model and approx. 60% (28°) for the EXTREME model. If you need to drive on a slope in longitudinal direction, you must bear in mind these side roll-over angles. If when driving in this way your vehicle tends to side roll-over, direct your vehicle down the hill by steering the wheels. Under these conditions never try to direct your vehicle up the hill by accelerating, because the centrifugal force generated by this operation would cause the vehicle to overturn. In addition you must consider that any ground unevenness or rocks may destabilize your vehicle, and cause a preventive roll-over.

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To avoid a side roll-over, deep trenches along the roads and ground subsidence as well as abrupt slopes starting from horizontal position and steep embankments are always to be tackled at right angles. With a small manoeuvre you must drive so that the vehicle’s longitudinal axis is at right angles to the slope, if possible. In the case of muddy or sandy route, if the drive line is at an angle along the slope, there is the risk that one of the axles slips on the side. And if the vehicle slips against a small obstacle on the downstream side, you may risk a side roll-over. 4. Driving along trenches and rolling terrain As explained under point 2 (Driving on a slope) slopes etc. should always be travelled along the slope line. Thanks to the large front and rear slope angles as well as the wide ramp angle (ground clearance on cat’s back) of our vehicles this is possible in most cases. Deep trenches or undulating land with slopes that at the base form an angle which is wider than the slope angle of our vehicles or just larger and deeper than the wheel diameter are to be driven over diagonally. Because in this case, depending on soil conditions, there may be a vertical displacement of the vehicle’s specific axis), we recommend engaging the differential locking devices mounted on your vehicle. If your vehicle is not provided with differential locking devices, you should drive along such undulations with force, to prevent the wheels from skidding. (Note: When driving across trenches there is a very strong unilateral compression and extension of the wheels of one axle. In this case the extended wheels loose contact with the ground and start spinning).

5. Driving over cat's backs Thanks to the wide ramp angle (ground clearance on the cat’s back) of our vehicles you will hardly exceed this angle in daily use of our vehicles. Anyway if you have to move in similar conditions, you must avoid damages to the torque distributor (as the lowest point in the centre of the vehicle).

6. Travelling over ruts in the road surface If the ruts in the road surface are deeper than the ground clearance of your vehicle, you should try driving staggered with them. If the space available does not allow this solution or your vehicle gauge is different from the distance between the ruts, try to use one of the ruts with one side of your vehicle. Anyway always drive along the ruts slowly, because if the speed is too high you may hit one of the walls of the ruts and cause your vehicle to „swing“, with the consequent risk of accidents. (Note: This mainly applies to deep and sandy ground).

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7. Crossing the water All parts of vehicles are water-tight against water waves only. Water basins and streams approx. 75 cm (JOBX4 model) or 90 cm (EXTREME model) deep can be crossed without suffering any damages. Anyway it is important to avoid long stays in water because water may slowly penetrate. In emergency also waters 120 cm max. deep can be crossed, but problems with the electric dynamo and water penetration in the axle and shift oil are to be expected. To prevent a lot of water waves from entering the engine compartment, select a drive speed able to cause low bow wave, if possible. In the case of vehicles without suction socket on the top any bow wave has to be absolutely avoided, to prevent water from entering the suction socket of the air filter. To avoid damages to the radiator and/or radiator fan, we suggest covering the radiator with a blanket. (Note: the water flowing through the radiator blades may destroy the running fan and its components and consequently damage the radiator). Always cross water with a low off-road gear and RPM higher than the traditional value used by the engine to transmit its max. torque. When RPM is high the gas flow rate is higher and therefore the risk that water enters the engine through the exhaust pipe is reduced. In addition, the vehicle requires a lot of traction force to resist not only the rolling force, which depends on the bottom, but also water waves. The bottom can be very different, and even if the water level is low, it may hinder the vehicle when crossing. In the case of running waters the bottom is generally composed of sand, gravel or rubble and therefore can be easily crossed, whilst in the case of stagnant waters it is covered with a fine sediment of sludge and mud, which may be very deep and offer little grip to the wheels. Before crossing the water you should check the bottom depth to avoid getting bogged down and causing damages to the vehicle. Before crossing the water engage the central locking device and any other axle locking devices. (Note: when getting out of the water remember that your vehicle brakes must dry “by braking” otherwise the braking distance would be very long with the consequent risk of accidents. In the case of vehicles with drum brakes, at the end of the journey you should open the brakes to eliminate any mud and pebbles). If you have crossed long distances of water or if you stayed for a long time in deep water because you got bogged down, you have to check all engine oils, shift and axle oils to verify any water penetration, and replace them, if necessary. For safety reason you should always cross water together with another vehicle. WARNING: Follow the maintenance instructions to avoid damages. 8. Driving on muddy soil If the soil is not too deep and muddy there will be no traction problems, assuming that suitable treads are mounted. If you have to cross short distances engage the front axle and cross the muddy points with force, if the distance is longer, drive at average speed with a low gear. In this situation it is important that the vehicle is kept moving, to prevent it from getting bogged down. According to mud depth and length of the crossing distance, adjust the tire air pressure in compliance with the off-road values.

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Note: You can find a table with tire air pressure for off-road driving in the User Guide. To increase traction you can use the mounted differential locking devices (Later on remember to reset the tire air pressure to road driving at the corresponding height). If the mud depth exceeds the ground clearance of your vehicle and you can no longer drive ahead, do not try useless manoeuvre to correct it, which would overstress the engine and above all the drive force and the differentials. In such cases the vehicle bogged down in the mud must be pulled out by suitable auxiliary means, such as winches and/or sand plates or by means of a tow truck. Please bear in mind that a muddy soil significantly increases the braking distance, in a similar way as when on ice and snow. WARNING: Follow the maintenance instructions to avoid damages. 9. Driving on sandy soil Anyone with experience of driving on sandy soil knows the thrust necessary to resist the high rolling force. Engage the front axle and always drive in 1st gear to safeguard your clutch as much as possible. You must decide whether to use the road or off-road gear depending on the ground condition and the actual vehicle weight. You should drive short sandy distances at quite high speed with a gear that allows your engine to still have a significant RPM amount available to reach the max RPM. If necessary, shift down before the vehicle looses too many RPMs. (Note: every time you change gear you risk getting stuck in sand, because for a few seconds no force acts on the wheels, therefore you should avoid changing gear). You should drive long sandy distances in a low gear able to provide your vehicle with enough drive force and sufficient RPM. You must drive as smoothly as possible, because sudden acceleration may cause the wheels to “spin”, and consequently the vehicle to get stuck in sand. Drive straight and avoid cornering, if possible. Stop your vehicle by braking softly. If you slam on the brakes the front axle is often clogged with sand and restart is difficult. To make driving on sand easier the tire air pressure should be reduced. This increases the tire ground contact and reduces the specific ground pressure of the vehicle, and hence reduces the rolling resistance. Remember to reset the tire air pressure for road drive at the corresponding height. Do not use differential locking devices on sandy soil!

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Since the drive force in the sand is already very good (otherwise you would not get stuck in sand), the differential locking devices tend to help you to get clear of it, after getting stuck, but experience demonstrates that they worsen the situation and the vehicle gets stuck in sand more and more, making rescue operations more difficult. Not to mention the extreme stress of all the transmission elements. If you get stuck in sand, do not try to get clear of it using 1st gear and slipping in the clutch. You would only get more and more stuck in sand until your axles, frame etc. bottom down. In addition, in this case, you will almost certainly risk damaging the clutch and tow bar of your vehicle. If you realize that your vehicle starts getting stuck in sand, immediately declutch, engage the reverse gear and try to reverse the way you came. Move back a few meters and try again to pass over this soft section with more force, or go around it. If you are not successful, start suitable rescue measures (sand plates or tow truck). 10. Driving on snow and ice Thanks to the technical characteristics of an off-road vehicle, such as the four-wheel drive, rough block-type pattern tires, differential locking devices etc. you have a clear advantage over ordinary cars when driving on snow and ice.

However you should familiarize yourself with the following physical driving characteristics:

- Despite the four-wheel drive and route stability during acceleration connected with traction, the braking distance of a 4x4s vehicle is as long as that of a regular road car.

- Due to the rough block-type pattern (so that only a little rubber is in contact with the road surface) and the quite hard rubber mix, the tires generally

mounted on off-road vehicles have a longer the braking distance on ice and compact snow, compared with a road vehicle with modern snow tires.

- The sensation of being safer provided by a four-wheel drive vehicle often induces the driver to drive too fast. Take care particularly when cornering.

- If roads are icy, mount snow chains, even if you have a 4x4s, in order to have safe control of the vehicle considering its size and weight. WARNING Un incorrect handling of the vehicle and/or its components (eventual installations provided on vehicle included) causes immediately the withdrawal of vehicle’s warranty.

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PTU (Power Transfer Units) Different kind of PTU may be installed in order to withdraw motion and use it to drive auxiliary devices as, for example, tipping bodies, cranes, government aided vehicles, etc. Depending on the mission and performances needed, PTU may be installed on: -gearbox -central differential -front side of the engine -back side of the vehicle Characteristics and performances are enclosed in this manual.

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All data mentioned in this end user and maintenance manual are approximate and not binding. BREMACH reserves itself the right to modify at any time and without advice this manual and data indicated above, in order to follow a continuous improvement

and development of it product. Edition 04/2010

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