Business Class M2 - TransChicago · Vehicle Speciﬁcation Decal The vehicle speciﬁcation decal...

IntroductionThis manual provides information needed to operateand understand the vehicle and its components.More detailed information is contained in the Owner’sWarranty Information for North America booklet, andin the vehicle’s workshop and maintenance manuals.

Custom-built Freightliner vehicles are equipped withvarious chassis and cab components. Not all of theinformation contained in this manual applies to everyvehicle. For details about components in your ve-hicle, refer to the chassis specification pages in-cluded in all new vehicles and to the vehicle specifi-cation decal, located inside the vehicle.

For your reference, keep this manual in the vehicleat all times.

IMPORTANT: Descriptions and specifications inthis manual were in effect at the time of printing.Freightliner Trucks reserves the right to discon-tinue models and to change specifications ordesign at any time without notice and withoutincurring obligation. Descriptions and specifica-tions contained in this publication provide nowarranty, expressed or implied, and are subjectto revisions and editions without notice.

Environmental Concerns andRecommendationsWhenever you see instructions in this manual to dis-card materials, you should first attempt to reclaimand recycle them. To preserve our environment, fol-low appropriate environmental rules and regulationswhen disposing of materials.

Event Data RecorderThis vehicle is equipped with one or more devicesthat record specific vehicle data. The type andamount of data recorded varies depending on howthe vehicle is equipped (such as the brand of engine,if an air bag is installed, or if the vehicle features acollision avoidance system, etc.).

Customer Assistance CenterHaving trouble finding service? Call the CustomerAssistance Center at 1-800-385-4357 or 1-800-FTL-HELP. Call night or day, weekdays or weekends, for

dealer referral, vehicle information, breakdown coor-dination, or Fleetpack assistance. Our people areknowledgeable, professional, and committed to fol-lowing through to help you keep your truck moving.

Reporting Safety DefectsIf you believe that your vehicle has a defect whichcould cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying Daimler Trucks North AmericaLLC.

If the NHTSA receives similar complaints, it mayopen an investigation, and if it finds that a safetydefect exists in a group of vehicles, it may order arecall and remedy campaign. However, NHTSAcannot become involved in individual problemsbetween you, your dealer, or Daimler Trucks NorthAmerica LLC.

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153); go to www.safercar.gov ; orwrite to: Administrator, NHTSA, 1200 New JerseyAvenue, SE, Washington, DC 20590. You can alsoobtain other information about motor vehicle safetyfrom www.safercar.gov .

Canadian customers who wish to report a safety-related defect to Transport Canada, Defect Investi-gations and Recalls, may telephone the toll-freehotline 1-800-333-0510, or contact TransportCanada by mail at: Transport Canada, ASFAD,Place de Ville Tower C, 330 Sparks Street, Ot-tawa, Ontario, Canada K1A 0N5.

For additional road safety information, please visitthe Road Safety website at: www.tc.gc.ca/roadsafety .

Foreword

STI-455-3 (10/10P)A24-01238-000

Printed in U.S.A.

www.safercar.gov

www.safercar.gov

www.tc.gc.ca/roadsafety

www.tc.gc.ca/roadsafety

© 2001–2010 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimlercompany.

No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmittedin any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per-mission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks NorthAmerica LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer towww.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com .

Foreword

http://www.daimler-trucksnorthamerica.com

www.freightlinertrucks.com

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Customer Assistance Center, ReportingSafety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foreword

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Heater, Ventilator and Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Steering and Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Fifth Wheels and Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111 Pretrip and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.112 Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.113 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.114 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.115 Hybrid Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.116 Natural Gas Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1

1

Vehicle IdentificationVehicle Specification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Federal Motor Vehicle Safety Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Canadian Motor Vehicle Safety Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Tire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2EPA Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Vehicle Specification DecalThe vehicle specification decal lists the vehiclemodel, identification number, and major componentmodels. It also recaps the major assemblies and in-stallations shown on the chassis specification sheet.One copy of the specification decal is attached to thedriver’s side sunvisor; another copy is inside the rearcover of the Owner’s Warranty Information for NorthAmerica booklet. An illustration of the decal is shownin Fig. 1.1 .

NOTE: Labels shown in this chapter are ex-amples only. Actual specifications may vary fromvehicle to vehicle.

Federal Motor Vehicle SafetyStandard (FMVSS) LabelsNOTE: Due to the variety of FMVSS certificationrequirements, not all of the labels shown willapply to your vehicle.

Tractors with or without fifth wheels purchased in theU.S. are certified by means of a certification state-ment (Fig. 1.2 ) and the tire and rim information, com-bined into one label. This label is attached to the leftrear door post, as shown in Fig. 1.3 .

If purchased for service in the U.S., trucks built with-out a cargo body have an incomplete certificationlabel (Fig. 1.4 ) attached to the left rear door post. Inaddition, after completion of the vehicle, a certifica-tion label similar to that shown in Fig. 1.2 must beattached by the final-stage manufacturer. This labelwill be located on the left rear door post and certifies

f08002111/21/96

USE VEHICLE ID NO.WHEN ORDERING PARTS

WHEELBASEENGINE NO.TRANS NO.FRT AXLE NO.REAR AXLE NO.REAR AXLE NO.RATIO

FOR COMPLETE PAINT INFORMATIONSEE VEHICLE SPECIFICATION SHEET

MANUFACTURED BY

MODELVEHICLE ID NO.

DATE OF MFRENGINE MODELTRANS MODEL MAINFRONT AXLE MODELREAR AXLE MODEL

PAINT MFRPAINT NO.

PART NO. 24−00273−010

COMPONENT INFORMATION

IMRON PAINT−CABCAB COLOR A: WHITE (4775)CAB COLOR B: BROWN (3295)CAB COLOR C: BROWN (29607)CAB COLOR D: DARK BROWN (7444)

Fig. 1.1, Vehicle Specification Decal, U.S.-Built VehicleShown

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2

3

1. Date of Manufacture: by month and year2. Gross Vehicle Weight Rating: developed by taking

the sum of all the vehicle’s gross axle ratings3. Gross Axle Weight Ratings: developed by

considering each component in an axle system–including suspension, axle, wheels, and tires–andusing the lowest component capacity as the valuefor the system

Fig. 1.2, Certification Statement, U.S.

1

2

f08011711/13/2001

1. Tire and Rim Information2. Certification Statement

Fig. 1.3, Label Location

11/14/2001 f080120

Fig. 1.4, Incomplete Vehicle Certification Label, U.S.

Vehicle Identification

1.1

that the vehicle conforms to all applicable FMVSSregulations in effect on the date of completion.

Canadian Motor Vehicle SafetyStandard (CMVSS) LabelsIn Canada, tractors with fifth wheels are certified bymeans of a "Statement of Compliance" label and theCanadian National Safety Mark (Fig. 1.5 ), which areattached to the left rear door post. In addition, tireand rim information (Fig. 1.6 ) is also included in thelabel attached to the left rear door post.

If purchased for service in Canada, trucks built with-out a cargo body and tractors built without a fifthwheel are certified by a "Statement of Compliance"label, similar to Fig. 1.2 . This label must be attachedby the final-stage manufacturer after completion ofthe vehicle. The label is located on the left rear doorpost, and certifies that the vehicle conforms to allapplicable CMVSS regulations in effect on the dateof completion.

Tire and Rim LabelsTire and rim labels certify suitable tire and rim combi-nations that can be installed on the vehicle, for the

given gross axle weight rating. Tires and rims in-stalled on the vehicle at the time of manufacture mayhave a higher load capacity than that certified by thetire and rim label. If the tires and rims currently onthe vehicle have a lower load capacity than thatshown on the tire and rim label, then the tires andrims determine the load limitations on each of theaxles.

See Fig. 1.6 for U.S. and Canadian tire and rim la-bels.

EPA Emission ControlVehicle Noise Emission Control LabelA vehicle noise emission control label (Fig. 1.7 ) isattached either to the left side of the dashboard or tothe top-right surface of the frontwall between thedash and the windshield.

IMPORTANT: Certain Freightliner incompletevehicles may be produced with incomplete noisecontrol hardware. Such vehicles will not have avehicle noise emission control information label.For such vehicles, it is the final-stage manufac-turer’s responsibility to complete the vehicle inconformity to U.S. EPA regulations (40 CFR Part205) and label it for compliance.

EPA07 and EPA10 Emission ControlTo meet EPA07 and EPA10 emissions regulations forvehicles domiciled in the USA or Canada, enginesmanufactured after December 31, 2006 (EPA07) orDecember 31, 2009 (EPA10) are equipped with anemission aftertreatment system. Vehicles domiciledoutside of the USA and Canada may not have after-treatment equipment, depending upon local statutoryemissions guidelines. There is a warning label(placement will vary), for important new warning indi-cators in the driver’s message display, that pertain tothe aftertreatment system.

f08002410/10/2006

Fig. 1.5, Canadian National Safety Mark

11/14/2001 f080119

1 2

1. Gross Weight Rating By Component in Axle System2. Gross Vehicle Weight Rating By Component in

Vehicle As a Whole

Fig. 1.6, Tire and Rim Information

10/06/98 f080026

24−00273−020

VEHICLE NOISE EMISSION CONTROL INFORMATIONFREIGHTLINER CORPORATIONTHIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSIONAPPLICABLE TO MEDIUM AND HEAVY TRUCKS.THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BYTHE NOISE CONTROL ACT OF 1972:A. THE REMOVAL OR RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF DESIGN (LISTED IN THE OWNER’S MANUAL) INCORPORATED INTO THIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT.B. THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE.

DATE OF MANUFACTURE 01/96

Fig. 1.7, Vehicle Noise Emission Control Label


1.2

It is a violation of US federal law to alter exhaustplumbing or aftertreatment in any way that wouldbring the engine out of compliance with certificationrequirements. (Ref: 42 U.S.C. S7522(a) (3).) It is theowner’s responsibility to maintain the vehicle so thatit conforms to EPA regulations.


1.3

2

Vehicle AccessCab Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Cab Entry and Exit, Vehicles With Two Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2Cab Entry and Exit, Vehicles With One Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

Cab Door Locks and HandlesOne key operates the ignition switch and all of thedoor locks.

IMPORTANT: Each key is numbered. Recordthe number so a duplicate key can be made, ifneeded.

To unlock the driver’s door from outside the cab, in-sert the key in the lockset and turn it one-quarter turnclockwise (Fig. 2.1 ). To remove the key, turn it coun-terclockwise to its original position. Pull out on thedoor pull handle to open the door.

To unlock the passenger’s door from outside the cab,insert the key in the lockset and turn it one-quarterturn counterclockwise. Turn the key clockwise to theoriginal position to remove it.

NOTE: The cab door locks can be operatedwhen the doors are open.

To lock a door from outside the cab, do either one ofthe following:

• Insert the key in the lockset and turn it in thedirection opposite to the unlocking direction(counterclockwise for the driver’s door, clock-wise for the passenger’s door). Close the doorif it is open.

• Push down the inside lock button (Fig. 2.2 ).Close the door.

To open the door from the inside, lift up on the doorlever. This will unlatch the door whether or not it islocked. If it is open, close the door by pulling theinner door grab handle.

To lock either door from inside the cab, slide the lockbutton downwards (Fig. 2.3 ). To unlock the doorwithout unlatching it, push the lock button upwards. Ared dot will show below the lock button when it isunlocked.

Grab Handles and AccessStepsFor ease of entry and exit, there are three grabhandles, one on the A-pillar, one on the inner B-pillar,and an optional one on the inside of the door. In ad-dition, the steering wheel may be used to providesecure handholds. There are one or two accesssteps to provide secure footholds.

10/22/2001 f720397

1

2

3

1. Key2. Lock

3. Door Pull Handle

Fig. 2.1, Exterior Door Handle

10/25/2001 f720398

1 2

3 4

5

To open the door from the inside, lift up on the door lever(arrow).1. Lock Button2. Armrest/Handle3. Door Lever4. Window Crank5. Inner Door Grab Handle (optional)

Fig. 2.2, Door Interior

Vehicle Access

2.1

NOTE: The A-pillar grab handle is not installedon the driver’s side.

The grab handles, access steps, and steering wheelare all part of the cab access system. Use these"helping hands" when getting into, or out of, the cab.They will increase your security and comfort.

Cab Entry and Exit, VehiclesWith Two Steps

WARNINGWet or dirty shoe soles greatly increase thechance of slipping or falling. If your soles are wetor dirty, be especially careful when climbingonto, or down from, the back-of-cab area.

Always maintain three-point contact with theback-of-cab access supports while entering andexiting the back-of-cab area. Three-point contactmeans both feet and one hand, or both handsand one foot, on the grab handles, steps, anddeck plates. Other areas are not meant to sup-port back-of-cab access, and grabbing or step-ping in the wrong place could lead to a fall, andpersonal injury.

Be careful not to get hands or feet tangled inhoses or other back-of-cab equipment. Careless-ness could cause a person to trip and fall, withpossible injury.

Use the cab access system (grab handles, accesssteps, and steering wheel) to enter or exit the cab.

Entering from the Driver’s SideTo enter the cab from the driver’s side, do the follow-ing steps (Fig. 2.4 ):

1. Use the door pull handle to open the driver’sdoor, and place anything that you are carrying inthe cab.

2. Grasp the B-pillar grab handle with both hands.Reach up as far as is comfortable.

3. Place your right foot on the bottom step, and pullyourself up.

4. Place your left foot on the top step.

5. Grasp the steering wheel with your left hand, andstep up.

6. Step into the cab with your right foot first, andgrasp the steering wheel with your right hand.

10/24/2001 f720401

1

2

3

Move the button down to lock, and up to unlock (arrows).The door is unlocked when the red dot shows.

1. Door2. Lock Button

3. Red Dot

Fig. 2.3, Door Lock Button

11/02/2001 f720399

1

5

4

3

2

1. Steering Wheel2. B-Pillar Grab Handle3. Bottom Step4. Top Step5. Inner Door Grab Handle (optional)

Fig. 2.4, Cab Access System, Driver’s Side

Vehicle Access

2.2

NOTE: You can also use the inner door grabhandle, if available, as a support when gettingup or down from the bottom step.

Exiting from the Driver’s SideTo exit the cab from the driver’s side, do the follow-ing steps (Fig. 2.4 ):

IMPORTANT: Do not attempt to exit the cabwhile carrying any items in your hands.

1. If you wish to take any items with you, after youexit the cab, place them in an accessible locationon the seat or cab floor. Make sure they will notget in your way as you exit.

WARNINGAlways face in when exiting the cab. Do not at-tempt to exit with your back to the cab, as youwould going down a flight of stairs. It is easier toslip or lose your balance. If you slip when exitingin this way, there is a greater likelihood of per-sonal injury.

2. Grasp the steering wheel with both hands. Placeyour left foot on the top step, and stand on thethreshold, facing into the cab.

3. Move your right hand to the B-pillar grab handle.

4. Move your right foot to the bottom step.

5. Move your left hand to the B-pillar grab handle.

6. Step to the ground with your left foot first.

7. Retrieve from the cab any items that you wish totake with you.


Entering from the Passenger’s SideTo enter the cab from the passenger’s side, do thefollowing steps (Fig. 2.5 ):

1. Open the passenger’s door, and place anythingthat you are carrying in the cab.

2. Grasp the B-pillar grab handle on the door withboth hands.

3. Place your left foot on the bottom step and stepup to the upper step with your right foot.

4. Move your right hand to the A-pillar cover grabhandle.

5. Place your left foot on the top step and step up.

6. Move your left hand to the A-pillar cover grabhandle.

7. Step into the cab with your left foot first.


Exiting from the Passenger’s SideTo exit the cab from the passenger’s side, do the fol-lowing steps (Fig. 2.5 ):


1. If you wish to take any items with you, after youexit the cab, place them in an accessible location

3

5

10/23/2001 f7204001

2

4

1. Bottom Step2. Top Step3. B-Pillar Grab Handle4. Sidewall Grab Handle (optional)5. A-Pillar Cover Grab Handle

Fig. 2.5, Cab Access System, Passenger’s Side andBack of Cab

Vehicle Access

2.3

on the seat or cab floor. Make sure they will notget in your way as you exit.


2. Grasp the A-pillar cover grab handle with bothhands, then place your right foot on the top stepwhile standing up from the seat facing inward.

3. Place your left foot on the top step.


5. Move your left foot to the bottom step.


7. Step to the ground with your right foot first.



Cab Entry and Exit, VehiclesWith One Step

WARNINGWet or dirty shoe soles greatly increase thechance of slipping or falling. If your soles are wetor dirty, be especially careful when climbingonto, or down from, the back-of-cab area.

Always maintain three-point contact with theback-of-cab access supports while entering andexiting the back-of-cab area. Three-point contactmeans both feet and one hand, or both handsand one foot, on the grab handles, steps, anddeck plates. Other areas are not meant to sup-port back-of-cab access, and grabbing or step-ping in the wrong place could lead to a fall, andpersonal injury.

Be careful not to get hands or feet tangled inhoses or other back-of-cab equipment. Careless-

ness could cause a person to trip and fall, withpossible injury.

Use the cab access system (grab handles, accesssteps, and steering wheel) to enter or exit the cab.

Entering from the Driver’s SideTo enter the cab from the driver’s side, do the follow-ing steps (Fig. 2.4 ):

1. Use the door pull handle to open the driver’sdoor, and place anything that you are carrying inthe cab. Use the door armrest/handle and, ifavailable, the inner door grab handle, as a sup-port if needed.

2. Grasp the B-pillar grab handle with both hands.Reach up as far as is comfortable.

3. Place your right foot on the step, and pull your-self up.

4. Step into the cab with your left foot.

5. Grasp the steering wheel with your left hand.

6. Step into the cab with your right foot, and graspthe steering wheel with your right hand.


Exiting from the Driver’s SideTo exit the cab from the driver’s side, do the follow-ing steps (Fig. 2.4 ):




Vehicle Access

2.4

2. Grasp the steering wheel with both hands. Placeyour left foot on the step, and stand on thethreshold, facing into the cab.



5. Move your right foot onto the step.

6. Step to the ground with your left foot first.



Entering from the Passenger’s SideTo enter the cab from the passenger’s side, do thefollowing steps (Fig. 2.5 ):

1. Open the passenger’s door, and place anythingthat you are carrying in the cab.

2. Grasp the B-pillar grab handle with both hands.

3. Place your left foot on the step and step up tothe cab with your right foot.

4. Move your right hand to the A-pillar cover grabhandle.

5. Move your left hand to the A-pillar cover grabhandle.

6. Step into the cab with your left foot.


Exiting from the Passenger’s SideTo exit the cab from the passenger’s side, do the fol-lowing steps (Fig. 2.5 ):




2. Grasp the A-pillar cover grab handle with bothhands, then place your right foot on the stepwhile standing up from the seat facing inward.

3. Place your left foot on the step.



6. Step to the ground with your right foot first.



Back-of-Cab AccessWhen trailer air and electrical connections cannot bereached conveniently from the ground, Federal MotorCarrier Safety Regulations require commercial carri-ers to provide back-of-cab access.

Optional grab handles are mounted on each cabsidewall, or on the left sidewall only. See Fig. 2.6 .Steps are mounted either on the fuel tank(s) or onmetal brackets. When a deck plate is necessary, it ismounted across the top of the frame rails.

IMPORTANT: Climb onto, and down from, back-of-cab access facing in toward the vehicle, asyou would on a ladder. Do not climb up or downfacing out away from the vehicle.

WARNINGWet or dirty shoe soles greatly increase thechance of slipping or falling. If your soles are wetor dirty, be especially careful when climbingonto, or leaving, the back-of-cab area.

Always maintain three-point contact with theback-of-cab access supports while entering and

Vehicle Access

2.5

exiting the back-of-cab area. Three-point contactmeans both feet and one hand, or both handsand one foot, on the grab handles, steps, anddeck plates. Other areas are not meant to sup-port back-of-cab access, and grabbing or step-ping in the wrong place could lead to a fall, andpersonal injury.

Be careful not to get hands or feet tangled inhoses or other back-of-cab equipment. Careless-ness could cause a person to trip and fall, withpossible injury.

Entering Back-of-CabWhen climbing onto the deck plate, do the following:

1. Grasp the sidewall grab handle with both hands.Reach up as far as is comfortable.

2. Place one foot on the bottom step and pull your-self up.

3. Place your other foot on the top step.

4. Move your lower hand to a higher position on thegrab handle.

5. Step onto the deck plate.

Climbing Down from Back-of-CabTo climb down from the back-of-cab area:

1. Grasp the sidewall grab handle with both hands.

2. Step one foot at a time onto the top step.

3. Move your upper hand to a lower position on thegrab handle.

4. Move one foot to the bottom step.

5. Move your upper hand to a lower position on thegrab handle.

6. Step to the ground with your upper foot first.

Battery AccessBattery CompartmentThe battery compartment is located in the lower partof the cab beneath and to the rear of the driver’sdoor. It is fastened by a quarter-turn fastener. Toopen the battery access door, turn the quarter-turnfastener with a small screwdriver. See Fig. 2.7 .

09/28/2007 f6023361

1

2

3

1. Steps2. Grab Handle

3. Deck Plate

Fig. 2.6, Back-of-Cab Access Supports (typical)

10/25/2001 f543934

Open the battery access door by turning the quarter-turnfastener (arrow) with a small screwdriver.

Fig. 2.7, Battery Compartment, Closed

Vehicle Access

2.6

With the battery access door open (Fig. 2.8 ), it iseasy to get access to the battery terminals for clean-ing, charging, or emergency jump starting.

To close the battery access door, do the followingsteps:

1. Swing the battery access door to line up thequarter-turn fastener with the hole in the cabdoor frame.

2. Close the battery access door and check to besure the quarter-turn fastener is engaged withthe hole.

3. Turn the fastener one-quarter turn.

Cab (Battery) Isolation SwitchThe cab isolation switch (see Fig. 2.9 ) is located onthe cab floor at the left of the driver’s seat, or insidethe battery box. The battery isolation switch reducesthe power to the cab and engine power wiring. Use itwhenever the vehicle is to be put out of service forextended periods.

IMPORTANT: The battery disconnect switchdoes not completely isolate the batteries fromthe electrical system. For service operations thatrequire that the batteries be disconnected, al-ways shut down the engine and remove thenegative battery cables.

NOTE: Whenever battery power is discon-nected, clocks and electronically tuned radiosmust be reset.

Hood Opening and ClosingThe hood can be raised to a full-open position. A tor-sion bar helps you to raise the hood, and to lower itto the operating position. Hood restraint cables pre-vent the hood from overtravel. A hood damper limitsthe closing speed. In the operating position, the hoodis secured to the cab-mounted half-fenders by ahold-down latch on each side of the hood.

To Open the Hood1. Apply the parking brakes.

2. Release both hood hold-down latches by pullingthe ends outward. See Fig. 2.10 .

CAUTIONDo not let the hood free-fall to the full-open posi-tion. To do so could cause damage to the hoodor hood straps.

3. Standing in front of the hood, raise the rear ofthe hood upward until it reaches the over-centerposition (45 degrees from vertical). Then slowlybring it to a stop.

To Close the Hood1. Push the hood over center.

10/24/2001 f543933

1

2

3

4

1. Top Step2. Battery3. Cab4. Battery Access Door

Fig. 2.8, Battery Compartment, Open

01/18/95 f600150a

Fig. 2.9, Cab (Battery) Isolation Switch

Vehicle Access

2.7

2. As the hood goes over center, the damper auto-matically slows its rate of descent. If needed, youcan also slow its rate of descent with your hand.

3. Make sure the hood is flush with the cowl, thensecure the hood by engaging both hood hold-down latches.

IMPORTANT: Make sure that both hold-downlatches are fully engaged before operating thevehicle.

Fuse IdentificationMain Fuse Box/PDMThe main fuse box, also known as the power distri-bution module, or PDM, is located under the hood onthe left front fender just forward of the bulkhead mod-ule. See Fig. 2.11 . To open the fuse box, pull downon the wire clips holding the lid on the fuse box.

A sticker inside the lid of the fuse box shows the lo-cations of the fuses and describes the circuit(s) thateach fuse protects (see Fig. 2.12 ). See Table 2.1 fordescriptions of a typical set of fuses. The fuses in themain fuse box are mini blade-type fuses. Batterypower fuses, located near the batteries, are bolt-inmegafuses.

Because the electrical system is multiplexed, no re-lays are needed. The multiplexing module performsthe functions normally provided by relays.

Fuse Identification, Main Fuse BoxPos.No.

Description Fuse Color Rating

F1 VCU (MBE900 only) Red 10 AmpF2 Blower Motor Green 30 AmpF3 Engine ECU Yellow 20 Amp

F4 Transmission ControlUnit Green 30 Amp

F5 Ignition Switch Tan 5 AmpF6 Spare — —F7 Bulkhead Module Green 30 AmpF8 ICU Red 10 Amp

F9 Transmission ControlUnit Yellow 20 Amp

F10 Door Locks (optional) Red 10 AmpF11 Mirrors (optional) Blue 15 AmpF12 Radio/Diagnostics Yellow 20 AmpF13 Chassis Module Green 30 Amp

F14 L/H Power Windows(optional) Blue 15 Amp

F15 Bulkhead Module Green 30 AmpF16 ABS ECU Blue 15 AmpF17 Chassis Module Green 30 AmpF18 Bulkhead Module Green 30 AmpF19 Chassis Module Green 30 AmpF20 Bulkhead Module Green 30 Amp

F21 R/H Power Windows(optional) Blue 15 Amp

F22 Bulkhead Module Green 30 AmpF23 Spare — —F24 Spare — —F25 Spare — —F26 Spare — —M1 Battery Power — 125 AmpM2 Battery Power — 125 AmpM3 Battery Power — 150 Amp

Table 2.1, Fuse Identification, Main Fuse Box

Trailer and Taillight Fuse BoxesThe trailer fuse box and the taillight fuse box, on ve-hicles so equipped, are mounted on a bracket withthe chassis module on the left-hand frame rail aft ofthe cab, or on a crossmember at the end of theframe rail. These may be referred to as the chassisfuse box or chassis PDM. See Fig. 2.13 for trailerfuse and relay information, and Fig. 2.14 for taillightfuse and relay information.

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1

2

3

4

1. Fender2. Latch Hook

3. Latch Handle4. Half-Fender

Fig. 2.10, Hood Hold-Down Latch

Vehicle Access

2.8

These fuse boxes contain mini blade-type fuses, 12-volt mini relays, and 12-volt micro relays.

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1

2

1. Bulkhead Module 2. Main Fuse Box

Fig. 2.11, Location of the Main Fuse Box

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Fig. 2.12, Main Fuse Box Diagram

09/28/2004 f544528

Fig. 2.13, Trailer Fuse Box Diagram

10/07/2004 f544541

Fig. 2.14, Taillight Fuse Box Diagram

Vehicle Access

2.9

3

InstrumentsInstrumentation Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Overhead Instrument Panel, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14Collision Warning System, Eaton VORAD EVT–300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

Instrumentation Control UnitFigure 3.1 shows a typical set of instruments for ve-hicles equipped with the M2 instrument cluster(ICU3-M2).

Figure 3.2 shows a more basic instrument cluster.The tachometer and the transmission temperaturegauge are not shown.

The M2 instrument cluster (ICU3-M2) is on vehicleswith engines manufactured before January 1, 2007,and the ICU3X is on vehicles with engines manufac-tured January 1, 2007 or later. They can be differen-tiated by their ISO icons.

There can be up to eight gauges on the driver’s in-strument panel (six electronic and two mechanical).Only the air gauges operate mechanically.

The M2 instrument cluster has the capability to driveindependent stand-alone gauges such as those in-stalled on the auxiliary dash panel. Figure 3.3 showsa typical dash.

Dash Message CenterThe dash message center is the heart of the instru-ment cluster. It has two parts, a set of 26 warningand indicator lights similar to those found on a con-ventional lightbar, and a dash driver display screen.

f610525a

1

2 3 4 5

6

7

8

12

11 10 909/10/2009

NOTE: This instrument cluster is shown with the U.S. speedometer, which shows miles per hour (mph) more prominentlythan kilometers per hour (km/h).

1. Engine Oil Pressure Gauge2. Dash Message Center3. Dash Driver Display Screen4. Headlight High-Beam Indicator5. Fuel Level Gauge

6. Primary Air Pressure Gauge7. Mode/Reset Switch8. Secondary Air Pressure Gauge9. Speedometer (U.S. version)

10. Tachometer (optional)11. Transmission Temperature Gauge

(optional)12. Coolant Temperature Gauge

Fig. 3.1, Gauge Layout, Typical, U.S. (EPA10 shown)

Instruments

3.1

The driver display screen is a one-line by seven-character liquid crystal display (LCD) that normallyshows odometer readings. Below this display is asmaller one-line by three-character LCD that showsvoltmeter readings.

The dash message center houses all of the standardand optional warning and indicator lights. Warningmessages and diagnostic fault codes will appear inthe driver display screen. For more information onthis system, see under the heading "Ignition Se-quence" in this chapter.

Ignition SequenceThe dash message center goes through a prescribedignition sequence each time the ignition switch isturned on. See Fig. 3.4 for the ignition sequence.

If service miles or service hours has been exceeded,either Fig. 3.5 or Fig. 3.6 will come up before thefault screen (if faults are present. If no faults arepresent and service hours or miles are exceeded,either Fig. 3.5 or Fig. 3.6 will stay displayed unti thepark brake is released with the engine running, orthe mode button is pressed.

When the ignition is turned on, all the electronicgauges complete a full sweep of their dials, thewarning and indicator lights light up, and the buzzersounds for 3 seconds.

NOTE: The air gauges do not sweep.

The following lights illuminate during the ignition se-quence:

• Fasten Seat Belt Warning

• Low Battery Voltage Warning

8 f610526c

1 2 3 4

9

10

5

7

09/10/2009

6

NOTE: This instrument cluster is shown with the NAFTA speedometer, which shows km/h more prominently than mph.

1. Engine Oil Pressure Gauge2. Dash Message Center3. Dash Driver Display Screen4. Fuel Level Gauge

5. Primary Air Pressure Gauge6. Mode/Reset Switch7. Secondary Air Pressure Gauge

8. Speedometer (NAFTA version)9. Headlight High-Beam Indicator10. Coolant Temperature Gauge

Fig. 3.2, Gauge Layout, Basic (EPA10 shown)

Instruments

3.2

• High Coolant Temperature Warning

• Low Engine Oil Pressure Warning

• Low Air Pressure Warning

• Parking Brake On Indicator

• All engine indicator/warning lights, includingCheck Engine, HET, DPF, and Stop Engine

• Check trans and Trans temp (if equipped)

• Cruise control active indicator

• Low fuel and Low DEF level lamp in FuelGauge (if equipped with EPA10-compliant en-gine)

• The DEF level bar graph in the Fuel Gauge willilluminate full scale (100% - all 4 segments w/green LEDs) during the gauge sweep and then

sequence through all the levels (100%, 75%,50%, 25%, 10%, 5%, 0%) when the gaugesweep is completed. (if equipped with EPA10-compliant engine)

NOTE: While the engine and ABS warning lightsilluminate during the ignition sequence, they arenot controlled by the instrument cluster but bytheir own system ECU (electronic control unit).

When the ignition switch has been turned on, theICU performs a self-test, looking for active faults.During the first half of the self-test, all segments ofthe display illuminate as follows:

• First line (odometer): "888888.8"

• Second line (units): "TRIP MI KM HOURS"

5

4

f610578

1

23

10/11/2001

NOTE: Instruments and controls, and their locations, may vary from those shown.

1. L/H Control Panel2. Instrumentation Control Unit (ICU3-M2)3. R/H Control Panel

4. Auxiliary Dash Panel5. Climate Control Panel

Fig. 3.3, Dash Panel Layout (typical)

Instruments

3.3

• Third line (voltmeter): "88.8 % VOLTS SER-VICE"

• Fourth line: "SPN ENGINE"

During the second half of the self-test, the softwarerevision level is displayed.

If there are no active faults, the driver display screendisplays the odometer.

If, however, the instrument cluster has received ac-tive fault codes from other devices, it displays themone after the other until the parking brake is re-leased, or the ignition switch is turned off. Once theparking brake is released, the dash message centerdisplays the odometer again.

NOTE: If active faults are present, take the ve-hicle as soon as possible to an authorizedFreightliner service facility.

POWER ON

PARK BRAKE

IGNITION ON

HEADLIGHTS ON

RELEASE PARK BRAKE

f04080410/26/2009

RELEASED − MOVING

FAULT CODESCREEN

IF NO FAULTSWERE DETECTED

ELECTRONIC GAUGE NEEDLESSWEEP, WARNING/INDICATORLIGHTS COME ON, BUZZER SOUNDS

IF FAULT DETECTED

ICU PERFORMS SELFTEST:

123456.7

ABS 11

ODOMETERSCREEN

123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

MI

MI

MI

/ IGNITION OFF

**

**

*

* HOURS SERVICE or MI SERVICE may display

** If the key was cycled off wile displaying Trip Miles, Trip Hours, or Ambient Air Temperature, that screen will be dis-played instead of odometer miles, when the key is cycled ON without any faults.

Fig. 3.4, Ignition Sequence

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SERVICEHOURS

f040805

Fig. 3.5, Service Hours Exceeded

10/26/2009

SERVICE

MI

f040806

Fig. 3.6, Service Miles Exceeded

Instruments

3.4

If the fault is a serious problem that requires immedi-ate attention, the engine protection system will acti-vate. In most cases, the check engine light will illumi-nate also.

Some examples of faults requiring immediate atten-tion include:

• High coolant temperature

• Low air pressure

• Low coolant level

• Low engine oil pressure

NOTE: The check engine light does not illumi-nate for a low air pressure fault.

The legend "SERVICE ENGINE" can appear on thedriver display screen as an active fault code. If thislegend appears, it means the trip miles (or hours)have gone beyond the next required service interval,as set by the vehicle operator.

IMPORTANT: If the legend "SERVICE ENGINE"does appear on the driver display screen whileoperating the vehicle, bring the vehicle to anauthorized Freightliner service facility whenconvenient.

OdometerThe odometer is set to display in either miles or kilo-meters, depending on the primary scale of thespeedometer. The legend, either "MI" or "KM," illumi-nates between the odometer and the volts displaywhen the engine is running or the headlights areturned on.

The odometer is a seven-digit display with a decimalpoint, until the vehicle has traveled 999,999.9 milesor kilometers (km). At one million miles (km), theodometer resets itself to "1000000," without the deci-mal point, and can continue up to 9,999,999. Theodometer only displays significant figures (no leadingzeros).

Mode/Reset SwitchThe mode/reset switch (Fig. 3.7 ) is located on theright side of the instrument cluster. The mode/resetswitch is used to scroll through the displays on themessage display screen, and to reset the trip dis-tance and trip hours values to zero.

When the odometer reading is displayed and theparking brake is applied:

• Press the mode/reset switch once and the tripdistance will display.

• Press the mode/reset switch a second timeand the trip hours (engine hours) will display.

• Press the mode/reset switch again and thetemperature screen will be displayed (ifequipped).

• Press the mode/reset switch again and the SE-LECT screen and the current units, MI or KM,will display.

• Press the mode/reset switch again and thetemperature alert screen will be displayed (ifequipped).

• Press the mode/reset switch again and thediagnostics/service screen will display.

• Press the mode/reset switch again and theenggine miles (kilometers) screen will display.

• Press the mode/reset switch again and the en-gine hours screen will display.

• Press the mode/reset switch again and the setup screen will display

• Press the mode/reset switch againe to returnto the odometer reading.

To reset trip miles and/or trip hours to zero, press themode/reset switch for 1 second or longer. To togglebetween MI (miles) or KM (kilometers), press themode/reset switch while in the SELECT screen.

09/25/99

PUSH− MODE HOLD− RESET

f610340

Fig. 3.7, Mode/Reset Switch

Instruments

3.5

Warning and Indicator LightsThere can be up to 26 warning and indicator lights(telltales) installed in the dash message center. SeeFig. 3.8 for 2004 engines, or see Fig. 3.9 for EPA07engines, or see Fig. 3.10 for EPA10 engines. Thereare four rows of lights. Lights installed in the top roware optional and their positions may vary. The lightsin the bottom three rows are installed in fixed posi-tions on all vehicles. Most are standard, but a feware optional.

Check Engine IndicatorThe amber check engine indicator light (CHECK EN-GINE legend) illuminates when certain faults are de-tected. If a critical engine condition exists (for ex-ample, low oil pressure, low coolant level, highcoolant temperature, high DPF soot level, or uncon-trolled DPF rengeneration), the check engine lightwill illuminate to alert the driver to correct the condi-tion as soon as possible. If the condition gets worse,the engine protection light will illuminate.

NOTE: If the check engine light illuminates dur-ing vehicle operation, take the vehicle directly toan authorized Freightliner service facility.

Engine Protection Warning

WARNINGWhen the red stop-engine light illuminates, mostengines are programmed to shut down automati-cally within 30 seconds. The driver must immedi-ately move the vehicle to a safe location at theside of the road to prevent causing a hazardoussituation that could cause bodily injury, propertydamage, or severe damage to the engine.

The red Stop Engine, or Engine Protect, warninglight illuminates to indicate that the protection systemavailable for the engine has been activated. Onsome engines, the engine ECU will derate the en-gine, allowing it to run, but at lower rpm and slowervehicle speed. The vehicle may be driven to a safelocation or to a service facility.

1 2 310 11 12

16 17 1822 23

4 5 6 7 8 913 14 15

19 20 2126 272524 f610593a

WHEELLOCK

WASHFLUID

INTAKEHEATER

WATERIN FUEL

WHEELSPIN

LOWWATER

CHECKTRANS

ENGFAN

LOWFUEL

03/05/2002

BRAKE

Typical installation shown. Location of legends installed in the top row may vary, and other legends may be specified.

1. Wheel Lock Warning (optional)2. Low Washer Fluid Indicator

(optional)3. Intake Heater On Indicator

(optional)4. Water In Fuel Indicator (optional)5. Wheel Spin Indicator (optional)6. Low Coolant Warning (optional)7. Check Transmission Indicator

(optional)8. Engine Fan On Indicator (optional)

9. Low Fuel Warning (optional)10. Check Engine Indicator11. Engine Protection Warning12. No Charge Indicator (optional)13. Tractor ABS Indicator14. Transmission Overheat Indicator

(optional)15. Trailer ABS Indicator (as applies)16. Low Oil Pressure Warning17. High Coolant Temperature

Warning

18. Fasten Seat Belts Warning19. Brake System Warning/Parking

Brake On Indicator20. Not Used21. Air Restriction Indicator (optional)22. Left-Turn Signal Arrow23. Low Battery Voltage Warning24. Dash Driver Display Screen25. High Beams On Indicator26. Low Air Pressure Warning27. Right-Turn Signal Arrow

Fig. 3.8, Warning and Indicator Lights, ICU3-M2 Pre-’07 Dash Message Center

Instruments

3.6

f61085010/18/2006

1 2 3 4

8 9 1014 15

5 6 7

11 12 1318 191716

ABS ABS

OPT OPT OPT OPT OPT OPT OPT OPT OPT

Typical installation shown. Location of legends installed in the top row may vary, and other legends may be specified.

1. Optional Indicator2. Check Engine Indicator3. Stop Engine Indicator4. Malfunction Indicator Light (MIL)5. Tractor ABS Indicator6. Transmission Temperature

Indicator7. Trailer ABS Indicator

8. Low Oil Pressure Warning9. High Coolant Temperature10. Fasten Seat Belt Warning11. Parking Brake On Warning12. Diesel Particulate Filter (DPF)

Status Lamp13. High Exhaust System

Temperature (HEST) Warning

14. Left-Turn Signal15. Low Battery Voltage Warning16. Driver Display Screen17. High Beams On Indicator18. Low Air Pressure Warning19. Right-Turn Signal

Fig. 3.9, Warning and Indicator Lights, ICU3X EPA07 Dash Message Center

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ABS ABSCHECK STOP

f611076

1 2 4 6

17 19 2116 18

10 12

24 26 2827 292322

14

20 25

TRIP MI KM HOURSSERVICEENGINE

VOLTSSPN

AIRFILTER

WASHFLUID

*WAIT*TO START

LOWWATER

CHECKTRANS MGMT OPT 9

WHEELSPIN*OPT 4*

**IDLE**

3 5 11 137 8 9

15

1. Air Filter Indicator2. Check Engine Indicator3. Washer Fluid Indicator4. Stop Engine Indicator5. Wait to Start6. Malfunction Indicator Light (MIL)7. Blank for Optional Indicator8. Wheel Spin Indicator9. Low Water Indicator10. Tractor ABS Indicator11. Check Transmission Indicator

12. Transmission TemperatureIndicator

13. Idle Manager Indicator14. Trailer ABS Indicator15. Blank for Optional Indicator16. Left-Turn Signal17. Low Oil Pressure Warning18. Low Battery Voltage Warning19. High Coolant Temperature20. Water in Fuel Indicator21. Fasten Seat Belt Warning

22. Driver Display Screen23. High Beams On Indicator24. Parking Brake On Warning25. Brake Air—Low Air Pressure

Warning26. Diesel Particulate Filter (DPF)

Status Lamp27. Cruise Control Enabled Indicator28. High Exhaust System

Temperature (HEST) Warning29. Right-Turn Signal

Fig. 3.10, Warning and Indicator Lights, ICU3X EPA10 Dash Message Center

Instruments

3.7

On other engines, the engine ECU will shut down theengine. It will at first derate the engine, and, if thecondition does not improve, shut it down completely30 seconds after the light comes on. The driver mustsafely bring the vehicle to a stop on the side of theroad before the engine shuts down.

To restart the engine (override the shutdown com-mand) turn the ignition switch to OFF, leave it there afew seconds, and turn the switch to START. The en-gine will run for a short period and shut down again ifthe condition does not improve.

IMPORTANT: Do not attempt to restart the en-gine while the vehicle is moving. Bring the ve-hicle to a safe stop and restart the engine withthe vehicle stopped.

Emergency BuzzerThe emergency buzzer sounds during the ignitionsequence and whenever one of the following condi-tions exists:

• The engine oil pressure falls below the presetlevel shown in Table 3.1 .

• The coolant temperature rises above the pre-set level shown in Table 3.2 .

• The air pressure falls below the preset level,which is 65 psi (448 kPa).

• The parking brake is set with the vehicle mov-ing at a speed greater than 2 miles per hour.

Warning and Indicator Lights

CHECK Check Engine (amber)Indicates an undesirable engine condition is detected orrecorded. If the condition gets worse, the stop engine orengine protection light will illuminate.

STOPStop Engine or Engine Protect(red)

Indicates a serious fault which requires the engine shut downimmediately. The engine ECU will reduce the maximumengine torque and speed, and, if the condition does notimprove, will shut down the engine within 30 seconds of thelight illuminating. The driver must safely bring the vehicle toa stop on the side of the road and shut down the engine assoon as the red light is seen. If the engine shuts down whilethe vehicle is in a hazardous location, the engine can berestarted after turning the key to the OFF position for a fewseconds.

High Exhaust System Temperature(HEST) (amber)

Slow (10-second) flash, indicates a regeneration is inprogress, and the driver is not controlling the engine idlespeed.

Solid illumination indicates a regeneration is in progress, withhigh exhaust temperatures at the outlet of the tail pipe, if thespeed is below 5 mph (8 km/h). It does not signify the needfor service; it only alerts the vehicle operator of high exhausttemperatures. See the engine operation manual for details.

Diesel Particulate Filter (DPF)Status (amber)

Solid illuminated indicates a regeneration is required.Change to a more challenging duty cycle, such as highwaydriving, to raise exhaust temperatures for at least 20minutes, or perform a parked regeneration. See the engineoperation manual for details.

Blinking indicates that a parked regeneration is requiredimmediately. An engine derate and shutdown will occur. Seethe instructions in the engine operation manual to perform astationary regeneration.

Malfunction Indicator Lamp (MIL)(amber)

Indicates an engine emissions-related fault, including, but notlimited to the aftertreatment system. See the engineoperation manual for details.

Instruments

3.8


Tractor ABS (amber)Indicates a problem with the ABS is detected. Repair thetractor ABS immediately to ensure full antilock brakingcapability.

Trailer ABS (amber) Indicates a fault is detected with the trailer ABS.

Left-Turn Signal (green) Flashes on and off whenever the outside turn signal lightsare flashing.

Right-Turn Signal (green) Flashes on and off whenever the outside turn signal lightsare flashing.

High-Beam Indicator (blue) Indicates the headlights are on high beam.

Low Air Pressure Warning (red)

For EPA07, activates with a buzzer when air pressure in theprimary or secondary air reservoir falls below 64 to 76 psi(440 to 525 kPa).

For EPA10, activates when suspension air is low.

Low Air Pressure Warning (red)Activates with a buzzer when air pressure in the primary orsecondary air reservoir falls below 64 to 76 psi (440 to 525kPa). (EPA10)

High Coolant Temperature Warning(red)

Activates with a buzzer when the coolant temperature goesabove a maximum level specified by the enginemanufacturer (see the engine manual).

Low Engine Oil Pressure Warning(red)

Activates with a buzzer when engine oil pressure goes belowa minimum level specified by the engine manufacturer (seethe engine manual).

Intake Heater (amber) Indicates the intake air heater is active. Wait to start.(EPA07)

BRAKE

Parking/Emergency Brake Warning(BRAKE!) (red)

Indicates the parking brake is engaged, or hydraulic brakefluid pressure is low. A buzzer activates when the vehicle ismoving over 2 mph (3 km/h) with the parking brake set.(EPA07)

Parking/Emergency Brake Warning(BRAKE) (red)

Indicates the parking brake is engaged, or hydraulic brakefluid pressure is low. A buzzer activates when the vehicle ismoving over 2 mph (3 km/h) with the parking brake set.(EPA10)

Cruise Control Activated (green) Indicates the cruise control is active.

Fasten Seat Belt Warning (red) Illuminates for 15 seconds when the ignition key is turned tothe ON position.

Instruments

3.9


Water in Fuel Warning (amber) Indicates that the fuel could contain water.

Low Battery Voltage Warning (red) Indicates battery voltage is 11.9 volts or less.

NOCHARGE No Charge Warning (amber) Indicates an alternator charge output failure.

Check Transmission Temperature Indicates high transmission temperature.

Check Transmission Indicates a transmission issue.

Overhead Instrument Panel,OptionalThe overhead instrument panel (Fig. 3.11 ), if in-stalled, holds the citizen’s band (C/B) radio, a micro-phone clip, and any switches that can not be accom-modated on the driver’s or auxiliary dash panels.

The underside of the overhead console also holdsthe sun visors and the optional dome/reading lightassembly. For more information on the dome/readinglight assembly, see Chapter 4 .

Speedometer and TachometerSpeedometerThree kinds of speedometer face (Fig. 3.12 ) areavailable. The U.S. version of the speedometer regis-ters speed in both miles per hour (mph) and kilome-ters per hour (km/h), with mph in the larger numbers.

The NAFTA version of the speedometer face re-verses this arrangement, with km/h in the largernumbers. The metric only version (not shown) showskm/h exclusively.

04/19/2002 f680028

1 2

1

3 4

1. Storage Area with Netting2. C/B Radio

3. Microphone Clip4. Dome/Reading Light Assembly

Fig. 3.11, Overhead Instrument Panel

Instruments

3.10

Tachometer, OptionalThe tachometer (Fig. 3.12 ) indicates engine speed inrevolutions per minute (rpm) and serves as a guidefor shifting the transmission and keeping the enginein the appropriate rpm range. For low idle and ratedrpm, see the engine identification plate.

Standard InstrumentsStandard instruments are supplied with the instru-ment cluster and should be present on every vehicle,with the following exceptions:

• The tachometer is optional on all vehicles.

• The transmission temperature gauge is op-tional on all vehicles.

Engine Oil Pressure Gauge

NOTICEA sudden decrease or absence of oil pressuremay indicate mechanical failure. Bring the vehicleto a safe stop and investigate the cause to pre-vent further damage. Do not operate the engineuntil the cause has been determined and cor-rected.

The engine oil pressure gauge (Fig. 3.13 ) displaysthe current engine oil pressure. If engine oil pressurefalls below the preset levels shown in Table 3.1 , firstthe check engine light will illuminate, and, if the con-dition does not improve, the engine protection lightwill also illuminate and the buzzer will sound. At this

point, the engine will derate or shut down, dependingon the type of engine protection system installed.

Oil Pressure *

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)Detroit Diesel 14 (97) min. 55 (350) min.Cummins 15 (103) 35 (241) min.Mercedes-BenzMBE900 7 (50) 36 (250)

Caterpillar 3126 10–20 (69–138) 30–45 (207–310)* Oil pressures are given with the engine at operating temperature. With

the engine cold, oil pressure may be higher. Individual engines may varyfrom the listed pressures; observe and record pressures when the engineis new to create a guide for checking engine condition.

Table 3.1, Oil Pressure Specifications

Coolant Temperature Gauge

NOTICEA sudden increase in coolant temperature mayindicate engine or cooling system failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

During normal engine operation, the coolant tem-perature gauge (Fig. 3.14 ) should read 175 to 195°F(79 to 91°C). If the temperature remains below 160°F(71°C) or exceeds the maximum temperature shownin Table 3.2 , inspect the cooling system to determinethe cause. See the M2 Workshop Manual for trouble-shooting and repair procedures.

10/09/2001

0

5

10

1520

30

RPM5

15

2535

4555

65

75

85

MPHkm/h

25

X100

30

5070

90

130

110

10

1 2f610527

1. Tachometer 2. Speedometer

Fig. 3.12, Speedometer and Tachometer

10/09/2001

0 100

50

PSI

OIL

f610528

Fig. 3.13, Engine Oil Pressure Gauge

Instruments

3.11

If coolant temperature rises above the preset levelsshown in Table 3.2 , first the check engine light willilluminate, and, if the condition does not improve, theengine protection light will also illuminate and thebuzzer will sound. At this point, the engine will derateor shut down, depending on the type of engine pro-tection system installed.

Maximum Coolant TemperatureEngine Make Temperature: °F (°C)

Detroit Diesel 215 (101)Cummins 225 (107)Mercedes-BenzMBE900

222 (105)

Caterpillar 3126 230 (110)

Table 3.2, Maximum Coolant Temperature

Transmission Fluid TemperatureGaugeThe transmission fluid temperature gauge is optionaland available on all vehicles.

During normal operation, the transmission fluid tem-perature gauge (Fig. 3.15 ) reading should not ex-ceed 250°F (121°C) at the sump.

NOTICEA sudden increase in transmission fluid tempera-ture that is not caused by a load increase mayindicate mechanical failure. Bring the vehicle to asafe stop and investigate the cause to preventfurther damage. Do not operate the vehicle untilthe cause has been determined and corrected.

Under heavy loads, such as when climbing steepgrades, temperatures may, for limited periods, climbabove those given here.

Fuel Level Gauge, Pre-EPA10On vehicles that are pre-EPA10 compliant, the fuellevel gauge indicates the level of diesel in the fueltank(s). See Fig. 3.16 . A single fuel gauge is stan-dard. If equipped with a second (optional) fuel gauge,each fuel tank level is indicated on a separategauge.

Fuel/Diesel Exhaust Fluid (DEF)Gauge, EPA10For engines that are EPA10 compliant, the fuel andDEF levels are measured in a dual purpose fuel/DEFgauge. See Fig. 3.17 .

The diesel fuel level is indicated at the top of thegauge, with a low-fuel warning lamp that illuminates

10/09/2001 f610565

WATER

100

150 200

250

F°

Fig. 3.14, Coolant Temperature Gauge

10/30/2001 f610600

TRANS

125 350

F

275200

Fig. 3.15, Transmission Fluid Temperature Gauge

10/09/2001 f610566

E F

1/2

FUEL

Fig. 3.16, Fuel Level Gauge, Pre-EPA10

Instruments

3.12

amber when the diesel fuel level registers 1/8th ofcapacity. The DEF level is indicated in the lightbar onthe lower portion of the gauge. There is a low DEFlevel warning lamp that illuminates amber when theDEF level reaches 10% of capacity. See Chapter 11 ,for details of the DEF gauge functions.

Primary and Secondary Air PressureGauges

WARNINGIf air pressure falls below minimum pressure, thebraking ability of the vehicle will be limited. Slowthe vehicle down and bring it to a gradual stop.Do not attempt to move the vehicle until air pres-sure has risen above the minimum level. Movinga vehicle without adequate braking power couldcause an accident resulting in personal injury ordeath.

Air pressure gauges (Fig. 3.18 ) register the pressurein the primary and secondary air systems. Normalpressure with the engine running is 100 to 120 psi(689 to 827 kPa) in both systems.

Air pressure gauges are required on all vehicles withair brakes. A low-air-pressure warning light and

buzzer, connected to both the primary and secondarysystems, activate when air pressure in either systemdrops below a minimum pressure of 65 to 75 psi(448 to 517 kPa).

When the engine is started, the warning light andbuzzer remain on until air pressure in both systemsexceeds minimum pressure.

VoltmeterThe voltmeter is a digital readout located on the bot-tom line of the dash message center whenever theignition switch is turned on. See Fig. 3.8 for 2004engines, or see Fig. 3.9 for EPA07 engines, or seeFig. 3.10 for EPA10 engines.

It indicates the vehicle charging system voltage whenthe engine is running and the battery voltage whenthe engine is stopped. By monitoring the voltmeter,the driver can be aware of potential charging systemproblems and have them fixed before the batteriesdischarge enough to create starting difficulties.

The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltage

08/21/2009

1/2ULTRA LOW SULFURDIESEL FUEL ONLY

E F

DEF

FE

f611045

1

2

3

4

1. Diesel Fuel LevelIndicator

2. DEF Level Indicator3. Low DEF Warning

Lamp (amber below10% DEF)

4. Low Fuel WarningLamp (amber at 1/8tank of fuel)

Fig. 3.17, Fuel/DEF Gauge, EPA10 10/22/2009 f610567

1

2

1. Primary Air Pressure Gauge2. Secondary Air Pressure Gauge

Fig. 3.18, Air Pressure Gauges

Instruments

3.13

of a fully charged battery is 12.7 to 12.8 volts whenthe engine is stopped. Battery voltage under 12.0volts is considered a low battery, and a completelydischarged battery will produce only about 11.0 volts.The voltmeter will indicate lower voltage as the ve-hicle is being started or when electrical devices inthe vehicle are being used.

If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at a repairfacility.

Optional InstrumentsOptional instruments are not found on every vehicle.They are stand-alones, not driven by the instrumentcluster, and are usually located on the auxiliary dashpanel. They are listed here in alphabetical order, tomake the information easier to find.

AmmeterAn optional ammeter (Fig. 3.19 ) measures currentflowing to and from the battery. When the batteriesare being charged, the meter needle moves to theplus side of the gauge; when the batteries are beingdischarged, the needle moves to the minus side. Aconsistent negative reading when the engine is run-ning indicates a possible problem with the chargingsystem.

Axle Oil Temperature Gauges,Forward and Rear

NOTICEA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the engine until the cause hasbeen determined and corrected.

During normal operation, optional axle oil tempera-ture gauges (Fig. 3.20 ), both forward and rear,should read between 160 and 220°F (71 and 104°C)for Meritor™ drive axles.

Under heavy loads, such as when climbing steepgrades, temperatures up to a maximum of 250°F(121°C) are not unusual.

Digital ClockThe optional digital clock (Fig. 3.21 ) has black char-acters on a constantly backlighted green display, witha brightness that automatically adjusts for day ornight. The clock has a 24-hour alarm, with a three-minute snooze feature.

1. To set the time of day:

1.1 Push the Run/Set (lower) switch to theright (TIME-SET position).

NOTE: When the hour setting is for a timebetween noon and midnight, the small letters

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Fig. 3.19, Ammeter

10/10/2001 f610571

Fig. 3.20, Axle Oil Temperature Gauge

Instruments

3.14

"PM" will appear in the lower left corner ofthe display; no "PM" display indicates anA.M. setting.

1.2 Advance the hour setting to the correctnumber by pushing and releasing the hourbutton as many times as needed. Or if thebutton is pressed and held in for longerthan 2 seconds, the numbers will continueto advance until the button is released.

1.3 Advance the minute setting by repeatedlypushing, or pushing and holding theminute button as needed.

1.4 Push the Run/Set switch to the middle(RUN) position.

2. To set the alarm time:

2.1 Push the Run/Set switch to the left(ALARM-SET position).

2.2 Set the alarm time by using the same pro-cedure that you used to set the time ofday; remember to set the hour for A.M.(no letters in the corner of the display), orP.M. as desired.

2.3 Return the Run/Set switch to the middle(RUN) position; the readout will return tothe time-of-day setting.

3. To operate the alarm:

3.1 With the alarm time set, push the alarm(upper) switch to the left. An alarm "wave"symbol and the letters "AL" will appear inthe upper left corner of the display whenthe alarm is on.

3.2 When the displayed time of day coincideswith the alarm time, the alarm will sound.If the SNOOZ button is not pushed or thealarm switch is not moved, the alarm willautomatically stop sounding after 1 minuteand will not sound again for 24 hours.

3.3 If desired, press the SNOOZ button whilethe alarm is sounding to shut the alarm offfor 3 minutes. The alarm symbol will flashin the display when the button is pushedand will continue to flash until the alarmswitch is moved or the alarm has soundedfor one minute. The snooze procedure canbe done as many times as desired.

3.4 Move the alarm switch to the right whenyou wish to shut off or cancel the alarm;the alarm symbol will disappear.

Engine Oil Temperature Gauge



During normal operation, the optional engine oil tem-perature gauge (Fig. 3.22 ) should read in the follow-ing temperature range:

• 177 to 203°F (81 to 95°C) for Mercedes-BenzMBE900 engines;

10/11/2001 f610576

Fig. 3.21, Digital Clock

Instruments

3.15

• 160 to 195°F (71 to 91°C) for Caterpillar 3126engines;

• 200 to 260°F (93 to 126°C) for Detroit Dieseland Cummins engines.

Under heavy loads, such as when climbing steepgrades, temperatures that exceed the normal oil tem-perature range for a short period are not unusual.

Under heavy loads, such as when climbing steepgrades, temperatures that exceed the normal oil tem-perature range for a short period are not unusual. Ifthe temperature returns to normal when the load de-creases, there is no problem.

Intake-Air Restriction IndicatorThe intake-air restriction indicator measures thevacuum on the engine side of the air cleaner at theair cleaner outlet. On standard installations, it ismounted on the intake air piping in the engine com-partment.

As an option for easier viewing, the intake-air restric-tion indicator (Fig. 3.23 ) can be mounted on thedash, usually on the right-hand control panel.

Intake-air restriction vacuum is measured in inches ofwater (inH2O).

If the yellow signal stays locked in the red zone, at orabove the values shown in Table 3.3 after the engineis shut down, the air cleaner needs to be serviced.The indicator then needs to be reset by pressing theblack button on the bottom of the indicator.

NOTE: Rain or snow can wet the filter andcause a higher than normal reading temporarily.

Intake-Air Restriction Vacuum ReadingsEngine Make * Initial inH 2O Service inH 2O

Cummins 12 25Detroit Diesel 12 20Mercedes-Benz 12 20Caterpillar 15 25* Turbocharged engines must be checked at full load and governed en-

gine speed.

Table 3.3, Intake-Air Restriction Vacuum Readings

Vehicles may be equipped with an optional go/no-gorestriction indicator without graduations (Fig. 3.24 ).

PyrometerA pyrometer registers the exhaust temperature nearthe turbocharger. Normal exhaust temperatures are700 to 1100°F (370 to 595°C). See Fig. 3.25 .

Variations in engine load can cause exhaust tem-peratures to rise as high as 1100°F (600°C). If thepyrometer reading shows that exhaust temperatureexceeds normal, reduce fuel to the engine until theexhaust temperature is reduced. Shift to a lower gearif the engine is overloaded.

Variations in engine load can cause exhaust tem-peratures to vary. If the pyrometer reading shows

10/10/2001 f610569

Fig. 3.22, Engine Oil Temperature Gauge

10/10/2001 f610568

Fig. 3.23, Intake-Air Restriction Indicator

Instruments

3.16

that exhaust temperature exceeds normal, reducefuel to the engine until the exhaust temperature isreduced. Shift to a lower gear if the engine is over-loaded.

Turbocharger Boost Pressure GaugeA turbocharger boost pressure gauge (Fig. 3.26 )measures the pressure in the intake manifold, in ex-cess of atmospheric pressure, being created by theturbocharger.

Collision Warning System,Eaton VORAD EVT–300

WARNINGThe Eaton VORAD EVT–300 Collision WarningSystem (CWS) is intended solely as an aid for analert and conscientious professional driver. It isnot intended to be used or relied on to operate avehicle. Use the system in conjunction with rear-view mirrors and other instrumentation to safelyoperate the vehicle. Operate this vehicle,equipped with the EVT–300 Collision WarningSystem, in the same safe manner as if the EVT–300 Collision Warning System were not present.

The EVT–300 Collision Warning System is not asubstitute for safe, normal driving procedures,nor will it compensate for any driver impairment,such as drugs, alcohol, or fatigue.

The EVT–300 Collision Warning System may pro-vide little or no warning of hazards such as pe-destrians, animals, oncoming vehicles, or crosstraffic.

Failure to drive safely and use the system prop-erly could result in personal injury and/or deathand severe property damage.

The Eaton VORAD EVT–300 is a computerized colli-sion warning system (CWS) that uses front-mounted(and side-mounted) radar to continuously monitorvehicles ahead of and alongside your vehicle.

04/08/2005 f090431

Fig. 3.24, Manual-Reset Air Restriction Indicator, Go/No-Go

10/10/2001 f610570

Fig. 3.25, Pyrometer

10/10/2001 f610574

Fig. 3.26, Turbo Boost Pressure Gauge

Instruments

3.17

NOTE: The side-mounted radar is optional andnot installed on all vehicles with a CWS.

The CWS warns of potentially dangerous situationsby means of visual and audible alerts. It performs infog, rain, snow, dust, smoke, and darkness. To bedetected, objects must be within the radar beam’sfield of view and provide a surface area that can re-flect back the radar beam. The beam sweeps anarea of 12 degrees in the horizontal plane and 5 de-grees in the vertical plane. This allows the determi-nation of the distance to, relative speed of, and angleto the target of vehicles and objects ahead.

The forward-looking antenna transmits radar signalsto, and receives them back from, vehicles and ob-jects ahead. It only reports those that are within yourlane. Road curvature information is provided by ayaw rate sensor in the CPU, which shapes the radardetection zone to the curve. The yaw sensor alsofunctions during turns.

An optional side sensor(s), not installed on all ve-hicles with a CWS, is mounted on the side of the ve-hicle. It transmits and receives radar signals for adistance of 2 to 10 feet (0.5 to 3 meters), alongsideyour vehicle. The side sensor can detect unseen ve-hicles and objects alongside your vehicle, movingand stationary, in a 15-degree vertical by 15-degreehorizontal beam pattern.

Refer to the Eaton website for additional information,www.roadranger.com .

Driver Display Unit (DDU)NOTE: All system controls are located on theDriver Display Unit (DDU).

The DDU contains the controls and indicatorsneeded to operate the system. See Fig. 3.27 . Indica-tors to inform the driver about the system’s operationare located on both the DDU and the optional sidesensor display.

The DDU controls system power, range for vehiclewarnings, speaker volume, and all other system func-tions. At the lower front edge of the DDU, a slot isprovided to insert the optional driver’s identification(ID) card.

• Alert and indicator lights advise of multiplewarning levels, system power, failure displaymode, and if so configured, failure of the driverto enter the ID card.

• A photo light sensor automatically adjusts alertand indicator light brightness depending on cablighting conditions.

• A small speaker provides audible alert tones towarn of closing on an object ahead and, whenequipped with an optional side sensor, of ob-jects alongside when the turn signal is acti-vated in preparation for a lane change.

• Additional tones indicate speaker volume, sys-tem failure, driver’s card status, and data ex-traction pass or fail.

See Table 3.4 for descriptions of the various alertlights and tones.

Alert Lights and Tones, DDULight Tone Description

Yellow None Object detected (first alert).

Yellow DoubleProximity alarm with vehiclemoving at less than 2 mph (3km/h).

YellowandOrange

None Following distance 2-3 seconds(second alert).

YellowandOrange

Single Following distance 1-2 seconds(target vehicle slows).

Yellow,Orangeand Red

Double Following distance 0-1 seconds(target vehicle slows).

Yellow,Orangeand Red

Continuous(twice persecond)

Following distance 1/2 second orless (or slow-moving vehicle).

Table 3.4, Alert Lights and Tones, DDU

Use the following instructions to operate the DDUcontrols and interpret the data provided by the CWS:

1. Push in the volume control and power ON/OFFknob to turn power on or off. Turn the knob leftor right to increase or decrease speaker volume.

NOTE: The system may be configured to haveno on/off capability. If the vehicle does not haveON/OFF control at the DDU, hold in the volumecontrol knob while turning the ignition switch tothe ON position.

2. At startup, a power-on LED test takes place. Allthe indicator and alert lights illuminate. Thegreen SC indicator light will flash eight times.

Instruments

3.18

www.roadranger.com

3. If the system’s configuration requires, insert thedriver’s ID card in the slot at the lower front edgeof the DDU. A high-pitched tone will sound whenthe driver’s ID card has been successfully read.One low tone will sound if the driver’s card hasbeen unsuccessfully read.

NOTE: The green power ON light blinks continu-ously if the system is on, configured to require adriver’s ID card, and the card is not inserted.

4. The speaker is located under the top cover ofthe DDU. It sounds audible tones to alert thedriver to potential hazards.

NOTE: The system may be configured so thatvolume control may be restricted to a rangeabove a minimum level.

5. To adjust the first alert detection range from 3seconds down to 2 seconds, rotate the rangecontrol knob from left to right. This will alsochange the second alert detection range from 2seconds down to 1.75 seconds.

NOTE: The system may be configured so thatrange control can not be adjusted by the driver.

6. Proximity Alarm: If your vehicle is traveling lessthan 5 mph (8 km/h) and an object is detectedless than 15 feet (4.5 meters) in front of your ve-hicle, and the closing rate is less than 2 mph (3km/h) but more than 1/2 mph (1 km/h), the prox-imity alarm activates (the yellow alert light illumi-nates and a low-frequency double tone sounds).

NOTE: All warnings apply only to objects withinthe maximum detection range and in your lane.Proximity alarm tones and vehicle-closing 1/2-second and two-second following interval tonesare configured items.

7. First Alert: The yellow alert light illuminates whenan object is detected within the system’s maxi-mum range of 350 feet (107 meters) on astraight road. Range is reduced in curves by theturn radius of the curve. This light also illumi-nates when the proximity alarm threshold iscrossed.

8. Second Alert: Both the yellow and orange alertlights illuminate when your vehicle is within a3-second following interval behind another ve-hicle in the same lane. If you are within a

VOLUME WARNING LEVEL RANGE

EATON VORAD

04/06/2001 f610486

ON SC

1

2

3 4 5

6

7

812

FAIL

1011 9

1. Red System Failure Indicator Light2. Green Power ON/Driver’s Card Status Indicator Light3. Volume Control and Power ON/OFF Knob4. Speaker5. Range Control Knob6. Green SC Indicator Light

7. Photo Light Sensor8. Driver’s ID Card Slot9. Red Alert Light10. Orange Alert Light11. Yellow Alert Light12. Distance/Danger Alert Lights

Fig. 3.27, Driver Display Unit (EVT-300)

Instruments

3.19

2-second following interval, and closing on thevehicle ahead, a warning tone will also sound.

9. Third Alert: All three alert lights, yellow, orange,and red, illuminate when you are 1 second (orless than 1 second) behind a vehicle. If the ve-hicle ahead is opening the interval, no tone willsound. If you are closing the interval, doubletones will sound. Within a 1/2-second or less fol-lowing interval, opening or closing, the tones willrepeat twice per second.

10. If a stationary vehicle or object, or an objectmoving less than 3.4 mph (5.5 km/h), is detectedwithin 220 feet (67 meters) and within 3 seconds,all three alert lights will illuminate and the doubletones will sound. This warning overrides all oth-ers and is not affected by the range control knobsetting.

IMPORTANT: The system is disabled in turnswith a radius of less than 750 feet (230 meters),and when the brakes are applied.

11. All tones are disabled in sharp turns or when thebrakes are applied. If the configuration permits,the three-second and two-second alert levelsmay be adjusted with the range control knob. Asingle low-frequency tone sounds when a systemfailure is detected. A medium-frequency tonesounds when the volume control level ischanged.

12. Successful downloading of Eaton Vehicle Infor-mation Management System (EVIMS) data willcause a double tone to sound. Unsuccessfuldownloading will cause a low-frequency tone tosound.

13. The photo light sensor senses lighting conditionsand automatically adjusts the intensity of the indi-cator and alert lights.

Side Sensor Display1. The yellow indicator light (Fig. 3.28 ) illuminates

continuously when no vehicle is detected by theside sensor(s).

2. The photo light sensor senses lighting conditionsand automatically adjusts the intensity of indica-tor and alert lights.

3. The red alert light illuminates when objects aredetected by the side sensor(s).

3.1 If the right turn signal is activated and theside sensor detects an object, the redalert light will illuminate and the DDUspeaker will sound a high-frequencydouble tone. This tone is sounded onlyonce per activation of the turn signal.

3.2 The red light will also illuminate and stayon if a failure of the side sensor is de-tected.

Special Road Situations

WARNINGThe Eaton VORAD EVT–300 Collision WarningSystem (CWS) is intended solely as an aid for analert and conscientious professional driver. It isnot intended to be used or relied on to operate avehicle. Use the system in conjunction with rear-view mirrors and other instrumentation to safelyoperate the vehicle. This system will not warn ofmany possible hazards. Do not assume it is "allclear" if no alert lights are illuminated.


01/27/97 f601259

2

3

1

1. Red Alert Light (vehicle or object detected)2. Photo Light Sensor3. Yellow Indicator Light (no vehicle or object detected)

Fig. 3.28, Side Sensor Display (EVT-300)

Instruments

3.20

Certain special road situations may affect the sys-tem’s ability to detect objects. These situations in-clude the effects of curves, dips, and hills that mayprovide an unexpected result:

NOTE: A warning may sound when an object isdetected in front of the vehicle even though thedriver intends to turn away or stop before reach-ing the object.

• When an object is detected in a very sharpright- or left-hand turn, the audible alarm willnot sound.

• When approaching a curve, before turning intoit, alarms may sound and lights illuminate be-cause of an object off the road, directly in linewith your vehicle. This will not occur when thebrakes are applied.

• Elevated obstacles such as overpasses andoverhead signs may be detected when ap-proaching a roadway descending to a lowerelevation.

• Vehicles cannot be detected on the other sideof a hill. An alarm will not sound until the objectis within the field of view of the antenna as-sembly.

• On approaching a steep hill, objects above thebeam cannot be detected. Generally, the beamhitting the road surface does not cause analarm.

• The side sensor only detects objects within itsfield of view, next to the tractor. A vehicle far-ther back, behind the field of view, will not bedetected.

• The side sensor range is set to detect averagesized vehicles, 2 to 10 feet (0.5 to 3 meters)away, in the adjacent lane. The side sensorprovides a 15-degree vertical by 15-degreehorizontal beam pattern.

• The radar beam of the CWS will detect nearrange cut-ins of approximately 30 feet (9meters) or less, depending on the angle of en-trance into the lane in front of your vehicle.

WARNINGHeavy rain or water spray at the side sensor maycause both the yellow and red lights on the sidesensor display to illuminate at the same time.

Under these conditions the system is temporarilyunable to provide adequate warnings.


NOTE: A continuous fixed object on the rightside of the vehicle such as a guard rail, wall,tunnel, or bridge may cause the side sensoralert light to stay on.

In Case of AccidentThe optional accident reconstruction capability pro-vides two segments of system data, one of whichcan be stored in system memory.

1. Push and hold the DDU range knob for at least 5seconds to store the first segment.

IMPORTANT: If the range knob is pushed again,a fail tone will sound.

2. Within 6 seconds, the green SC indicator lightwill blink rapidly 8 times, confirming that the datahas been saved.

3. After the first segment is saved, the second seg-ment runs continuously but only contains the last10 minutes (approximately) of system data.

NOTE: Once the first memory segment is fro-zen, the other can’t be frozen. Only by discon-necting the main CPU connector can the sec-ond memory segment be preserved. You mustreturn the CPU to Eaton VORAD for download-ing and interpretation of accident reconstructiondata.

4. The system will cease recording data 30 sec-onds after the vehicle comes to a stop.

5. After 30 days from the date the memory was fro-zen, the information will be cleared automatically.

Maintenance and DiagnosticsIMPORTANT: Servicing the Eaton VORAD EVT–300 Collision Warning System should be doneonly by qualified technicians. Special skills andequipment are required. Take your vehicle to anauthorized Freightliner service facility for repairs,or contact Eaton VORAD at (800) 826-4357.

Instruments

3.21

1. Keep the antenna assembly and side sensor(s)free of a buildup of mud, dirt, ice, or other debristhat might reduce the system range.

2. The system tests itself continuously and evalu-ates the results every 15 seconds. If a problemis detected with the front radar system, the redFAIL light on the DDU illuminates continuously aslong as the failure is active. The correspondingfault code is stored in the CPU memory.

3. When the system is placed in failure displaymode, both active and inactive fault codes canbe indicated by the DDU. Inactive faults arethose that have occurred and have been cleared.Active faults are those that are still present.

4. Fault codes provide the driver the ability torecord the system faults during a trip and to no-tify his maintenance department or EatonVORAD. In this mode, specific fault codes areindicated by the pattern of blinks of the driverdisplay unit red FAIL light.

5. Each fault code is a two-digit number, as shownin the Eaton VORAD Collision Warning SystemDriver Instructions. The red FAIL light blinks thesame number of times as the first digit, a pauseof approximately 3/4 of a second follows, thenthe light blinks the same number of times as thesecond digit.

6. Display the fault codes.

6.1 Press and hold the DDU volume controland power ON/OFF knob for at least 9seconds.

IMPORTANT: The system will turn off if yourelease the knob before 9 seconds havepassed.

6.2 Continue pressing the knob until the FAILlight begins to blink.

6.3 After 9 seconds, the DDU FAIL light be-gins to blink out the first fault code.

6.4 After finishing one code, the system waits3 seconds, and then begins the next faultcode.

6.5 If no faults are found, or after all the cur-rent fault codes have been issued, a code41 is blinked out to indicate the end of thesequence.

Instruments

3.22

4

ControlsIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Multifunction Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8All-Wheel-Drive Controls, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Adjustable Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14Other Dash-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14Heater/Air Conditioner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16

Ignition Switch and KeyThe ignition switch (Fig. 4.1 ) has four positions: AC-CESSORY, OFF, ON, and START. In addition, thesame key locks and unlocks the cab doors.

In the OFF position, the key slot is vertical; the keycan be inserted and removed only in this position.The following can be operated in the off position (re-gardless of whether the key is inserted): The low-beam headlights, taillights, brake lights, road lights,dome lights, clearance lights, turn signals, hazardwarning lights, horn, CB radio, power windows, ciga-rette lighter, clock, and electric oil pan heater.

In the ACCESSORY position, the key is turned coun-terclockwise. The radio, stereo system, mirror heat,air dryer, backup lights, and all of the electrical sys-tems that are operable in the off position are oper-able in the accessory position.

In the ON position, the key is turned clockwise andall electrical systems are operable. The low air pres-sure and low oil pressure warning lights (or mes-sages) and buzzer operate until the engine is startedand pressure is built up.

Electrical SystemThe Business Class® M2 features a new type ofelectrical system, different from any previous vehicle.Multiple electrical signals are carried along a simpli-fied set of wires, reducing the size of wiring bundles.There are significantly fewer wires overall, meaningless chance of damage, shorts and other problems.

WARNINGDo not attempt to modify, add, splice, or removeelectrical wiring on this vehicle without authoriza-tion from Freightliner Engineering. Doing socould damage the electrical system and result ina fire that could cause serious personal injury orproperty damage.

There are two new electrical modules, a master mod-ule located near the frontwall (bulkhead module) anda slave module located between the frame rails(chassis module).

This new wiring system features intelligent controlsthat blink to show switch activity and error conditions.These controls cannot be distinguished by their ap-pearance, only by their function.

For more information about these controls, see underthe headings "Axle Switches" and "SuspensionDump Switch."

Lighting ControlsThe lighting controls mentioned under this headinggenerally operate through switches located on thedash.

Two types of dash switches are used:

• Paddle switches with a single paddle located inthe center of the switch. The paddle can beraised or lowered to perform a function.

• Rocker switches that can be pressed at eitherthe upper or lower end to perform a function.Certain rocker switches are guarded to preventthem from being switched on or off acciden-tally.

When the panel lights are on, most switch legendsare backlit with a colored light, usually green. Thisallows the driver to find the switch more easily in thedark. When the switch is on, the switch icon is nor-mally backlit with a colored light, usually amber.Some switch icons are dead-fronted (not visible untilthe switch is turned on). When turned on, someswitches are illuminated from within by a red oramber LED (light-emitting diode).

Control PanelsThe left-hand control panel (Fig. 4.2 ) contains a lou-vered window outlet for the face vents of the heating,

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Fig. 4.1, Ignition Switch Positions

Controls

4.1

ventilation, and air conditioning system (HVAC), andfour switches arranged in a vertical line, usually theheadlight, panel light increase/decrease, and thecruise control On/Off and Set/Resume switches.

The instrument cluster (ICU3-M2) is located right be-hind the steering wheel. No controls are installed onthe standard instrument cluster.

The right-hand control panel (Fig. 4.2 ) usually con-tains the transmission push-button shift selector (onvehicles with automatic or automated transmission)and the trailer brake lever (hand control valve). Onvehicles with manual transmission, a variety ofswitches are installed here. If there is a dash-mounted air-restriction indicator, it is often mountedhere.

The radio panel contains two louvered dash outletsfor the face vents of the HVAC, one on either side ofthe radio (if installed).

The auxiliary dash panel (Fig. 4.2 ) below the radiopanel contains the marker interrupt switch, the airbrake valve knobs, the cigarette lighter, and a varietyof switch options.

The HVAC climate control panel is on a separatepanel below the auxiliary dash panel, between thetwo cupholders.

Exterior Light ControlsHeadlight/Parking Light SwitchThe headlight/parking light switch (Fig. 4.3 ) is apaddle switch located on the left-hand control panelabove the cruise control switches. When the paddleis lowered, the parking lights illuminate (the front turnsignals, the cab marker and identification lights, andthe taillights). When the paddle is raised, the low-beam headlights illuminate, along with all the parkinglights. To turn off all lights, return the paddle to thecenter position.

NOTE: The front turn signal is the amber lens ineach headlight unit. The low-beam headlight isthe top clear lens in each headlight unit.

When the headlights or parking lights are on, thepanel lights also illuminate. An amber light in theswitch backlights either the top icon (for headlightsand parking lights) or the bottom icon (for parkinglights only).

Panel Light Increase/Decrease SwitchWhen the panel lights are on, they can be eitherbrightened or dimmed by using the INCR/DECRrocker switch just below the headlight switch(Fig. 4.4 ). To brighten the panel lights, press on theupper part of the rocker (at the INCR legend). To dim

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1. Left-Hand Control Panel2. Instrumentation Control Unit3. Right-Hand Control Panel4. Radio Panel5. Auxiliary Dash Panel

Fig. 4.2, Switch and Gauge Panels

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Raise the paddle to illuminate the headlights, low beam.

Lower the paddle to illuminate the parking lights.

Fig. 4.3, Headlight/Parking Light Switch

Controls

4.2

the panel lights, press on the lower part of the rocker(at the DECR legend).

When the panel lights are on, both legends are back-lit in green.

Daytime Running LightsSwitching on the ignition and releasing the parkingbrakes automatically activates the daytime runninglights, if equipped. The daytime running lights willoperate until the parking brakes are applied or theheadlights are turned on.

NOTE: Daytime running lights are standard onall Canadian vehicles.

The daytime running lights illuminate at about two-thirds of normal power.

Marker Light Interrupt SwitchThe marker light interrupt (MRKR INT) paddle switchtemporarily flashes the marker lights and taillights(Fig. 4.5 ). With the vehicle lights on, raise the paddleto briefly turn off the marker lights and taillights. Withthe vehicle lights off, raise the paddle to briefly turnon the marker lights and taillights.

Turning off the vehicle lights automatically turns offthe marker lights. When the panel lights are on, themarker light icon and MRKR INT legend are backlitin green.

Road Light Switch, OptionalThe road light (ROAD LAMP) rocker switch operatesthe optional road lights, which are recessed into thefront bumper or mounted on the lower edge of a cut-out in the center of the front bumper.

The low beam headlights must be turned on beforethe road lights can be turned on. The road lights willnot illuminate if the high beam headlights are alreadyon, and switching from low beams to high beams willswitch off the road lights.

To turn the road lights on, press on the upper part ofthe rocker (at the road light icon). See Fig. 4.6 . Toturn the road lights off, press on the lower part of therocker (at the ROAD LAMP legend).

When the road lights are on, the road light icon isbacklit in amber. When the panel lights are on, theROAD LAMP legend is backlit in green.

Utility Light Switch, OptionalThe utility light switch operates one of the followinglights or sets of lights:

• A single round utility light swivel-mounted inthe center of the cab roof;

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Fig. 4.4, Panel Light Increase/Decrease Switch

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Raise the paddle to flash the marker lights.

Fig. 4.5, Marker Light Interrupt Switch

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Fig. 4.6, Road Light Switch

Controls

4.3

• Two round utility lights mounted in fixed posi-tions on each side of the cab roof;

• Two flush-mounted utility lights mounted on theback of the cab, one on each side.

To turn the utility light(s) on, press in on the upperpart of the utility light (UTLY LAMP) rocker switch(Fig. 4.7 ). To turn the utility light(s) off, press on thelower part of the rocker (at the UTLY LAMP legend).

When the utility lights are on, the diagonal light beamicon is backlit in red. When the panel lights are on,the UTLY LAMP legend is backlit in green.

Spotlight, OptionalThe spotlight switch operates one of the followinglights or sets of lights:

• A single spotlight and pivoting handle assemblymounted on the driver’s door;

• Two spotlights and pivoting handle assembliesmounted, one on each side, on both the driv-er’s and passenger’s doors.

To turn the spotlight(s) on, press in on the upper partof the spotlight (SPOT LAMP) rocker switch(Fig. 4.8 ). To turn the spotlight(s) off, press on thelower part of the rocker (at the SPOT LAMP legend).

When the spotlight(s) is on, the diagonal light beamicon is backlit in red. When the panel lights are on,the SPOT LAMP legend is backlit in green.

Interior Lights and Light ControlsThe interior lights include dome lights, red maplights, and clear reading lights.

Dome LightsDiffuse dome lights are installed on all cabs. Thestandard dome light has a clear lens and is installedon the back of the cab above the rear window. SeeFig. 4.9 for the rear dome light.

On cabs with an overhead console, there is an op-tional overhead dome light assembly containing adiffuse dome and a clear reading light. See Fig. 4.10for the optional dome/reading lights on the overheadconsole.

Light ReplacementRear Dome LightTo replace the rear dome light (Fig. 4.9 ), do the fol-lowing steps:

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Fig. 4.7, Utility Light Switch

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Fig. 4.8, Spotlight Switch

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To remove the lens, press in at the mounting tabs(arrows).

Fig. 4.9, Rear Dome Light

Controls

4.4

1. Press in on the lens at the four mounting tabs(arrows).

2. Replace the bullet-type bulb and install the lenson the lamp base with the button at the bottom.

Overhead Console Dome/Reading LightsTo replace the overhead console dome/reading lights(Fig. 4.10 ), do the following steps:

1. Remove the tapping screws that attach the lampassembly and trimplate to the overhead console.

2. Separate the lamp assembly from the trimplateand disconnect the wiring harness.

3. Replace the lamp assembly.

4. Snap the lamp assembly and trimplate together.

5. Connect the lamp assembly to the wiring har-ness.

6. Insert the tabs on the trimplate into the slots onthe overhead console attachment plate.

7. Center the lamp assembly in the headliner cutoutand install the center tapping screw.

8. Install the remaining tapping screws.

Dome Light SwitchesIn the standard cab, there is one dome light switch inthe driver’s door that turns on the diffuse dome lightwhen the driver’s door is opened. In one option, twoswitches are installed, so that the diffuse dome lightturns on when either the driver’s or passenger’s dooris opened.

Clear Reading Lights, OptionalClear reading lights are available as a option. Theyare included only in the light assembly installed inthe overhead console, located next to the diffusedome light in the same fixture (Fig. 4.10 ). Like thedome lights, the reading lights are door-activated.

Multifunction Turn SignalSwitchThe multifunction turn signal switch is attached to thesteering column, just below the steering wheel, onthe left-hand side. This switch has the followingfunctions:

• The turn signals

• The windshield wipers and washers

• The headlight high beams

• The hazard warning flasher

See Fig. 4.11 for the multifunction switch and itscomponent parts.

Turn-Signal ControlsThe turn signal lever (Fig. 4.12 ) is mounted on thesteering column. Moving the lever down turns on the

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1. Overhead Console2. Trimplate

3. Light Assembly

Fig. 4.10, Overhead Console Dome Lights

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Press down on the upper part of the rocker to activatethe hazard warning flashers.1. Washer Button2. Wiper Control Dial3. Turn Signal Lever4. Hazard Flasher (red rocker switch)5. Multifunction Switch Module

Fig. 4.11, Multifunction Turn Signal Switch

Controls

4.5

left turn signal lights; moving it up turns on the rightturn signal lights.

When one of the turn-signal lights is on, a green indi-cator arrow flashes at the far left or far right of thewarning and indicator light panel.

The lever automatically returns to the neutral position(self-cancels the switch) when the steering wheelreturns to the straight ahead position after a turn. Tocancel the signal manually, move the lever to theneutral position.

Windshield Wiper/Washer Controls

CAUTIONDo not move the wiper arms manually. Wipermotor damage will occur if the arms are moved.

The wipers are operated by a rotary switch in thewiper control dial, which is on the end of the turn sig-nal lever. See Fig. 4.13 . There are five delay set-tings, marked on the dial by lines of increasinglength, and two steady speed settings, LO and HI.

Rotating the control dial forward (in a counterclock-wise direction) turns the wipers on. If they are al-ready on, rotating the handle further forward (to afaster speed setting) increases the speed of the wip-ers through the various delay settings, and to LO andthen HI.

Rotating the control dial in the opposite direction(clockwise) causes the wipers to slow down. Rotating

the control dial clockwise as far as it will go (to theOFF setting) turns the wipers off.

The washers are operated by a yellow button at thevery end of the turn signal lever. To operate thewashers, press the button in and hold it in until youwant the washers to stop.

Headlight High BeamsPush the turn signal lever forward, towards the wind-shield, to turn on the high-beam headlights. Pull theturn signal lever back to its original position to turnthem off. See Fig. 4.14 .

When the high beam headlights are on, a blue lightilluminates on the instrument cluster between the ta-chometer and speedometer. For vehicles built to op-erate in the United States, switching on the highbeams will switch off the road lights.

NOTE: The ignition switch must be on for thehigh beams to work.

With the headlight low beams on, pull the lever back-ward, towards the steering wheel, to flash the highbeams (turn them on momentarily).

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Move the lever down to turn on the left turn signals.

Move the lever up to turn on the right turn signals.

Fig. 4.12, Turn Signal Controls

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Rotate the control dial away from you to turn the wiperson, or speed them up.

Rotate the control dial towards you to slow the wipersdown, or turn them off.1. Washer Button2. OFF Position3. Delay Positions4. Wipers On, Low Speed5. Wipers On, High Speed

Fig. 4.13, Wiper/Washer Controls

Controls

4.6

The headlight low beams remain on continuouslyduring high beam operation. If the low beam head-lights are turned off by use of the headlight switch,the high beams turn off also.

Hazard Warning FlasherThe hazard warning light flasher (Fig. 4.11 ) is a redrocker switch located on the top of the multifunctionswitch module. When the flashers are activated, allof the turn signal lights (front, side, and rear) and thetwo green indicator arrows on the control panel willblink on and off.

To flash the hazard warning lights, press down onthe upper part of the rocker (towards the dash). Tostop the hazard warning lights, press down on thelower part of the rocker (towards the steering wheel).

Horn ControlsNOTE: It is possible to have both the electricand the air horn installed on one vehicle.

Electric HornA single electric horn is standard. Dual electric hornsare available as an option.

The button for the electric horn is located in the cen-ter of the steering wheel. To sound the horn, pressdown on the button. See Fig. 4.15 .

Air Horn, OptionalSingle and dual air horns are available as options.

The air horn is controlled by a wire lanyard hangingdown just inboard on the driver’s door. See Fig. 4.16 .Pull downward on the lanyard to sound the air horn.

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Move the lever away from you to turn on the high beams.Move the lever back to its original position to turn themoff.

Move the lever towards you to flash the high beamsmomentarily.

1. Turn Signal Lever 2. Boot

Fig. 4.14, Headlight High Beams

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To sound the electric horn, press down on the hornbutton.1. Horn Button

Fig. 4.15, Electric Horn Control

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To sound the air horn, pull down on the lanyard (arrow).

Fig. 4.16, Air Horn Control

Controls

4.7

Powertrain ControlsAfter-Treatment System (ATS)Request/Inhibit Regen SwitchA parked regen of the ATS can be initiated with therequest/inhibit regen switch. It may also be used toinhibit the vehicle from performing an automaticregen. See Fig. 4.17.

The style and function of switch will vary with the en-gine make and model. See the engine operationmanual for operation details.

Cruise Control Switches

CAUTIONDo not attempt to shift gears without using theclutch pedal when the cruise control is engaged.Failure to follow this precaution will result in atemporarily uncontrolled increase in enginespeed; transmission damage and gear strippingcould result.

On standard models, cruise control is activated bytwo dash switches. See Fig. 4.18 . On some models,cruise control can be activated by a button on thetransmission shift knob.

• The On/Off Switch—this two-position rockerswitch bears the legend SPD CNTL on thelower half of the switch. When cruise control ison, an amber light illuminates in the top part ofthe switch.

• The Set/Resume Switch—this three-positionpaddle switch bears the legend RES/ACC

above the paddle and SET/CST below thepaddle.

NOTE: For more information about cruise con-trol operation, see Chapter 7 .

Engine Brake Switch, OptionalThe engine brake switch controls the degree of en-gine braking. Normally there are two paddleswitches, a two-position On/Off Switch to activate theengine brake, and a two-position HI-LO Switch tocontrol the amount of engine braking.

To turn the two-position On/Off Switch on, raise thepaddle. When the two-position switch is on, anamber LED (light-emitting diode) illuminates insidethe switch.

To turn the two-position HI-LO Switch on high, raisethe paddle (at the HI-LO icon). To turn the two-position HI-LO Switch on low, lower the paddle (atthe ENG BRK legend). See Fig. 4.19 .

A three-position switch is used on MBE900 enginesequipped with both the regular engine brake and theconstant-throttle (decompression) brake. It works the

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Fig. 4.17, Request/Inhibit Regen Switch

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To turn cruise control on, press the upper half of the On/Off (rocker) switch. To turn cruise control off, press thelower half of the On/Off (rocker) switch.1. Cruise Control On/Off (rocker) Switch2. Cruise Control Set/Resume (paddle) Switch

Fig. 4.18, Cruise Control Switches, Dash-Mounted

Controls

4.8

same as the two-position HI-LO switch, except thatthere is a third (off) position when the switch is left atits normal position.

The engine brake turns off automatically or when theclutch pedal is pressed. On vehicles without a clutchpedal, the brake pedal can be used to deactivate theengine brake. For more information about enginebrake operation, see Chapter 7 .

When the panel lights are on, the HI-LO icon is back-lit in amber on the HI-LO switch. On both switches,the ENG BRK legend is backlit in green when thepanel lights are on.

Exhaust Brake Switch, OptionalThe optional exhaust brake is controlled by a dash-mounted rocker switch to help slow the vehicle whenthe accelerator is released. See Chapter 7 under theheading "Exhaust Braking System, Optional" for addi-tional information.

To turn the exhaust brake on, press on the upperpart of the rocker (at the light inside the switch). Theexhaust brake turns off automatically. See Fig. 4.20or Fig. 4.21 .

When the exhaust brake switch is on, an amber LEDilluminates inside the switch. When the panel lightsare on, the EXHST BRK legend is backlit in green.

Engine Fan Switch, OptionalThe engine cooling fan can be turned on by the en-gine fan switch (ENG FAN legend). The fan will con-tinue to operate for a set amount of time and thenturn off unless the coolant temperature is highenough to continue the fan operation.

To turn the engine fan on, press on the upper part ofthe rocker (at the fan icon). See Fig. 4.22 .

When the engine fan is running, the fan blade icon isbacklit in amber. When the panel lights are on, theENG FAN legend is backlit in green.

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1. On/Off Switch 2. HI-LO Switch

Fig. 4.19, Engine Brake Switches

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Fig. 4.20, Exhaust Brake Switch

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Fig. 4.22, Engine Fan Switch

Controls

4.9

Transmission ControlsIf so equipped, the transmission range control valveand splitter valve are attached to the gearshift knob.Transmission shift pattern labels are located insidethe cab. See Chapter 8 for complete transmissionoperating instructions.

On vehicles with standard Allison On-Highway Seriesautomatic transmission, the shift selector is lever-activated. The display mounted on the steering col-umn provides four forward ranges and one reverserange. See Fig. 4.23 .

When the transmission is in D (drive), the vehicle willoperate in the overdrive (5th) gear. To shift down intothe direct drive (4th) gear, use the overdrive lockoutswitch (O/D legend). See Fig. 4.24 . The transmissionwill shift into 4th gear and remain in that gear unlessa range inhibitor is active, such as engine overspeed.See Chapter 8 for more information about rangeinhibitors.

To shift to fourth gear, press on the upper part of therocker (at the LED). The LED will come on and stayilluminated until the bottom part of the rocker switchis pressed.

On vehicles with Allison MD Series automatic trans-mission or Eaton Autoshift automated transmission, apush-button shift selector provides four, five, or sixforward ranges and one reverse range. See Chap-ter 8 for more information about the push-button shiftselector.

Axle SwitchesAll axle switches contain a red LED (light-emittingdiode) that illuminates the switch from within whenthe switch is turned on (the upper part of the rockeris pressed). The legend under the LED, if any, is notvisible until the switch is turned on.

IMPORTANT: A guard is positioned around allaxle switches to prevent unintentional activation.

NOTE: For more information on axle switchfunction, see Chapter 8 .

Differential Lock Switch

CAUTIONDifferential lock should only be engaged whenthe vehicle is stopped or moving slowly at lowthrottle. This will prevent internal axle damage.

The differential lock switch is a two-position guardedrocker switch. See Fig. 4.25 . It causes the wheels oneach axle governed by the switch to rotate together.It is also known as side-to-side wheel lock.

To lock the wheels together, press the upper half ofthe rocker momentarily (at the LED). To turn off dif-ferential lock, press the upper half of the rockeragain.

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1. All Series, Standard (without park)2. 1000/2400 Series, Optional (with park)3. 2000 Series, Optional (with auto-apply parking

brake)

Fig. 4.23, Steering Column-Mounted Shift Controls

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Fig. 4.24, Overdrive Lockout Switch

Controls

4.10

When the panel lights are on, the double-axle icon isbacklit in green.

IMPORTANT: The differential lock switch isguarded to prevent unintentional switch activa-tion. If the LED in the switch begins to blink dur-ing normal operation, when the switch has notbeen activated, this indicates an error condition.Bring the vehicle to an authorized Freightlinerservice facility as soon as possible.

Interaxle Lock Switch

CAUTIONThe interaxle lock should not be engaged on avehicle with obviously spinning wheels. Engage-ment at high speed or power can damage theaxle(s).

The interaxle lock switch is a two-position guardedrocker switch installed on vehicles with dual driveaxles. See Fig. 4.26 . It causes both axle shafts torotate together.

To lock the axles together, press the upper half of therocker momentarily (at the LED). To turn off interaxlelock, press the upper half of the rocker again.

When the panel lights are on, the double-axle icon isbacklit in green.

IMPORTANT: The interaxle lock rocker switch isguarded to prevent unintentional switch activa-tion. This switch does not have a diagnosticblink function when inactive.

Axle Shift Switch

CAUTIONTo prevent transmission and axle damage, makesure the automatic transmission is in high rangewhen performing an axle shift with the vehiclemoving.

The axle shift switch is a two-position guarded rockerswitch installed on vehicles with two-speed axles.See Fig. 4.27 .

To shift the axle from low speed to high speed, pressthe upper half of the rocker momentarily (at theLED). To turn the axle shift off (switch from highspeed back to low speed), press the upper half ofthe rocker again.

NOTE: On vehicles with tandem drive axles,there is an interlock that prevents a 2-speedaxle from shifting whenever the interaxle lock ison.

When the panel lights are on, the AXLE SHIFT leg-end is backlit in green.

IMPORTANT: The axle shift switch is guarded toprevent unintentional switch activation. If the

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Fig. 4.25, Differential Lock Switch

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Fig. 4.26, Interaxle Lock Switch

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Fig. 4.27, Axle Shift Switch

Controls

4.11

LED in the switch begins to blink during normaloperation, when the switch has not been acti-vated, this indicates an error condition. Bring thevehicle to an authorized Freightliner service fa-cility as soon as possible.

All-Wheel-Drive Controls,OptionalAll-wheel-drive (AWD) allows the driver to directdriveline power to all four axles, front and rear. Twoswitches are used to control AWD: an AWD operationswitch used to activate all-wheel-drive, and an AWDrange switch used to select the high or low range.AWD controls are not multiplexed.

AWD Operation SwitchThe AWD operation switch is a two-position rockerswitch with a light-emitting diode (LED) that illumi-nates when AWD is engaged. The legend LOCKEDis underneath the LED on the upper half of theswitch. On the lower half is the legend AWD. SeeFig. 4.28 . When the panel lights are on, the AWDlegend is backlit in green.

To engage AWD, press the upper half of the rockerswitch. The LED illuminates to indicate that AWD isengaged. To turn off AWD, press the lower half of theswitch. The LED goes out to indicate the AWD is nolonger engaged.

When AWD is engaged, the LOCKED legend isbacklit in red. In addition, a red indicator with the leg-end T-CASE ENGAGED displays on the dash mes-sage center.

AWD Range Switch

CAUTIONTo prevent damage to the transfer case and thedriveline, stop the vehicle and apply the parkingbrake before using the range switch.

The AWD range switch is used under similar condi-tions to those of the axle shift switch on a two-speedrear axle. Use the high range when driving at normalspeeds under off-road conditions, or on non-pavedsurfaces. Use the low range when extra traction isneeded at lower speeds; for example, under condi-tions of mud, snow, or ice. This switch should beused only when AWD has been engaged.

In most cases, the AWD range switch is a two-position rocker switch with the legends LO RANGEat the upper end and HIGH RANGE at the lowerend. On vehicles with a power take-off unit (PTO),the three-position switch has a neutral (N-TRL) posi-tion in the middle. See Fig. 4.29 . When the panellights are on, the HIGH RANGE legend is backlit ingreen.

Two-Position Switch (no PTO)On vehicles without a PTO, high range is consideredstandard operation. To activate the low range, pressthe upper half of the switch. When the low range isactivated, the LO RANGE legend is backlit in red. Inaddition, a red indicator with the legend T-CASE LORNG displays on the dash message center. Toswitch back to HIGH RANGE, press the lower half ofthe switch.

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LOCKED

AWD

Fig. 4.28, AWD Operation Switch

1

f610808

LO

RANGEHIGH

RANGELO

RANGEHIGH

N−TRL

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2

1. Two-Position Switch2. Three-Position Switch

Fig. 4.29, AWD Range Switches

Controls

4.12

Three-Position Switch (with PTO)

IMPORTANT: Always use the N-TRL switch po-sition when operating the PTO.

On vehicles with a PTO, neutral is considered stan-dard operation (switch in the middle position). Anamber indicator with the legend T-CASE NTRL dis-plays on the dash message center.

To activate the high range, press the lower half of theswitch. No indicator displays on the dash messagecenter with the high range activated. Press the upperhalf to return to N-TRL.

To activate the low range, press the upper half of theswitch. A red indicator with the legend T-CASE LORNG displays on the dash message center. On theswitch, the LO N-TRL legend is backlit in red. Pressthe lower half to return to N-TRL, and then press thelower half again to select HIGH RANGE.

BrakingParking Brake Control ValveThe yellow diamond-shaped knob (Fig. 4.30 ) on theauxiliary dash panel operates the parking brake con-trol valve (park brake switch). Pulling the yellow knobapplies the tractor parking brakes (spring brakes).Pushing in the knob releases the tractor parkingbrakes. Before the parking brakes can be released,the air pressure in either air brake system must be atleast 65 psi (448 kPa).

See Chapter 9 under the heading "Dual Air BrakeSystem" for further information about the parkingbrake control valve.

Trailer Air Supply ValveThe red octagonal-shaped knob (Fig. 4.30 ) on theauxiliary dash panel operates the trailer air supplyvalve. After the vehicle and its air hoses are con-nected to a trailer, and the pressure in the air systemis at least 65 psi (448 kPa), the red knob must bepushed in (and should stay in) to charge the trailerair supply system and release the trailer spring park-ing brakes. Before disconnecting a trailer or whenoperating a vehicle without a trailer, the red knobmust be pulled out.

See Chapter 9 under the heading "Dual Air BrakeSystem" for further information about the trailer airsupply valve.

Trailer Brake LeverThe trailer brake lever (hand control valve) is usedfor applying the trailer brakes without applying thetruck or tractor brakes. It is usually mounted on theright-hand control panel. See Fig. 4.31 . See Chap-ter 9 under the heading "Dual Air Brake System" foroperating instructions.

Meritor™ WABCO® Antilock BrakingSystem (ABS)The Meritor WABCO Antilock Braking System (ABS)has an amber tractor indicator light (TRACTOR ABSlegend) and, if equipped with automatic traction con-trol (ATC), an amber wheel spin indicator light(WHEEL SPIN legend). See Fig. 4.32 .

f610291

1 2

03/10/99

1. Trailer Air Supply Valve (red knob)2. Parking Brake Control Valve (yellow knob)

Fig. 4.30, Brake Valve Control Knobs

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Fig. 4.31, Trailer Brake Lever

Controls

4.13

On vehicles equipped with a compatible trailer, thereis also an amber trailer indicator light (TRAILER ABSlegend).

See the brake system operating instructions in Chap-ter 9 for more information about ABS.

Adjustable Steering ColumnTo tilt the steering column, press down on the footpedal located below the steering column. Tilt thesteering column up or down to the desired position.Release the foot pedal to lock the steering column inplace. See Fig. 4.33 .

To telescope the steering column, press down on thefoot pedal located below the steering column. Pullthe steering wheel closer to you or push the steeringwheel farther away from you. Release the foot pedalto lock the steering column in place.

Other Dash-Mounted ControlsWindshield-Fan Switches, OptionalCeiling-mounted defogger fans are operated byLOW/OFF/HIGH toggle switches located in the baseof the fan.

Cigarette LighterPush in the lighter to heat the element. The lighterwill stay in and will automatically pop out when theelement is hot.

CB Radio ConnectionsAn antenna connection and positive (+) and negative(–) power connections are provided for a CB radio.

21 3

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1. Tractor ABS Indicator2. Wheel Spin Indicator

(optional)

3. Trailer ABS Indicator

Fig. 4.32, ABS Indicator Lights

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1

2

3

4

5

1. Multifunction TurnSignal Switch

2. Headlight Switch3. Ignition Switch

4. Adjustable SteeringColumn foot Pedal

5. Steering Wheel

Fig. 4.33, Adjustable Steering Column

Controls

4.14

Suspension Dump Switch

NOTICEDo not operate the vehicle over uneven groundsuch as ramps, speed bumps, curbs, etc. withthe air springs deflated. Doing this may lead toair bag separation from the piston, preventing thesuspension air springs from reinflating.

NOTICENever exhaust air from the suspension whiledriving. When the air is exhausted, the suspen-sion will not absorb road shocks, and compo-nents may be damaged.

The suspension dump switch is a two-positionguarded rocker switch (Fig. 4.34 ). It allows the air inthe vehicle air suspension to be quickly exhausted,lowering the rear of the vehicle. This makes it easierto connect to, or disconnect from, a trailer.

To lower the rear of the vehicle quickly, press theupper half of the rocker momentarily (at the LED). Toraise the suspension to its normal height, press theupper half of the rocker again.

When the panel lights are on, the tractor icon isbacklit in green.

IMPORTANT: The suspension dump switch isguarded to prevent unintentional switch activa-tion. This switch does not have a diagnosticblink function when inactive.

When the suspension dump switch is pressed, threeresponses are possible: a normal response, a slowresponse, and an abnormal response.

Normal Response: The LED in the switch blinkswhile the suspension is deflating or filling. When it iscompletely deflated, the LED comes on steady andstays illuminated. In normal operation, the suspen-sion may dump or fill so quickly that the blinking ofthe switch is barely noticeable.

If operation of the switch is not possible for any rea-son (vehicle is moving faster than 5 mph, ignition isturned off, etc.), the LED will stop blinking and turnoff.

Slow Response: If operation of the switch is slowedfor any reason (by cold weather, low air pressure,etc.), the switch will continue to blink until the sus-pension completes a dump or fill. As in the normalresponse, the LED comes on steady and stays illumi-nated when the suspension if fully deflated.

Abnormal Response: If the LED blinks for more than10 seconds, the suspension dump mechanism maynot be operating properly. Bring the vehicle to an au-thorized Freightliner service facility for testing.

If the ignition is turned off while the vehicle is indump mode, the power to the dump solenoid is cutoff to prevent battery drain, and the suspension sys-tem will autofill the rear air springs. The suspensionwill also autofill if the vehicle is operated with thesuspension dumped, and the speed is over 5 mph(e.g. -- driver forgot to inflate the bags or there was asystem failure).

Suspension Autofill Override ValveThe suspension autofill override option is a dash airvalve, that keeps the suspension deflated when theignition is turned off. To operate it, turn off the ignitionthen push the override valve knob. See Fig. 4.35 .When the ignition is turned on, the override valve willrelease automatically, and the suspension will autofill.The suspension dump switch will then operate nor-mally as described previously.

Heater/Air Conditioner ControlPanelStandard controls (Fig. 4.36 ) for the heating, ventila-tion, and air-conditioning system (HVAC) consist ofan eight-speed fan switch, an air selection switch,and a temperature control switch. On vehicles withair conditioning, the panel also contains a telltaleLED and an air recirculation button. See Chapter 6for detailed operating instructions for the HVAC.

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Fig. 4.34, Suspension Dump Switch

Controls

4.15

Seat ControlsBench Seat Adjustment ControlsThe standard bench seat has one control: the seatslide lever. See Fig. 4.37 . The two-person benchseat and the non-suspended passenger seat haveno controls.

Suspension Seat Adjustment ControlsAll controls for adjusting air suspension seats arelocated within easy reach of the occupant.

Due to the maximum adjustability of mid- and high-back air suspension seats, it is possible to combinethe seat back recline adjustment and the seat slide

adjustment so that the seat back contacts the back-wall. It is the responsibility of the driver to adjust theseat to prevent damage to the seat and the cab inte-rior.

All adjustment controls for a suspension seat are lo-cated on the seat base. See Chapter 5 for completeinstructions.

PUSH TO

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Fig. 4.35, Suspension Autofill Override Valve

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231

40

1 2 3

f831452

1. Fan Switch2. Air Selection Switch3. Temperature Control Switch

Fig. 4.36, HVAC Climate Control Panel, Standard

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1

2

1. Three-Person Seat2. Seat Slide Lever

Fig. 4.37, Full Bench Seat

Controls

4.16

5

Cab FeaturesWindows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7Air Bag, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

WindowsStandard windows operate mechanically using ahand crank.

Power windows are optional, and can be installed onone side or both sides. One power window switch(window icon) will be installed on the dash for eachwindow. See Fig. 5.1 . If your vehicle is equipped withpower windows, press up to raise the window; pressdown to lower the window. Releasing the switchcauses the window to stop.

Standard vent (wing) windows do not open. Operat-ing vent windows are optional. To open the operatingvent window, turn the latch on the window and pushthe window open. See Fig. 5.2 .

MirrorsThe standard outside mirrors are mounted on thedoor frame. There is a primary rear view mirror and aconvex mirror.

Mirror Heat Switch, OptionalOne or both outside door mirrors can be heated tokeep them clear of fog, frost, and ice.

To heat the mirrors, press the upper part of the mir-ror heat switch (MIRR HEAT) on the dash. SeeFig. 5.3 . When the mirror heat switch is on, anamber indicator light illuminates inside the switch.

The mirror heat switch is a smart switch (fully multi-plexed).

Power Mirrors, OptionalThe main outside mirrors, if heated, can be equippedwith an electrical remote control located on the driv-er’s door. See Fig. 5.4 .

To select the mirrors on the left-hand side, press theleft side of the mirror select switch. To select the mir-rors on the right-hand side, press the right side of themirror select switch.

The keypad has four arrow keys, pointing up, down,left, and right. To adjust the mirror position, press thekeypad in the direction you want the mirror to move.

Down View Mirror, OptionalA down view mirror can be installed on the top of thepassenger door frame to allow the driver a view of

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Press up to raise the window; press down to lower thewindow. Releasing the switch causes the window to stop.

Fig. 5.1, Power Window Switch

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1

2

1. Latch 2. Vent Window

Fig. 5.2, Operating Vent Window (optional)

MIRRHEAT

10/09/2001 f610524

To heat the mirrors, press up; press down to turn off theheat.

Fig. 5.3, Mirror Heat Switch

Cab Features

5.1

the area adjacent to the right side of the cab. SeeFig. 5.5 .

SeatsGeneral Information

WARNINGKeep hands, tools, and other objects away fromthe scissor points under the seats. Failure to doso could cause personal injury.

Unless otherwise noted, all seat adjustments shouldbe made while seated and before the engine isstarted.

Due to the high degree of adjustability found in high-back air suspension seats, it is possible to set theseat back recline adjustment and the seat slide ad-justment in such a combination that the seat backwill come into contact with the rear wall of the cab. Itis the responsibility of the driver to adjust the seat toprevent damage to the seat and the cab interior.

The following is a description of adjustments that areavailable on one or more seats. Not all seats have allof the adjustments listed below.

1. Seat Slide (fore-and-aft): When this adjustment ismade, the entire seat moves forward or back-ward on its track (Fig. 5.6 ).

2. Isolator: This feature (also referred to as back-slap isolator or Chugger-Snubber®) reduces theamount of road shock by isolating the occupantfrom the motion of the vehicle, and allowing theupper seat to move in a simple pendulum mo-tion. Whenever the isolator is not desired, it canbe locked out (Fig. 5.6 ).

3. Lumbar Support: Lumbar support changes theshape of the seat back to give more or less sup-port to the occupant’s lumbar (lower back) area.

10/05/2001 f610523

1

2

To adjust the mirror position, press the keypad on thedoor in the direction you want the mirror to move.

1. Mirror Select Switch 2. Keypad

Fig. 5.4, Power Mirror Switch Pad

10/05/2001 f720396

1

1. Mirror

Fig. 5.5, Down View Mirror (optional)

10/05/2001 f910482

A

B

A. Seat Slide (fore-and-aft) AdjustmentB. Isolator Feature

Fig. 5.6, Seat Slide Adjustment and Isolator Feature

Cab Features

5.2

This adjustment is either mechanical or air con-trolled, depending on make and model of theseat (Fig. 5.7 ).

4. Headrest: When this adjustment is made, theupper part of the backrest (back cushion)changes angle to provide head and upper backsupport (Fig. 5.7 ).

5. Backrest Tilt: This adjustment pivots the backrestforward or backward (Fig. 5.8 ).

6. Seat Cushion Tilt: This adjustment raises or low-ers the front and/or back of the seat (bottom)cushion. This adjustment is easier to performwhen all weight is removed from the seat(Fig. 5.8 ).

7. Seat Tilt: When this adjustment is made, the seatassembly, both backrest and seat cushion, tiltsforward or backward (Fig. 5.8 ).

8. Ride Height Adjustment: The entire seat movesup or down when adjusting the ride height. Theadjustment is either manual or air controlled, de-pending on the make and model of the seat(Fig. 5.9 ).

9. Damper: When you sit on the seat, a levelingvalve places you in the center of the ride zone.When the damper is adjusted properly under nor-

mal driving conditions, the seat should not top orbottom against the limits of the vertical travel.

10. Ride Firmness: A firmer ride gives a better feelfor the road but less protection against uneven-ness in the road surface. A softer ride smoothsout the bumps.

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A

B

f910483

A. Lumbar Support B. Headrest Adjustment

Fig. 5.7, Lumbar Support and Headrest Adjustment

A

B

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A. Backrest Tilt B. Seat Cushion Tilt

Fig. 5.8, Cushion Tilt Adjustments

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A

f910485

A. Ride Height

Fig. 5.9, Ride Height Adjustment

Cab Features

5.3

Bench SeatsThe three-person full bench seat is standard. SeeFig. 5.10 .

The full bench seat has a seat slide adjustment toallow more or less leg room for the driver and pas-sengers. Release the seat slide lever and push back-wards or forwards to move the seat along its track.

High-back air suspension seats are optional for bothdriver’s and passenger’s seats. Also available are anon-suspended passenger’s seat, and a two-personbench seat with a safe or tool box located under theseat.

No adjustments are possible on the two-personbench seat or the non-suspended passenger seat.

Bostrom SeatSeat Slide AdjustmentMove the seat slide and isolator lever (Fig. 5.11 ) tothe left and hold it there to slide the seat forward orbackward to the desired position.

IsolatorTo engage the isolator, put the seat slide and isolatorlever in the center position. Lock out the isolator bymoving the lever to the right.

Lumbar SupportTo increase lumbar support, rotate the lumbar sup-port knob forward. To decrease lumbar support, ro-tate the knob rearward.

On seats equipped with air lumbar support, press thecontrol valve upward to increase lumbar support.Press the control valve downward to decrease lum-bar support.

Seat Cushion TiltRotate the seat cushion tilt knob to increase or de-crease seat cushion tilt.

Backrest TiltTo tilt the backrest, lean forward slightly to removepressure from the cushion and hold the backrest tiltlever rearward. Lean backward slowly to the desiredposition and release the lever to lock the backrest inplace.

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1

2

1. Three-Person Seat2. Seat Slide Lever

Fig. 5.10, Full Bench Seat

1

23

45

6

7

10/10/96 f910131

1. Backrest Tilt Lever2. Air Lumbar Support Control Valve (optional)3. Damper Adjustment Switch4. Height Adjustment Switch5. Seat Cushion Tilt Knob6. Seat Slide and Isolator Lever7. Lumbar Support Knob (standard)

Fig. 5.11, Bostrom Seat

Cab Features

5.4

Ride Height and Damper AdjustmentTo raise the seat, press the upper portion of theheight adjustment switch. To lower the seat, pressthe lower portion of the switch.

Press the damper adjustment switch to adjust thedamper.

National 2000 Series SeatSeat Slide AdjustmentMove the seat slide lever (Fig. 5.12 ) to the left andhold it there to slide the seat forward or backward tothe desired position. Move the lever back to its origi-nal position to lock the seat in place.

IsolatorTo use the isolator feature, turn the isolator handle tothe horizontal position. Turn the isolator handle downto lock out the isolator.

Lumbar SupportTo adjust the lumbar support, use the lumbar supportswitch on the side of the seat to give more or lesssupport to your lower back.

Backrest TiltTo tilt the backrest, turn the backrest tilt knob untilthe desired position is reached.

Seat Cushion AdjustmentTo adjust the height of the front of the seat cushion,lift the front cushion height adjustment handle, andpull forward or push back to the desired setting.

To adjust the height of the rear of the seat cushion,remove your weight from the seat and turn the rearcushion adjustment knob to one of three positions.

Ride Height AdjustmentTo raise or lower the height of the seat, use theheight adjustment switch on the side of the seat.

Sears SeatSeat Slide AdjustmentPush the seat slide (fore-and-aft adjustment) lever(Fig. 5.13 ) all the way to the left and slide the seatforward or backward, as desired. Release the leverto lock the seat in the desired position.

11/14/2000

1

234

5

f910445

6

7

1. Backrest Tilt Knob2. Lumbar Support Switch3. Height Adjustment Switch4. Seat Slide Lever5. Front Cushion Height Adjustment Handle6. Isolator Handle7. Rear Cushion Adjustment Knob

Fig. 5.12, National 2000 Series Seat10/08/2001 f910487

1

2

34

5

1. Seat Slide Lever2. Seat Cushion Tilt Adjustment3. Ride Height Knob4. Lumbar Support Lever5. Backrest Lever

Fig. 5.13, Sears Low Profile Seat

Cab Features

5.5

IsolatorTo engage the isolator (if installed), move the seatslide and isolator lever (Fig. 5.14 ) all the way to theright. To lock out the isolator, move the isolator leverto the center position.

Lumbar SupportMove the three-position lumbar support lever upwardto increase lumbar support (firmer). Move the leverdownward to decrease lumbar support (less firm).

NOTE: This three-position lever (see inset) doesnot rotate a full 360 degrees.

For seats with air support, use the aft rocker switchon the control panel on the left-hand side of the seat(Fig. 5.15 ). Press up to make the seat firmer; pressdown to make the seat less firm.

Seat Cushion TiltTo raise the seat cushion, lift upward on the front ofthe seat cushion, and then push it rearwards. Tolower the seat cushion, pull forward on the front ofthe seat cushion, and then push downwards.

Backrest AdjustmentTo adjust the backrest, push downwards on the back-rest lever just below the bottom of the backrest cush-ion. With the lever down, lean forward or backwardto the desired position. Release the lever to lock thebackrest in place.

Ride Height AdjustmentPush the ride height knob inwards to inflate the aircylinder, raising the height of the seat. Pull the rideheight knob outwards to deflate the air cylinder, low-ering the height of the seat.

For seats with air support, use the forward rockerswitch on the control panel on the left-hand side ofthe seat (Fig. 5.15 ). Press up to raise the seat; pressdown to lower the seat.

Ride Firmness AdjustmentFor a softer ride, remove the snap ring and pin fromthe shock absorber bracket (see inset). Relocate thepin in the other set of holes in the bracket and se-cure it with the snap ring.

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1

2

3

4

56

7

8

NOTE: Armrests are optional.1. Lumbar Support Lever2. Backrest Lever3. Ride Height Knob4. Shock Absorber Bracket (ride firmness)5. Pin (ride firmness)6. Snap Ring (ride firmness)7. Seat Slide and Isolator Lever8. Seat Cushion Adjustment

Fig. 5.14, Sears Fleetmaster Seat (with isolator)

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1. Ride Height Switch2. Air Lumbar Support Switch

Fig. 5.15, Air Controls, Sears Seat

Cab Features

5.6

Seat Belts and Tether BeltsGeneral InformationSeat belt assemblies are designed to secure personsin the vehicle to help reduce the chance of injury orthe amount of injury resulting from accidents or sud-den stops. For this reason, Daimler Trucks NorthAmerica LLC urges that the driver and all passen-gers, regardless of age or physical condition, useseat belts when riding in the vehicle.

WARNINGAlways use the vehicle’s seat belt system whenoperating the vehicle. Failure to do so can resultin severe personal injury or death.

Seat belt assemblies in Daimler Trucks NorthAmerica (DTNA) vehicles meet Federal Motor Ve-hicle Safety Standard 209, "Type 1" and "Type 2" re-quirements.

When transporting a child, always use a child re-straint system or the vehicle seat belts as appropri-ate. To determine whether a child restraint system isrequired, review and comply with applicable stateand local laws. Any child restraint used must complywith Federal Motor Vehicle Safety Standard 213,"Child Restraint Systems." When providing a childrestraint system, always carefully read and follow allinstructions pertaining to installation and usage forthe child. Make certain the child remains in the re-straint system at all times when the vehicle is in mo-tion.

In addition to seat belt assemblies, tether belts areinstalled on suspension-type seats. Tether belts helpsecure the seat to the floor and are intended to re-strain the seat and seat belt in case of an accident orsudden stop.

IMPORTANT: Seat belts have a finite life whichmay be much shorter than the life of the vehicle.Regular inspections and replacement as neededare the only assurance of adequate seat beltsecurity over the life of the vehicle.

Seat Belt Inspection

WARNINGInspect and maintain seat belts and tethers asinstructed below. Seat belts and tethers that weredamaged or stressed in an accident must be re-placed, and their anchoring points must bechecked. When any part of a seat belt systemneeds replacement, the entire seat belt must bereplaced, both the retractor and the buckle side.Do not attempt to modify the seat belt system;doing so could change the effectiveness of thesystem. Failure to replace damaged or stressedseat belts or any modifications to the systemmay result in personal injury or death.

Inspect the seat belts and tether belts (if soequipped).

1. Check the web for fraying, cuts, or extreme wear,especially near the buckle latch plate and in theD-loop guide area.

2. Check the web for extreme dirt or dust, and forsevere fading from exposure to sunlight.

3. Check the buckle and latch for operation and forwear or damage.

4. Check the Komfort Latch or the Sliding KomfortLatch (if equipped) for function and cracks orother damage.

5. Check web retractor for function and damage.

6. Check the mounting bolts for tightness andtighten any that are loose.

Seat Belt OperationThree-Point Seat Belt With Komfort Latchor Sliding Komfort Latch

WARNINGWear three-point seat belts only as describedbelow. Three-point seat belts are designed to beworn by one person at a time. In case of an acci-dent or sudden stop, personal injury or deathcould result from misuse.

Fasten the seat belts before driving. Fastening athree-point seat belt while driving creates a haz-ard.

Cab Features

5.7

When engaged and used properly, the Komfort Latch(Fig. 5.16 ) and the Sliding Komfort Latch (Fig. 5.17 )introduce a small amount of slack into the seat belt,resulting in a more comfortable ride.

1. Slowly pull the latch end of the three-point seatbelt out of the retractor and pull it across yourlap (from outboard to inboard) far enough to en-gage the buckle. If the retractor locks too soon,allow the belt to retract slightly, then slowly pull itout again.

2. Fasten the three-point seat belt by pushing thelatch into the buckle. Listen for an audible click.See Fig. 5.18 .

3. Tug on the seat belt to make sure it is securelyfastened. If the buckle unlatches, repeat thisstep. If the problem continues, replace the three-point seat belt.

4. Snug the seat belt to your waist.

5. Position the shoulder strap diagonally acrossyour chest with the adjustable D-loop bracket (ifequipped). If desired, engage the Komfort Latchor Sliding Komfort Latch as follows.

If equipped with a Sliding Komfort Latch, makesure that the shoulder strap is snug against yourchest. Without loosening the shoulder strap,push the Sliding Komfort Latch switch to the"ON" position. See Fig. 5.17 . To activate thelatch lean forward until you hear a click. This willallow for approximately 1 inch (2.5 cm) of slackbetween your chest and the shoulder harness.Once engaged, the latch will allow you to leanforward about 5 inches (13 cm) without having toreset the latch. Leaning forward more than 5

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A B

A. Disengaged B. Engaged

Fig. 5.16, Komfort Latch

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Fig. 5.17, Sliding Komfort Latch

01/18/95 f910004a

Fig. 5.18, Fastening the Three-Point Belt

Cab Features

5.8

inches (13 cm) will disengage the Sliding Kom-fort Latch, requiring it to be reset.

If equipped with a Komfort Latch, pull on theshoulder strap to lessen the pressure of the strapon your shoulder and chest. Allow no more than1 inch (2.5 cm) of slack between your chest andthe shoulder harness. More slack can signifi-cantly reduce the seat belt effectiveness in anaccident or a sudden stop. While holding the beltslack, press the Komfort Latch lever up, clamp-ing the seat belt webbing (Fig. 5.19 andFig. 5.20 ).

6. Unbuckle the three-point seat belt and releasethe Komfort Latch or the Sliding Komfort Latchas follows.

If equipped with a Sliding Komfort Latch, un-buckle the seat belt, then tug on the shoulderbelt to release the Sliding Komfort Latch, orpress the Sliding Komfort latch to the "OFF" po-sition, then unbuckle the seat belt.

If equipped with a Komfort Latch, unbuckle theseat belt, then release the Komfort Latch by giv-ing the shoulder belt a quick tug. If you lean for-ward against the shoulder belt, the Komfort Latchwill automatically release, and will need to bereset.

NOTE: Neither the Komfort Latch nor the SlidingKomfort Latch need to be manually released inan emergency situation. Each will release byitself under rough road or other abnormal condi-tions. Make sure the three-point seat belt iscompletely retracted when it is not in use.

Air Bag, OptionalYour vehicle may or may not be equipped with adriver’s air bag supplemental restraint system.

The air bag, when used with seat belts, provides ad-ditional protection to the driver in severe frontal colli-sions. The operational readiness of the air bag sys-tem is indicated by the supplemental restraint system(SRS) indicator on the dash. The SRS indicatorcomes on when the engine is started and then goesoff. The indicator will remain on if there is a problemwith the air bag system. The vehicle should be ser-viced if the SRS indicator does not come on whenthe engine is started or if the SRS indicator remainson.

WARNINGAir bags are designed to inflate only in severefrontal collisions. The driver and the passengershould always wear seat belts. For maximum pro-tection in a collision or rollover, always be in anormal seated position with your back againstthe seat back and your head upright. Fasten yourseat belt and ensure that it is properly positionedon your body as described under the "Seat BeltOperation" heading. Since the air bag inflateswith considerable speed and force, a proper seatposition will keep you a safe distance from theinflating air bag.

A

01/06/95 f910048a

A. 1 Inch (2.5 cm) Maximum

Fig. 5.19, Adjusting Shoulder Harness Clearance,Komfort Latch

11/02/95 f910144

Fig. 5.20, Locking the Komfort Latch

Cab Features

5.9

Do not place objects on the steering wheel or be-tween you and the steering wheel. Keep yourhands on the sides and lower portion of thesteering wheel. Any objects may cause harm dur-ing an accident.

Failure to follow these instructions may result indeath or personal injury.

Air Bag Safety GuidelinesThe air bag system contains components that usecombustible chemicals. Because these chemicals arecombustible, care must be taken when replacing orhandling system components.

WARNINGConsider undeployed air bags to be dangerousand capable of deploying at any time. Do not at-tempt to service the air bag system unlesstrained to do so. Damaged air bag systemsshould be examined by qualified personnel be-fore any attempt is made to remove or to deploythe air bag. All intentional deployments and test-ing of the system should be performed by trainedpersonnel. Unintentional or improper air bag de-ployment could cause severe bodily injury ordeath.

Do not attempt to disassemble the air bag inflatorunit or breach the integrity of the sealed metallicinflator case. Doing so could cause severe bodilyinjury or death.

Do not allow system chemicals to contact otherliquids, combustibles, and flammable materials.Doing so could cause chemical burns or per-sonal injury.

The surface of the deployed air bag may containsmall amounts of sodium hydroxide (which is aby-product of the gas generant combustion) andmetallic sodium. Sodium hydroxide may be irri-tating to the skin and eyes. Always wear rubbergloves and safety glasses when handling a de-ployed air bag. Immediately wash your hands andexposed skin areas with a mild soap and water.Flush your eyes immediately if exposed to so-dium hydroxide.

Review and comply with the following list ofwarnings. Failure to do so could result in severeinjury or death.

• Keep all liquids, acids, halogens, heavymetals, and heavy salts away from the airbag system.

• Do not cut, drill, braze, solder, weld, strike,or probe any part of the air bag system.

• Do not expose the air bag module to elec-tricity. Never probe a circuit.

• Do not attempt to adapt, reuse, or install anair bag system in any vehicle other than thespecific vehicle for which it is designed.

• Do not cut wires or tamper with the connec-tor between the vehicle wiring harness andthe air bag module. Cutting or removing theconnector from the system will disable thesafety shunt and could cause unintentionaldeployment.

• Allow deployed air bag systems to coolafter deployment.

• Wear rubber gloves and safety glasseswhen handling a deployed air bag.

• Wash your hands and exposed skin surfaceareas immediately after handling a de-ployed system.

• Store, transport, dispose of, and recycledeployed air bag system components inaccordance with all applicable federal,state, and local regulations.

• The air bag module may contain perchlor-ate material: special handling may apply,see www.dtsc.ca.gov/hazardouswaste/perchlorate .

• Keep all heavy objects in the cab secured.

Cab AmenitiesCup HoldersThere are two cup holders molded into the lower partof the auxiliary dash panel, one on either side of theHVAC control head.

Cab StorageThere are storage bins in the dash and the overheadconsole. On vehicles with optional individual driver’sand passenger seats, there is a center storage con-sole between the seats.

Cab Features

5.10

www.dtsc.ca.gov/hazardouswaste/perchlorate

www.dtsc.ca.gov/hazardouswaste/perchlorate

There is a dash storage bin located under the cupholders on the center panel. The bin has a hingedcover and can be used to store sunglasses. There isalso a small storage pocket above the radio.

Overhead StorageVehicles without an overhead console have two stor-age bins located above the windshield.

On vehicles equipped with an overhead console,most vehicles have a storage bin located in the over-head console. See Fig. 5.21 . The overhead storagebin is often removed and replaced with a CB radio.

Two map holders with netted openings are locatedoverhead, one on either side of the overhead con-sole.

Center Storage Console (optional)On vehicles with individual driver’s and passenger’sseats, a center storage console can be installed be-tween the seats.

The center storage console has a table top that canbe lifted up to deploy a writing surface. SeeFig. 5.22 .

In another version, the center storage console has aprinter top with a paper slot in it. See Fig. 5.23 .

Windshield Washer ReservoirThe standard location for the windshield washer res-ervoir is on the right-hand side of the cab underneath

the door, just above the trailing edge of the top cabstep. See Fig. 5.24 .

10/08/2001 f680027

1 2

3

1. Overhead Storage Bin 2. Overhead Console 3. Map Holder Netting

Fig. 5.21, Overhead Storage

10/08/2001 f680026

1

2

3

4

1. Table Top2. Storage Console Cover3. Storage Area4. Storage Console Base

Fig. 5.22, Center Storage Console (with writing surface)

Cab Features

5.11

10/08/2001 f680025

1

2

3

1. Printer Top2. Printer/Paper Area

3. Storage Console Base

Fig. 5.23, Center Storage Console (printer option)

10/08/2001 f820378a

12

3

1. Cab2. Washer Reservoir Fill Cap3. Top Step

Fig. 5.24, Windshield Washer Reservoir

Cab Features

5.12

6

Heater, Ventilator and AirConditioner

Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

Climate Control PanelThe climate control panel allows you to control theheating, ventilating, defrosting, and air conditioningfunctions. The climate control panel without air condi-tioning is shown in Fig. 6.1 . The climate controlpanel with air conditioning is shown in Fig. 6.2 .

Fan SwitchThe fan switch controls the fan speed and forcesfresh or recirculated air through the air outlets. Thefan switch has eight fan speeds and an off position.

To increase airflow, turn the fan switch to the right orto a higher number. To decrease the airflow, turn theswitch to the left or to a lower number.

Air Selection SwitchThe air selection switch allows you to control the flowof air through the face outlets, the floor outlets, thedefrost (windshield) outlets, or a combination ofthese outlets to give you nine air selection modes ona system without air conditioning. See Fig. 6.3 . Asystem with air conditioning has 11 air selection

231

40

1 2 3

f831452a06/17/2003

1. Fan Switch 2. Air Selection Switch 3. Temperature Control Switch

Fig. 6.1, Climate Control Panel Without Air Conditioning

1 2 3

5 4 f831453a06/18/2003

231

40

1. Fan Switch2. Air Selection Switch

3. Temperature Control Switch4. Recirculation Button

5. Recirculation Indicator

Fig. 6.2, Climate Control Panel With Air Conditioning

Heater, Ventilator and Air Conditioner

6.1

modes, four of which are air conditioning modes. SeeFig. 6.4 .

Air Selection Switch Without AirConditioning1. Face Mode: Directs all airflow through the face

or instrument panel outlets.

2. Selection between Face Mode and Bi-LevelMode: Directs 75 percent of the airflow throughthe face outlets and 25 percent through the flooroutlets.

3. Bi-Level Mode: Directs the airflow equally to theface outlets and the floor outlets.

4. Selection between Bi-Level Mode and FloorMode: Directs 25 percent of the airflow throughthe face outlets and 75 percent through the flooroutlets.

5. Floor Mode: Directs all airflow through the flooroutlets.

6. Selection between Floor Mode and Floor/Defrost Mode: Directs 75 percent of the airflow

through the floor outlets and 25 percent throughthe defrost outlets.

7. Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets.

8. Selection between Floor/Defrost Mode andDefrost Mode: Directs 75 percent of the airflowthrough the defrost outlets and 25 percentthrough the floor outlets.

9. Defrost Mode: Directs all airflow through thedefrost outlets.

Air Selection Switch With AirConditioning1. Air Conditioning Face Mode: Directs all airflow

through the face or instrument panel outlets.

2. Selection between the Air Conditioning FaceMode and the Air Conditioning Bi-Level

06/17/2003

1

2

34

5

6

7

8

9

f831455

1. Face Mode2. Selection Between Face Mode and Bi-Level Mode3. Bi-Level Mode4. Selection Between Bi-Level Mode and Floor Mode5. Floor Mode6. Selection Between Floor Mode and Floor/Defrost

Mode7. Floor/Defrost Mode8. Selection Between Floor/Defrost Mode and Defrost

Mode9. Defrost Mode

Fig. 6.3, Air Selection Switch Without Air Conditioning

f831462

1

2

3

4

56

7

8

9

10

1106/18/2003

A

A. Air Conditioning Modes1. Air Conditioning Face Mode2. Selection Between Air Conditioning Face Mode and

Air Conditioning Bi-Level Mode3. Air Conditioning Bi-Level Mode4. Selection Between Air Conditioning Bi-Level Mode

and Face Mode5. Face Mode6. Selection Between Face Mode and Floor Mode7. Floor Mode8. Selection between Floor Mode and Floor/Defrost

Mode9. Floor/Defrost Mode10. Selection between Floor/Defrost Mode and Defrost

Mode11. Defrost Mode

Fig. 6.4, Air Selection Switch With Air Conditioning


6.2

Mode: Directs 75 percent of the airflow to theface outlets and 25 percent to the floor outlets.

3. Air Conditioning Bi-Level Mode: Directs theairflow equally to the face outlets and the flooroutlets.

4. Selection between the Air Conditioning Bi-Level Mode and the Face Mode: Directs 25percent of the airflow to the face outlets and 75percent to the floor outlets.

5. Face Mode: Directs all airflow through the faceoutlets.

6. Selection between Face Mode and FloorMode: Directs the airflow equally through theface outlets and the floor outlets.

7. Floor Mode: Directs all airflow through the flooroutlets.

8. Selection between Floor Mode and Floor/Defrost Mode: Directs 75 percent of the airflowthrough the floor outlets and 25 percent throughthe defrost outlets.

9. Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets. Therecirculation button will not work in this mode.

10. Selection between Floor/Defrost Mode andDefrost Mode: Directs 75 percent of the airflowthrough the defrost outlets and 25 percentthrough the floor outlets. The recirculation buttonwill not work in this mode.

11. Defrost Mode: Directs all airflow through thedefrost outlets. The recirculation button will notwork in this mode.

Temperature Control SwitchThe temperature control switch is used to select thedesired temperature. Turn the switch to the left(counterclockwise) for cool air, or to the right (clock-wise) for hot air. There are 21 positions on the tem-perature control switch ranging from full cool air tofull hot air.

Fresh Air ModeFresh air, or outside air, is circulated through theheating and air conditioning system unless the recir-culation mode, if equipped, is turned on.

Recirculation ModeThe recirculation mode is only available on vehicleswith air conditioning.

The recirculation mode limits the amount of outsideair entering the cab. Press the recirculation button toprevent dusty or smoky air from entering the cab.The recirculation mode can also be used to decreasethe time required to cool or heat the cab interior dur-ing extreme outside temperature conditions. Whenthe recirculation mode is on, the recirculation indica-tor will be on. See Fig. 6.2 .

The recirculation mode is not available when the airselection switch is in one of the following modes:

• floor/defrost mode

• selection between floor/defrost mode and de-frost mode

• defrost mode

When the recirculation mode is turned on, it will stayon for 20 minutes, or until the recirculation button ispressed again, or the air selection switch is turned toa defrost mode.

IMPORTANT: On vehicles built before May 2,2003, the recirculation mode turns off aftertwenty minutes and can be turned back onwhen the recirculation button is pressed again.On vehicles built from May 2, 2003, the systementers a partial recirculation mode for five min-utes after being in full recirculation mode for 20minutes. This cycle repeats as long as the sys-tem is in recirculation mode.

NOTE: To prevent the buildup of fumes or odorsinside the cab on a vehicle built before May 2,2003, do not use the recirculation mode formore than 20 minutes. It is recommended thatthe recirculation mode remains off for five min-utes before it is turned back on.

DefrostingBefore using any of the defrost modes, clear thescreen at the base of the windshield if snow or ice ispresent.


6.3

Air Conditioning, OptionalThere are four air conditioning modes on the air se-lection switch. The air conditioning settings on the airselection switch are blue, in addition to the selectionbetween the air conditioning bi-level mode and theface mode.

IMPORTANT: Operate the air conditioner atleast five minutes each month, even during coolweather. This helps prevent drying and crackingof the refrigerant compressor seals and reducesthe chance of refrigerant leaks in the system.

NOTE: The heating and air conditioning systemhas a brushless blower motor with a protectionor shutdown mode to prevent damage due tooverheating and overcurrent conditions. If thebrushless blower motor goes into a protectionmode, the motor will operate at a slower speed.If the overheating or overcurrent condition con-tinues, the motor will shut down and stop com-pletely.

The motor will resume proper operation after themotor has cooled or the overcurrent conditionhas been resolved. It will be necessary to cyclethe fan switch off, and then on, to reset themotor. If the problem appears repeatedly, takethe vehicle to an Freightliner dealer or autho-rized service outlet for repairs.


6.4

7

EnginesAftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10Starting After Extended Shutdown or Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14High-Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15Exhaust Braking Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16

Aftertreatment System (ATS)IMPORTANT: EPA07 and EPA10 emissionsregulations apply to vehicles domiciled inCanada and the USA at the time of printing thismanual. Vehicles that are domiciled outside ofthe USA and Canada may not have EPA07- orEPA10-compliant engines with an emission af-tertreatment system, depending upon localstatutory emissions guidelines.

EPA07 Aftertreatment System (ATS)On-road diesel engines built after December 31,2006 are required to meet EPA07 guidelines for re-duced exhaust emissions of particulate matter andnitrogen oxides (NOx). NOx is limited to just over 1gram per brake horsepower hour (g/bhp-hr), and par-ticulate matter cannot exceed 0.01 g/bhp-hr.

EPA07-compliant engines require ultralow-sulfur die-sel (ULSD) fuel, and they should never be run onfuel with sulfur content higher than 15 ppm. In addi-tion, they require low-ash engine oil. The followingguidelines must be followed, or the warranty may becompromised.

• Use ultralow-sulfur diesel (ULSD) with 15 ppmsulfur content or less, based on ASTM D2622test procedure.

• Do not use fuel blended with used engine lubeoil or kerosene.

• Engine lube oil must have a sulfated ash levelless than 1.0 wt %, meeting the API CJ-4 indexspecifications.

IMPORTANT: Using non-specification fuels oroils can lead to shortened diesel particulate filter(DPF) cleaning or exchange intervals. For ex-ample, using CI-4+ oil with 1.3% sulfated ash(30% more ash content) may result in the needfor DPF cleaning or exchange 20 to 30% soonerthan would normally be required.

The "exhaust system" in EPA07-compliant vehicles iscalled the aftertreatment system (ATS). The ATS var-ies according to engine manufacturer and vehicleconfiguration, but instead of a muffler, an aftertreat-ment system has a device that outwardly resemblesa muffler, called the aftertreatment device (ATD).

IMPORTANT: See your engine operation manualfor complete details and operation of the after-treatment system.

Inside the ATD on Mercedes-Benz, Detroit Diesel,and Cummins engines, the exhaust first passes overthe diesel oxidation catalyst (DOC), then it passesthrough the DPF, which traps soot particles. If ex-haust temperature is high enough, the trapped sootis reduced to ash, in a process called passive regen-eration (regen). Passive regeneration occurs as thevehicle is driven normally under load; the driver isnot even aware that it is happening. The harder anEPA07 engine works, the better it disposes of soot,as the exhaust heat alone is enough to burn the sootto ash. Over the course of a workday, however, pas-sive regeneration cannot always keep the ATD filterclean, so the filter must undergo active regenera-tion .

In active regeneration, extra fuel is injected into theexhaust stream to superheat the soot trapped in theDPF and turn it to ash. Active regeneration happensonly when the vehicle is moving above a certainspeed, determined by the engine manufacturer. Con-sult manufacturers’ documentation for details. Bothactive and passive regeneration happen automati-cally, without driver input.

If conditions do not provide for at-speed active re-generation, the vehicle will need a driver-activatedparked regeneration . The vehicle must be standingstill, and the driver must initiate parked regen. Com-pleting a parked regen takes 20 minutes to an hour,depending on ambient conditions.

DANGERDuring parked regeneration, exhaust tempera-tures are very high, and could cause a fire, heatdamage to objects or materials, or personal in-jury to persons near the exhaust outlet.

Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-als, and anything else that may be damaged orinjured by prolonged exposure to high heat.

There are three warning lamps in the driver messagecenter that alert the driver of the need to perform aparked regen, clean the filter, or of an engine faultthat affects the emissions.

Engines

7.1

A slow (10-second) flash of the high exhaust systemtemperature (HEST) lamp, indicates a regeneration isin progress, and the driver is not controlling the en-gine idle speed.

A solid illuminated high exhaust system temperature(HEST) lamp, alerts the operator of high exhausttemperature during the regeneration process, whenthe speed is below 5 mph (8 km/h). See Fig. 7.1 .The HEST lamp does not indicate the need for anykind of vehicle or engine service; it only alerts thevehicle operator of high exhaust temperatures. Thedriver must be careful that the exhaust pipe outlet isnot directed at any person, or at any object or mate-rial that can be damaged or ignited by the heat.

WARNINGActive regeneration can occur automatically anytime the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (800°C), which is hotenough to ignite or melt common materials, andto burn people. The exhaust can remain hot afterthe vehicle has stopped moving.

A steady yellow DPF lamp indicates that a parkedregen is required soon, and should be scheduled forthe earliest convenient time. See Fig. 7.2 . A blinkingyellow DPF lamp indicates that a parked regen isrequired immediately, or an engine derate may occur.

A solid yellow malfunction indicator lamp (MIL) indi-cates an engine fault that affects the emissions. SeeFig. 7.3 .

Diesel particulate filter servicing must be performedby an authorized service facility, and a record must

be maintained for warranty purposes. The recordmust include:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

The request regen switch is located on the dash.See Fig. 7.4 . The function of the switch varies bythe engine make and model in the vehicle. See theengine operation manual for switch operation details.

NOTE: The regen switch can start an activeregen only when the DPF light is illuminatedbecause the engine software calls for a manualregen.

The regen-inhibit switch provides additional controlover the aftertreatment regeneration process. A drivermay decide to use this feature if they are haulingcargo that should not be exposed to possible highexhaust temperatures from an automatic regen.

09/25/2006 f610816a

Fig. 7.1, High Exhaust System Temperature (HEST)Lamp

09/25/2006 f610815a

Fig. 7.2, Diesel Particulate Filter (DPF) Status Lamp

09/25/2006 f610814a

Fig. 7.3, Malfunction Indicator Lamp (MIL)

Engines

7.2

When activated, the inhibit switch will stop a regen-eration cycle in progress, and prevent the start of aregeneration cycle until the switch is no longer ac-tive. See Fig. 7.5 .

EPA10 Aftertreatment System (ATS)The EPA mandates that all engines built after De-cember 31, 2009 must reduce the level of emissionsexhausted by the engine to the following levels:

• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

• Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, diesel engines installed inDaimler Trucks North America (DTNA) chassis fordomicile in Canada and the USA use an aftertreat-ment system (ATS) with an aftertreatment device(ATD) and Selective Catalytic Reduction (SCR) tech-nology to reduce NOx downstream of the engine.

NOTICEUsing non-specification fluids can result in seri-ous damage to the ATS. It is extremely importantthat the following guidelines be followed for ve-hicles with EPA10-compliant engines, or damagemay occur to the ATD, and the warranty may becompromised.

• Use ultralow-sulfur diesel with 15 ppm sulfurcontent or less.


• Engine lube oil must have a sulfated ash levelless than 1.0 wt %; currently referred to asCJ-4 oil.

• Use only certified diesel exhaust fluid (DEF) inthe DEF tank.

After exhaust gasses leave the engine, they flow intothe ATS. First they flow into a two-part ATD, com-prised of a diesel oxidation catalyst (DOC), and adiesel particulate filter (DPF). The DPF traps sootparticles, then exhaust heat converts the soot to ashin the DPF, in a process called regeneration (regen).The harder an engine works, the better it disposes ofsoot. When the engine is running under load andregen occurs without input, it is called passive regen.If the engine isn’t running hot enough, the electroniccontrols may initiate an active regen, whereby extrafuel is injected into the exhaust stream before thediesel particulate filter, to superheat the soot trappedin the filter and burn it to ash. Both types of regenoccur without driver input.

WARNINGActive regeneration can occur automatically anytime the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (800°C), which is hotenough to ignite or melt common materials, andto burn people. The exhaust can remain hot afterthe vehicle has stopped moving.

Operating at reduced engine load will allow soot toaccumulate in the DPF. When this occurs, the DPFlamp illuminates, indicating that a regen must be per-formed, and the driver must either bring the vehicleup to highway speed to increase the load, or parkthe vehicle and initiate a parked regen. See ParkedRegen, later in this chapter for instructions.

f61084810/02/2006

Fig. 7.4, Request Regen Switch

f61094407/30/2009

Fig. 7.5, Regen-Inhibit Switch

Engines

7.3

After the exhaust stream passes through the ATD, itflows through another canister housing the SCR de-vice. A controlled quantity of diesel exhaust fluid(DEF) is injected into the exhaust stream, where heatconverts it to ammonia (NH3) gas. This mixture flowsthrough the SCR device, where the ammonia gasreacts with the NOx in the exhaust, to produce harm-less nitrogen (N2) and water vapor (H2O), which thenexits out of the tailpipe.

ATS Warning LampsThe malfunction indicator lamp (MIL) illuminates toindicate a fault that affects the emissions. SeeFig. 7.6 .

Warning lamps in the driver’s message center alertthe driver of situations with the aftertreatment sys-tem. A decal attached to the driver’s sun visor ex-plains the aftertreatment system DPF, HEST, andDEF warning lamps. See Fig. 7.7 .

• An illuminated DPF lamp indicates a regen isneeded.

• A slow, 10-second flashing of the HEST lampalerts the driver that a parked regen is inprogress, but the exhaust temperatures are stillrelatively cool. It also indicates that the high-idle speed is being controlled by the enginesoftware, not the driver.

• A steadily illuminated HEST lamp alerts theoperator of high exhaust temperatures whenvehicle speed is below 5 mph (8 km/h) while itis performing an automatic regen, and during aparked regen.

• An illuminated DEF warning lamp in the gauge,indicates that the DEF tank should be refilledat the next opportunity.

Parked Regen

DANGERDuring parked regeneration, exhaust tempera-tures are very high, and could cause a fire, heatdamage to objects or materials, or personal in-jury to persons near the exhaust outlet.

Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-als, and anything else that may be damaged orinjured by prolonged exposure to high heat.

A reference card is included with the driver’s docu-mentation package initially in the glove box, that ex-plains the ATS warnings, and actions required toavoid further engine protection sequences. SeeFig. 7.8

The regen switch, located on the dash, is used toinitiate a parked regen of the aftertreatment device. Itis a momentary switch, that you press and hold for 4seconds to activate. See Fig. 7.9 .

NOTE: The regen switch can initiate a parkedregen only when the DPF lamp is illuminated(because the engine software is signaling for aparked regen.)

The regen-inhibit switch provides additional controlover the aftertreatment regeneration process. A drivermay decide to use this feature if they are haulingcargo that should not be exposed to possible highexhaust temperatures from an automatic regen.When activated, the inhibit switch will stop a regen-eration cycle in progress, and prevent the start of aregeneration cycle until the switch is no longer ac-tive. See Fig. 7.10 .

To initiate a parked regeneration, perform the follow-ing steps.

1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).

09/25/2006 f610814a

Fig. 7.6, MIL Warning

Engines

7.4

2. Set the parking brake. If the parking brake wasalready set, you must release it, then set itagain.

For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.

If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

3. Press and hold the regen switch for 4 seconds.The engine will increase rpm and initiate theregen process.

4. After the parked regen has run for 20 to 40 min-utes, the regen cycle is completed. The engineidle speed will drop to normal, and the vehiclemay be driven normally. The HEST lamp may be

illuminated, but will go out when the vehiclespeed exceeds 5 mph (8 km/h), or the systemhas cooled to normal operating temperature.

5. To stop a parked regen at any time during theprocess, engage the clutch, brake, or throttlepedal, or turn off the engine.

DPF MaintenanceEventually ash will accumulate in the DPF and thefilter will require servicing. DPF servicing must beperformed by an authorized technician, following theengine manufacturer’s instructions. A record must bemaintained for warranty purposes, that includes:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

DPF Regen Needed

Hot Exhaust

DEF Refill Needed

Diesel Particulate Filter (DPF)regeneration is needed.

If flashing, regenerate as soon aspossible. Engine derate possible.

Hot exhaust can cause fire.

Keep flammables and people awayfrom exhaust.

Diesel Exhaust Fluid (DEF) level islow. Engine derate likely.

Refill tank with certified DEF.

See operator’s manual or glove compartment card for complete instructions.24−01656−000

IMPORTANT

DEF

07/16/2009 f080161

1

2

3

1. DPF Warning Lamp 2. HEST Warning Lamp 3. DEF Warning Lamp

Fig. 7.7, Warning-Lamp Decal, Sunvisor

Engines

7.5

DEFDEF is used in the aftertreatment system to lowerNOx in the exhaust stream. DEF is colorless andclose to odorless. (It may have a slightly pungentodor similar to ammonia.) It is nontoxic, nonflam-mable and biodegradable. It is mildly corrosive toaluminum, but it will not affect the strength or struc-ture of the aluminum. A white powder may be notice-able around components that the DEF comes in con-tact with. Around 12°F (-11°C) DEF freezes to slush,but is not damaged or destroyed if frozen, and is fully

usable when thawed. The DEF supply lines are elec-trically heated and are purged when the engine isshut down. The DEF in the tank is allowed to freezewhile the vehicle is non-operational. At start up, nor-mal operation of the vehicle is not inhibited if theDEF is frozen; an immersion heater with engine cool-ant flowing through it will warm the DEF once theengine is running, to allow the SCR system to oper-ate.

f080147

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended

Filter is reaching

Bring vehicle tohighway speeds to

Filter RegenerationNecessary

Filter is nowreaching maximumcapacity.

To avoid enginederate bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service

(Solid) (Flashing) (Flashing)

CHECK CHECK

(Flashing)

INDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

to highway speedsto allow for anAutomaticRegeneration orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed −engine will beginderate.

Regeneration must be performed.Check engine operator’s manualfor details −engine will shut down.

For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.

06/29/2009

24−01583−000B

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.

A regeneration is inprogress.

Flashing

Solid

Fig. 7.8, Exhaust-Aftertreatment Warnings Reference Card

f61084810/02/2006

Fig. 7.9, Regen Switch

f61094407/30/2009

Fig. 7.10, Regen-Inhibit Switch

Engines

7.6

DEF TankEPA10-compliant vehicles are equipped with a DEFtank located on the driver’s side of the vehicle, usu-ally behind the battery box, or an optional locationforward of the fuel tank for day cab configurations.See Fig. 7.11 , and Fig. 7.12 . The DEF tank has a 19mm filler neck inlet that prevents the hose from adiesel outlet from being inserted, and has a blue capfor easy identification.

DEF consumption will vary depending on ambientconditions and vehicle application.

Fuel/DEF GaugeThe fuel and DEF levels are measured in a dual pur-pose fuel/DEF gauge. See Fig. 7.13 .

The diesel fuel level is indicated at the top of thegauge, and a low-fuel warning lamp illuminatesamber when the diesel fuel level registers 1/8th ofcapacity.

The lower portion of the gauge has a DEF warninglamp that illuminates when the DEF tank is less than10% full, and a DEF lightbar that indicates the levelin the DEF tank as follows.

• Between 75% and 100% full, four bars are illu-minated green.

• Between 50% and 75% full, three bars are illu-minated green.

• Between 25% and 50% full, two bars are illu-minated green.

• Between 15% and 25% full, one bar is illumi-nated green.

• Between 5% and 15% full, one bar is illumi-nated amber.

• Between empty and 5% full, one bar is flashingred.

DEF Warnings and Engine DeratesThere are safety controls that warn the driver andderate the engine when the DEF level registersbelow 10%, or if the DEF tank is contaminated.

IMPORTANT: Under no circumstances will theengine be suddenly shutdown due to runningthe vehicle out of DEF, or improper fluid in theDEF tank.

One of the following conditions must apply be-fore a major derate will occur (speed may belimited to 5 mph/8 km/h).

• If the diesel tank is refueled but the DEF tankis left empty, the next startup will have a majorderate applied.

07/24/2009 f470542

1

2

1. Batteries 2. DEF Tank

Fig. 7.11, DEF Tank Located Behind the Battery Box

07/24/2009 f470541

12

1. DEF Tank 2. Fuel Tank

Fig. 7.12, DEF Tank Located Forward of the Fuel Tank

Engines

7.7

• If a fuel refill has not been detected but 350gallons (1325 liters) of fuel have been con-sumed since the DEF empty warning, the nextstartup will have a major derate applied.

NOTICETampering with any portion of the DEF system,or diluting the fluid, will result in a system faultdetection, and a possible major engine derate.

DEF Level—WarningWhen the DEF level in the tank drops to 10% full,the DEF warning lamp in the gauge is illuminatedsolid (amber), and one bar of the DEF-level lightbaris illuminated solid amber. See Fig. 7.14 .

DEF Level—Warning and Minor EngineDerateWhen the DEF level in the tank drops to approxi-mately 5% full, the DEF warning lamp flashes amber,and one bar of the DEF-level lightbar flashes red. OnDetroit Diesel engines, the engine will perform aminor torque derate of 25%, the speed will be limitedto 55 mph (88 km/h), and the CHECK engine lamp(amber) illuminates. On Cummins engines, when theDEF level drops to 2.5% the engine will perform aminor derate of approximately 25%, and the CHECKengine lamp (amber) illuminates. See Fig. 7.15 .

Minor engine derate occurs.

DEF Tank is Empty—Warning and MinorEngine DerateWhen the DEF tank registers empty, the DEF warn-ing lamp illuminates, and one bar of the DEF-levellightbar flashes red. The CHECK engine lamp illumi-nates, the malfunction-indicator lamp (amber) illumi-nates, and the engine remains at a minor derate.See Fig. 7.16 .

07/27/2009 f611037

B


E F

DEF

FE


E F

DEF

FE


E F

DEF

FE

A C

1 2

A. 4 lamps steady green in lightbar, 100% full.B. 1 lamp steady amber in lightbar, DEF 5 to 15% full.

C. 1 lamp flashing red in lightbar, DEF less than 5% full.

1. Low Fuel Warning Lamp (amber at 1/8 tank of fuel) 2. Low DEF Warning Lamp (amber at 10% DEF)

Fig. 7.13, Fuel/DEF Gauge

A

B

07/09/2009 f470537

A. DEF Warning Lamp (solid amber)B. DEF-Level Lightbar (1 bar solid amber)

Fig. 7.14, DEF Level—Warning

Engines

7.8

DEF Tank-Empty Warning Ignored—Warning, Major Engine Derate, VehicleSpeed LimitedAfter the DEF tank registers empty, if the diesel tankis filled but the DEF is not refilled, the CHECK en-gine lamp, malfunction-indicator lamp, and the STOPengine lamp (red) will be illuminated, and a majorengine derate will occur at the next start up. Vehiclespeed will be limited to 5 mph /8 km/h. SeeFig. 7.17 . After the DEF tank is refilled, and the SCRsystem senses sufficient DEF levels, the engine willreturn to normal operation.

DEF Contaminated—Warning and MajorEngine DerateIf a contaminant is detected in the DEF tank, thesensors in the SCR system will activate a minor en-gine derate sequence with a 55 mph (88 km/h)

speed limit. This fault turns on the check engine lightand MIL, and starts a 10 hour engine timer and 500mile (800 km/h) distance accumulator. If these limitsare exceeded and the fault is not corrected, the ve-hicle will perform a major engine derate and warningsequence. The STOP engine lamp will illuminate,engine torque will derate 25%, and speed will be lim-ited to 5 mph (8 km/h). See Fig. 7.16 and, Fig. 7.17 .After the DEF tank is refilled with DEF, and the SCRsystem senses proper NOx levels, the engine willreturn to normal operation.

Engine StartingFor cold-weather starting, refer to "Cold WeatherStarting" later in this chapter.

Whenever you start an engine, watch for any signsof engine problems. If the engine vibrates, misfires,or makes unusual noises, turn the engine off as soonas possible and determine the cause of the problem.Frequently, engine damage may be avoided by aquick response to early indications of problems.

NOTICEWhen starting a vehicle equipped with a manualtransmission and clutch lockout switch, theclutch pedal must be fully depressed during theentire start sequence. Failure to do so can causethe pinion to release and re-engage, which couldcause ring gear and starter pinion damage.

If a vehicle does not start on the first attempt,make sure that the engine has completelystopped rotating before reapplying the starter

A

B

07/09/2009 f470538

A. DEF Warning Lamp (flashing amber)B. DEF-Level Lightbar (1 bar flashing red)

Fig. 7.15, DEF Level—Warning and Minor EngineDerate

A

B

07/09/2009 f470539

Minor engine derate occurs.A. DEF Warning Lamp (flashing amber)B. DEF-Level Lightbar (1 bar flashing red)

Fig. 7.16, DEF Tank Empty—Warning and EngineDerate

A

B

07/09/2009 f470540

Major engine derate occurs when safe.A. DEF Warning Lamp (flashing amber)B. DEF-Level Lightbar (1 bar flashing red)

Fig. 7.17, DEF Tank-Empty Warning Ignored—Warningand Major Engine Derate

Engines

7.9

switch. Failure to do so can cause the pinion torelease and re-engage, which could cause ringgear and starter pinion damage.

Moving a vehicle with the starter and/or using thestarter to bump the engine for maintenance pro-cedures is strictly prohibited. Use of these meth-ods to bump the engine over or move the vehiclecan cause the pinion to release and re-engage,which could cause ring gear and starter piniondamage.

Ring gear and starter pinion damage caused byimproper starting procedures is not warrantable.

Pre-StartNOTE: These pre-start steps apply to all en-gines.

1. Perform the engine pretrip inspection and dailymaintenance checks in Chapter 11 .

2. Set the parking brake.

3. For manual transmissions, place the transmis-sion in neutral and disengage the clutch.

For automatic transmissions, make sure thetransmission shift control is in neutral or park.

NOTE: On vehicles equipped with a neutral startswitch, the transmission must be in neutral be-fore the engine can be started. For air start sys-tems, check the air supply before starting theengine. There must be 100 psi (689 kPa) of airpressure available.

4. Turn the ignition switch to the ON position(Fig. 7.18 ). All the electronic gauges on the ICU(instrumentation control unit) complete a fullsweep of their dials, the warning and indicatorlights light up, and the buzzer sounds for threeseconds.

Starting Precautions, All Engines

WARNINGNever pour fuel or other flammable liquid into theair inlet opening in the air intake in an attempt tostart the vehicle. This could result in a flash firecausing serious personal injury or property dam-age.

NOTICEDo not crank the engine for more than 30 sec-onds at a time. Wait two minutes after each try toallow the starter to cool. Failure to do so couldcause starter damage.

NOTE: Some starters are equipped with op-tional overcrank protection. If overcranking oc-curs, a thermostat breaks the electrical circuit tothe starter motor until the motor has cooled.

NOTICEProtect the turbocharger during the start-up bynot opening the throttle or accelerating the en-gine above 1000 rpm until minimum engine idleoil pressure registers on the gauge. Failure to doso could damage the turbocharger.

Cold-Weather StartingElectronic engines do not normally require specialstarting aids. At low temperatures, oil pan heaters orwater jacket heaters are sometimes used to assist instarting. See the engine manufacturer’s operationmanual for starting aids that are approved for specificengines.

Starting After ExtendedShutdown or Oil ChangeAn engine in storage for an extended period of time(over winter, for example) may accumulate water in

09/12/2001 f610509


Engines

7.10

the oil pan through normal condensation of moistureon the internal surfaces of the engine. Oil diluted bywater cannot provide adequate bearing protection atstart-up. For this reason, change the engine oil andfilters after extended storage.

NOTICEFailure to eliminate water-diluted lubricating oilmay lead to serious engine damage at startup.

Before engine start-up, complete the engine pretripand post-trip inspections and maintenance proce-dures in Chapter 11 .

Engine Break-InEvery engine is tested on a dynamometer beforeshipment, eliminating the need for a break-in period.Before running the engine for the first time, follow theinstructions in the engine manufacturer’s operationmanual.

Engine Operation

DANGERDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut down the engine when in anarea where flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.

All Freightliner diesel engines comply with the re-quirements of the Federal (U.S.) Clean Air Act. Oncean engine is placed in service, the responsibility formeeting both state and local regulations is with theowner/operator.

IMPORTANT: EPA07 and EPA10 emissionsregulations apply to vehicles domiciled inCanada and the USA at the time of printing thismanual. Vehicles that are domiciled outside ofthe USA and Canada may not have EPA07- orEPA10-compliant engines with an emission af-tertreatment system, depending upon localstatutory emissions guidelines.

NOTICEIt is extremely important that the following pointsbe followed for vehicles with EPA07- or EPA10-compliant engines, or damage may occur to theaftertreatment device, and the warranty may becompromised.

• Use ultralow-sulfur diesel with 15 ppm sulfurcontent or less.


• Engine lube oil must have a sulfated ash levelless than 1.0 wt %; currently referred to asCJ-4 oil.

• Adequate maintenance of the engine and thediesel-particulate filter are the responsibility ofthe owner/operator, and are essential to keepthe emission levels low. Good operating prac-tices, regular maintenance, and correct adjust-ments are factors that will help to stay withinthe regulations.

The driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifthe engine malfunctions. If the driver doesn’t under-stand how the warning system works, an engineshutdown could occur, causing a safety hazard. SeeChapter 3 for information.

All engines have an operating range specific to thatengine in which the engine performs most efficiently.The operating range extends from maximum torquerpm at the low end to engine rated speed at the highend. Most engines deliver best fuel economy whenoperated in the low- and mid-speed segments of theefficiency range and produce maximum horsepowerat rated speed, which is also the recommendedmaximum speed of the engine. For specifics for anyengine refer to the engine manufacturer’s operationmanual.

Prolonged idling of engines is not recommended, andis illegal in some states. The belief that idling a die-sel engine causes no engine damage is wrong. Idlingproduces sulfuric acid, that is absorbed by the lubri-cating oil, and eats into bearings, rings, valve stems,and engine surfaces. If you must idle the engine forcab heat or cooling, the high idle function of thecruise control switches should be used. An idlespeed of 900 rpm should be enough to provide cabheat in above freezing ambient temperatures.

Engines

7.11

If the engine is programmed with the idle shutdowntimer, ninety seconds before the preset shutdowntime, the CHECK ENGINE light will begin to flash ata rapid rate. If the position of the clutch pedal or ser-vice brake changes during this final ninety seconds(CHECK ENGINE lamp flashing) the idle shutdowntimer will be disabled until reset.

Cruise Control

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow covered, slippery, orroads with a loose driving surface. Failure to fol-low this precaution could cause a collision orloss of vehicle control, possibly resulting in per-sonal injury or property damage.

Dash-Mounted Switches

NOTICEDo not attempt to shift gears without using theclutch pedal when the cruise control is engaged.Failure to follow this precaution will result in atemporarily uncontrolled increase in enginespeed; transmission damage and gear strippingcould result.

On standard models, cruise control is activated bytwo dash switches (Fig. 7.19 ).

• The On/Off Switch—this two-position rockerswitch bears the legend SPD CNTL on thelower half of the switch. When cruise control ison, an amber light illuminates in the top part ofthe switch.

• The Set/Resume Switch—this three-positionpaddle switch bears the legend RES/ACCabove the paddle and SET/CST below thepaddle.

1. To cruise at a particular speed, do these steps:

1.1 Press the upper half of the On/Off (rocker)switch on the instrument panel.

1.2 Hold the accelerator pedal down until thespeedometer reaches the desired speed.

1.3 Momentarily lower the paddle of the Set/Resume switch to SET/CST.

2. To disengage the cruise control, do these steps:

2.1 Press down the brake pedal (on automaticor manual transmission) or

Press down the clutch pedal (on manualtransmission only)

2.2 Press the lower half of the On/Off (rocker)switch on the instrument panel.

3. To resume a preselected cruise speed, do thesesteps:

3.1 If the On/Off (rocker) switch on the instru-ment panel is off, turn it on.

3.2 Momentarily raise the paddle of the Set/Resume switch to RES/ACC. Cruise willreturn to the last speed selected.

NOTE: If the ignition is shut off, the speedmemory will be lost.

4. To adjust cruise speed up, raise the paddle ofthe Set/Resume switch to RES/ACC and hold it

09/13/2001

1

2

f610510

To turn cruise control on, press the upper half of the On/Off (rocker) switch. To turn cruise control off, press thelower half of the On/Off (rocker) switch.1. Cruise Control On/Off (rocker) Switch2. Cruise Control Set/Resume (paddle) Switch

Fig. 7.19, Cruise Control Switches, Dash-Mounted

Engines

7.12

there until the vehicle accelerates to the newspeed, as desired.

5. To adjust cruise speed down, lower the paddle ofthe Set/Resume switch to SET/CST and hold itthere until the vehicle decelerates to the newspeed, as desired.

Shift Knob Controls, OptionalCruise control can also be activated by the optionalPAUSE, RESUME, and SET buttons on the transmis-sion shift knob (Fig. 7.20 ).

1. To cruise at a particular speed, do these steps:

1.1 Hold the accelerator pedal down until thespeedometer reaches the desired speed.

1.2 Push the SET button on the transmissionshift knob.

2. To disengage the cruise control, do these steps:

2.1 Press down the brake pedal (on automaticand manual transmission) or

Press down the clutch pedal (on manualtransmission only)

2.2 Push the PAUSE button on the transmis-sion shift knob.

3. To resume a preselected cruise speed, push theRESUME button on the transmission shift knob.Cruise will return to the last speed selected.

NOTE: If the ignition is shut off, the speedmemory will be lost.

4. To adjust cruise speed up, push the SET buttonand hold it in until the vehicle accelerates to thenew speed, as desired.

5. To adjust cruise speed down, push the RESUMEbutton and hold it in until the vehicle deceleratesto the new speed, as desired.

Power Takeoff (PTO) GovernorFront Engine Power Take Offs (PTO) are devicesused to tap into engine power to run auxiliary de-vices. Common uses are vehicles with hydraulicpumps which power additional equipment. The fol-lowing instructions are general guidelines for operat-ing a PTO.

1. Set the parking brake. Shift the transmission toneutral.

2. Press the dash PTO switch. Release the switchwhen the light begins to blink.

When the light comes on steadily, the PTO isengaged and ready to operate. In stationarymode, the vehicle must remain in neutral with theparking brake set.

3. To activate the mobile mode, shift from neutral toreverse, 1st, or 2nd gear. The clutch will openand the PTO will disengage for a moment.

4. Touch the throttle pedal to close the clutch andengage the PTO in mobile mode. The PTO maybe operated with the transmission in the follow-ing gears only: R-N-1-2.

NOTE: Do not attempt to change gears whilethe vehicle is moving. The transmission will ig-nore the request.

5. To end the mobile mode, bring the vehicle to astop. The clutch will open and shut off power tothe PTO.

6. To resume stationary mode, shift to neutral. ThePTO will engage.

7. To end stationary mode, press the dash switch.When the light in the switch goes out, power tothe PTO is shut off. Shut down the engine.

05/23/95 f260316

Fig. 7.20, Cruise Control Buttons on the TransmissionShift Knob

Engines

7.13

Cold-Weather OperationSatisfactory performance of a diesel engine operatingin low ambient temperatures requires modification ofthe engine, surrounding equipment, operating prac-tices, and maintenance procedures. The lower thetemperature, the greater the amount of modificationrequired. For service products approved for use incold weather for your engine, see the engine manu-facturer’s engine operation manual, supplied in thevehicle documentation package.

If satisfactory engine temperature is not maintained,maintenance costs will increase due to greater en-gine wear. If the engine coolant temperature be-comes too low, raw fuel will wash the lubricating oiloff the cylinder walls and dilute the crankcase oil,causing all moving parts of the engine to suffer frompoor lubrication.

If the engine is in good mechanical condition and theprecautions necessary for cold-weather operation aretaken, ordinary cold weather will not cause difficultyin starting, or loss of efficiency.

The following points are important to observe whenoperating in cold weather:

• Check for cracks in the batteries, for corrosionof the terminals, and for tightness of the cableclamps at the terminals.

• Charge the batteries to full capacity. Replaceany battery that is damaged.

• If so equipped, turn off the load disconnectswitch after the engine is shut down, to preventbattery discharge.

• Have the alternator output checked at an au-thorized service provider.

• Check the condition and tension of the drivebelts.

• Refer to the engine manufacturer’s engine op-eration manual for recommended heaters, low-viscosity lubricating oils, wintergrade fuels, andapproved coolants.

A winterfront may be used to improve cab heatingwhile idling. If a winterfront is used, at least 25% ofthe grille opening should remain open in sectionedstripes that run perpendicular to the charge-air-coolertube-flow dirrection. This assures even coolingacross each tube, and reduces header to tubestress, and possible failure. Winterfronts should only

be used when the ambient temperature remainsbelow 10°F (-12°C).

High-Altitude OperationEngines lose horsepower when operated at high alti-tude because the air is too thin to burn as much fuelas at sea level. This loss is about three percent foreach 1000 feet (300 m) altitude above sea level for anaturally aspirated engine.

All engines used on M2 vehicles are altitude-compensated by the use of a turbocharger. This re-duces smoky exhaust at high altitudes, requires lessdownshifting, and allows the engine to make betteruse of its fuel. Nevertheless, shift gears as needed toavoid excessive exhaust smoke.

Engine Shutdown1. With the vehicle stopped, apply the parking

brakes and place the transmission in neutral.

NOTICEIdle the engine one to two minutes before shut-ting it down. After hard operation, shutting downthe engine without idling may cause damage tothe turbocharger.

2. Allow the engine to idle one to two minutes be-fore shutting it down. This allows the lubricatingoil and the coolant to carry heat away from thecombustion chambers, bearings, shafts, andseals. The extreme heat may cause bearings toseize or oil seals to leak.

IMPORTANT: Bearings and seals in the turbo-charger are subjected to the high heat of com-bustion exhaust gases. While the engine is run-ning, this heat is carried away by oil circulation,but if the engine is stopped suddenly, the turbo-charger temperature may rise as much as 115°F(46°C).

NOTICEExcept in an emergency, do not shut down theengine when the coolant temperature is above194°F (90°C). To do so could damage the engine.

3. Turn off the ignition switch and shut down theengine.

Engines

7.14

Engine BrakingThe engine brake switch controls the degree of en-gine braking. Normally there are two paddleswitches, a two-position On/Off Switch to activate theengine brake, and a two-position HI-LO Switch tocontrol the amount of engine braking.

To turn the two-position On/Off Switch on, raise thepaddle. When the two-position switch is on, anamber LED (light-emitting diode) illuminates insidethe switch.

To turn the two-position HI-LO Switch on high, raisethe paddle (at the HI-LO legend). To turn the two-position HI-LO Switch on low, lower the paddle (atthe ENG BRK legend). See Fig. 7.21 .

When the panel lights are on, the Hi-Lo legend isbacklit in amber on the three-position switch. On boththe three-position switch and the two-position switch,the ENG BRK legend is backlit in green when thepanel lights are on.

Whenever vehicle braking is required on good roadconditions, the engine brake may be used in con-junction with the service brakes. There is no timelimit for operation of the engine brake. However, anengine brake does not provide the precise controlavailable from the service brakes, and is not a sub-stitute for a service braking system.

WARNINGUsage of the engine brake as the primary brakingsystem can cause unpredictable stopping dis-tances, that could result in personal injury or

property damage. Service brakes are the primaryvehicle braking system.

Since the engine brake is most effective at rated en-gine speed, gear selection is very important. Gearingdown the vehicle, within the limits of the rated enginespeed, makes the engine brake more effective. Rec-ommended engine braking speed is above 1800 rpmand below the rated speed.

WARNINGThe engine brake must be disengaged whenshifting gears, by using the clutch. If the enginebrake is engaged when the transmission is inneutral, the braking power of the engine brakecan stall the engine, which could result in loss ofvehicle control, possibly causing personal injuryand property damage.

NOTICEDo not allow the engine to exceed 2500 rpm. Se-rious engine damage could result.

"Control speed" is the speed at which the enginebrake performs 100 percent of the required downhillbraking, resulting in a constant speed of descent.The control speed varies, depending on vehicleweight and the downhill grade.

For faster descent, select a higher gear than thatused for control speed. Service brakes must then beused intermittently to prevent engine overspeed andto maintain desired vehicle speed.

A driver may descend slower than control speed byselecting a lower gear, being careful not to over-speed the engine. Occasional deactivation of the en-gine brake may be necessary to maintain the desig-nated road speed under these conditions.

Below a set engine temperature when the engine iscold, the brake may be disabled depending on thebrake type.

To activate the engine brake after the engine iswarmed up and the vehicle is in motion:

• Remove your feet from both the clutch andthrottle pedals. Press the dash-mounted ENGBRK switch to toggle the engine brake ON.

The engine brake will engage at the rate lastset on the brake intensity switch.

10/17/2001 f610588

1 2

1. On/Off Switch 2. Hi-Lo Switch

Fig. 7.21, Engine Brake Switches

Engines

7.15

• Move the intensity switch to the desired inten-sity. Depending on engine model, LO will pro-vide 1/3 or 1/2 of the full braking capacity ofthe engine. HI will provide maximum enginebraking.

Use the dash-mounted switch set at the LOposition when driving on flat, open stretches ofroad. If the service brakes are still required toslow down on a grade, switch to a higher set-ting on the dash switch, until there is no needfor the service brakes. Grade descent speedshould be such that the service brakes areused infrequently and that they remain cool,thus retaining their effectiveness.

• For maximum retarding, maintain the top gov-erned speed of the engine through the appro-priate selection of gears. When shifting gears,the engine brake will disengage when theclutch pedal is depressed, then engage whenthe clutch pedal is released.

• To cancel the engine brake application, togglethe ENG BRK switch OFF.

If the engine is equipped with both cruise control andan engine brake, the engine brake can operate auto-matically while in cruise control mode. If the cruisecontrol/engine brake function is turned on in theDDEC VI system programming, the engine brake willcome on "low" when the set road speed increases afew miles-per-hour (kilometers-per-hour) above thecruise set speed. The maximum amount of braking(low, medium, high) is selected with the dashswitches. When the vehicle returns to the set cruisespeed, the engine brake will turn off.

The engine brake will only operate when the accel-erator pedal is fully released. Disengaging the clutchwill prevent the engine brake from operating.

Vehicles equipped with antilock braking systems(ABS) have the ability to turn the engine brake off ifa wheel-slip condition is detected. The engine brakewill automatically turn itself back on once the wheelslip is no longer detected. The DDEC VI system willdeactivate the engine brake system when the enginespeed falls below 1000 rpm or when the vehicleslows down to a preset speed, depending on DDECprogramming. This prevents stalling the engine.

Exhaust Braking SystemsExhaust Brake SwitchThe optional exhaust brake is controlled by a dash-mounted rocker switch to help slow the vehicle whenthe accelerator is released.

To turn the exhaust brake on, press on the upperpart of the rocker (at the light inside the switch). Theexhaust brake turns off automatically. See Fig. 7.22or Fig. 7.23 .

When the exhaust brake switch is on, an amber LEDilluminates inside the switch. When the panel lightsare on, the EXHST BRK legend is backlit in green.

Mercedes-Benz Exhaust BrakeAn exhaust brake is an optional auxiliary braking sys-tem that assists but does not replace the servicebrake system. The exhaust brake can be used aloneor together with the constant-throttle valves for steep

f61058911/28/2001


f610589a03/31/2009


Engines

7.16

or long grades. The exhaust brake switch located onthe control panel, in combination with the acceleratorand clutch pedals, allows the driver to make maxi-mum use of the exhaust brake in off-highway andmountain driving as well as in traffic or high-speedhighway driving.

When only the exhaust brake is installed, a two-position switch on the dash controls the engine brak-ing system. The exhaust brake is only active whenthe engine speed is between 1100 and 2700 rpm.Depressing the accelerator or clutch pedal deacti-vates the exhaust brake. The ABS system, when ac-tive, also deactivates the exhaust brake.

The exhaust brake is a butterfly valve mounted in theexhaust pipe. When the driver’s foot is not on theaccelerator pedal and the upper half of the exhaustbrake switch is pressed in, with the amber light onthe switch illuminated, an air cylinder shuts the but-terfly valve, which restricts the flow of exhaust gasesand retards the engine. This retarding action is car-ried through the engine and drivetrain, slowing thevehicle and reducing the need for frequent servicebrake applications.

Exhaust brakes are not intended for use as the pri-mary braking system during vehicle operation.

Operating Characteristics

WARNINGDo not use the exhaust brake when driving onslippery or low-traction road surfaces. Failure tofollow this precaution could result in a loss ofvehicle control and possible personal injury orproperty damage.

Before starting the engine, make sure that the lowerhalf of the exhaust brake switch is pressed in andthe amber light is not illuminated. Do not turn the ex-haust brake on until the engine has reached normaloperating temperatures.

When you remove your feet from both the accelera-tor and clutch pedals and the upper half of the ex-haust brake switch is pressed in with the amber lightilluminated, the exhaust brake is applied. The follow-ing conditions should exist if the brake is operatingproperly:

• A slight change in the sound of the engine maybe noticed when the exhaust brake is applied.

• Exhaust smoke should appear normal.

• Engine temperature should remain in the nor-mal operating range.

• Road speed usually decreases when the ex-haust brake is applied during a descent. Whenthe vehicle is carrying a heavy load or thegrade is extremely steep, you may need toapply the service brakes occasionally.

• Do not expect a retarding effect similar to sud-den hard application of the service brakes. Theexhaust brake retards the vehicle with asmooth braking effect.

• During a descent, the tachometer usuallyshows a drop in rpm, depending on the gradeand the vehicle load.

• Depending on the grade and vehicle load, youmay or may not feel the retarding force actingagainst your body when the brake is applied.The retarding force of the brake may not al-ways be noticed, but it is actually preventingthe vehicle from going much faster.

Make sure the exhaust brake is turned off beforeshutting down the engine.

Driving DownhillWhile approaching a steep grade, make sure that theupper half of the exhaust brake switch is pressed in,with the amber light illuminated. The exhaust brakecomes on as soon as you remove your foot from theaccelerator pedal. While going down the grade, usea low enough gear to safely descend with a minimumapplication of the service brakes. As a general guide-line, use the same gear as you would to ascend thehill.

NOTICEDo not allow the engine to exceed its governedspeed, or serious engine damage could result.

Apply the service brakes to reduce the engine rpm ormake a slower descent by using a lower gear.

Pacbrake® Exhaust BrakeThe Pacbrake exhaust brake is intended as asupplement to the service brakes and will not bringthe vehicle to a complete stop. The Pacbrake willassist in the control or reduction of road speed in

Engines

7.17

conjunction with, or independent of, the servicebrakes. The amount of retarding or braking force iscontrolled by the driver.

Pacbrake Operation (Caterpillar)The Pacbrake is controlled by the exhaust brakeswitch and the throttle pedal. All applications are ad-ditionally affected, controlled, or governed by enginespeed through transmission gear selection. The Alli-son MD3060 transmission has automatic downshift-ing when the exhaust brake is requested. See theinformation on the "Allison World Transmission" laterin this chapter.

On some applications, when the Pacbrake is in use,it may be necessary to check that the cruise controlis not set and that the throttle is in the idle position.

On some applications, the engine, transmission,cruise control, and the Pacbrake exhaust brake mayelectronically interact with each other, which auto-matically operates their functions. Following aresome examples of the programmed options that maybe available with the cruise control in the on position:

• The coast mode engages the Pacbrake whenthe service brake is applied and disengageswhen the service brake is released.

• The latch mode engages the Pacbrake whenthe service brake is applied and the Pacbrakeremains on after the service brake is released.The Pacbrake is disengaged when anotherinput (depressing the throttle or clutch, enginespeed drops below 800 rpm, or the exhaustbrake switch is turned off) is supplied.

• The manual mode does not require the cruisecontrol switch to be on, and operates thePacbrake manually at the driver’s discretion.

The amount of braking power the engine will developis related to the speed (rpm) of the engine. Thehigher the engine rpm, the greater the retardingpower.

Certain conditions may require that the transmissionbe downshifted in order to generate adequate rpmfor the amount of retarding power required. Pacbrakeexhaust brakes are designed and approved for safeuse at 300 rpm above the engine’s maximum gov-erned rpm. Refer to individual engine manufacturer’sspecifications.

The Pacbrake will function best if it is used all of thetime. However, if the vehicle is used inconsistently orseasonally, it may be necessary to perform a preven-tive maintenance procedure.

1. With the engine shut down, use any oil-free ornonpetroleum-based high-heat lubricant, andspray or coat a sufficient amount on the restrictervalve shaft and the attaching locations at eachend of the actuation cylinder. See Fig. 7.24 .

2. With your hands or a pair of pliers, motion thevalve several times to distribute the lubricantdown the shaft and the attaching locations.

NOTE: Starting the engine and idling for shortperiods of time is not recommended. During acold engine start-up, enough moisture is devel-oped within the engine and the exhaust systemto create a corrosion hazard that could affectthe future operation of the Pacbrake. The brakehousing may trap water in the valve shaft borecausing corrosion in an improperly functioningor nonfunctioning brake. If it is necessary to pe-riodically start the engine, it is recommendedthat normal operating temperatures be attainedbefore shutting down the engine.

Allison World TransmissionPacbrake exhaust brakes on engines that are usedwith the Allison World Transmission MD series, areinterfaced with the transmission electronic controlmodule (ECM). An exhaust-brake-enabled transmis-sion ECM will usually provide converter lockup in

03/06/2000 f490228

AA

A

A. Lubrication Point

Fig. 7.24, Pacbrake Exhaust Brake and Air Cylinder

Engines

7.18

gears two through six. Effective exhaust braking be-gins when the transmission automatically downshiftsinto fifth gear (62 mph or less). Once on, thePacbrake exhaust brake will control road speedand/or slow the vehicle sufficiently that the transmis-sion will automatically downshift, if necessary, to Alli-son’s preselect mode.

The preselect mode is normally assigned to secondgear; however, the transmission can be repro-grammed by an Allison Transmission Distributor tothird or fourth gear, should the operator desire. If ad-ditional retarding power is required before the auto-matic downshifting occurs, you can select a lowertransmission gear on the Allison shift selector.

Engines

7.19

8

DrivetrainClutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Allison On-Highway Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3Allison MD Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5Eaton® Fuller® Straight-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8Eaton Fuller Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9Eaton Fuller AutoShift™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12Freightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15Mercedes-Benz Manual Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22Mercedes-Benz Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22Meritor™ Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28

ClutchesClutch OperationApplying the Clutch BrakeThe purpose of the clutch brake is to stop the trans-mission gears from rotating in order to engage thetransmission gears quickly in making an initial start.To apply the clutch brake, put the transmission inneutral and press the clutch pedal to the floor.

CAUTIONNever apply the clutch brake while the vehicle ismoving. The clutch pedal should never bepressed down fully before putting the transmis-sion in neutral. Considerable heat will be gener-ated, which will be detrimental to the frictiondiscs, release bearings, and transmission frontbearings.

Applying the clutch brake with the transmission still ingear puts a reverse load on the gear. At the sametime, it will have the effect of trying to stop or decel-erate the vehicle with the clutch brake. Rapid wear offriction discs will take place necessitating frequent re-placement.

Vehicle Overload, or Overloading theClutch

CAUTIONOverloading will not only result in damage to theclutch, but also to the entire powertrain.

Clutches are designed for specific vehicle applica-tions and loads. These limitations should not be ex-ceeded.

Riding the Clutch PedalRiding the clutch pedal is destructive to the clutch.Partial clutch engagement permits slippage, and gen-erates excessive heat. Riding the clutch pedal willalso put a constant thrust load on the release bear-ing, which can thin out the lubricant. Release bearingfailures can be attributed to this type of misuse.

Holding the Vehicle on an Incline With aSlipping ClutchA slipping clutch accumulates heat faster than it canbe dissipated, resulting in early clutch failures. Neveruse the clutch to hold a vehicle on a hill.

Coasting With the Clutch Released(pedal down) and the Transmission inGear

WARNINGDo not coast with the clutch released (pedal de-pressed) and the transmission in gear. Highdriven-disc rpm could cause the clutch facing tobe thrown off the disc. Flying debris could causeinjury to persons in the cab.

If the transmission remains in a low gear and the ve-hicle gains speed, as may occur on a downgrade,the input shaft and clutch driven disc will turn atspeeds that are higher than normal. This occurs be-cause the rear wheels and the driveline become theinput for the transmission, and a higher-than-normalspeed for a given transmission gear translates to ahigher rpm value for the clutch driven disc.

Clutch driven discs are designed to allow for someamount of excess rotational speed, but the facinghas a limited burst strength. If the clutch driven discrpm increases too much, the clutch facing can bethrown off the disc(s).

Engaging the Clutch While CoastingEngaging the clutch while coasting can result in tre-mendous shock loads and possible damage to theclutch as well as to the entire drivetrain.

Report Erratic Clutch Operation PromptlyReporting erratic clutch operation as soon as pos-sible will give maintenance personnel a chance toinspect the clutch components.

CAUTIONOperating the vehicle with incorrect clutch pedalfree-travel could result in clutch damage. SeeGroup 25 of the Business Class ® M2 WorkshopManual for free-pedal adjustment procedures andspecifications.

Drivetrain

8.1

On mechanical clutch linkages, free-pedal travelshould be included and commented on daily in thedriver’s report, since clutch free-pedal travel is thebest guide to the condition of the clutch and the re-lease mechanism.

Clutch WearThe major reason clutches wear out too soon is ex-cessive heat. Clutches are designed to absorb anddissipate more heat than encountered in typical op-eration. The temperatures developed in typical op-eration will not break down the clutch friction sur-faces. However, if a clutch is slipped excessively orrequired to do the job of a fluid coupling, high tem-peratures develop quickly and destroy the clutch.Temperatures generated between the flywheel,driven discs, and pressure plates can be highenough to cause the metal to flow and the frictionfacing material to char and burn.

CAUTIONDo not allow sustained slippage of the clutch;this could severely damage the clutch disc, pres-sure plate, or flywheel. Damage caused by clutchslippage due to improper break-in is not warrant-able.

Slipping and excessive heat are practically nonexist-ent when a clutch is fully engaged. But during themoment of engagement, when the clutch is pickingup the load, it generates considerable heat. An incor-rectly adjusted or slipping clutch will rapidly generatesufficient heat to destroy itself.

The most important items that a driver should beaware of to ensure long service life of the clutch in-clude: starting in the right gear, recognizing clutchmalfunctions, and knowing when to adjust a clutch.

Clutch AdjustmentsSome clutches have an internal adjustment. See theapplicable section in Group 25 of the BusinessClass® M2 Workshop Manual for clutch adjustmentprocedures and specifications.

CAUTIONOperating the vehicle with the clutch incorrectlyadjusted could result in clutch or clutch brakefailure.

Clutch LubricationThe release bearing should be lubricated at frequentintervals. See Group 25 of the Business Class® M2Maintenance Manual for intervals and procedures.

CAUTIONFailure to lubricate the release bearing as recom-mended could result in release bearing damageand damage to the clutch.

NOTE: The Sachs hydraulic clutch does not re-quire lubrication of the release bearing.

Sachs Hydraulic ClutchThe Sachs hydraulic clutch is a 14.5-inch (365 mm)push-type clutch that is used with the Mercedes-Benz medium-duty transmissions, models MBT520and MBT660.

NOTE: All Mercedes-Benz transmission modelsrequire a hydraulic clutch system. For more in-formation on the Mercedes-Benz transmissions,see under the heading "Mercedes-Benz ManualTransmissions."

The clutch hydraulic system consists of three maincomponents:

• A pedal unit, including the pedal, master cylin-der and fluid reservoir,

• A slave cylinder at the clutch,

• A hydraulic hose that connects the master andslave cylinders.

Keep the clutch fluid reservoir full to the MAX mark.If fluid level falls below the MIN mark, have the hy-draulic system checked for leaks at an authorizedFreightliner service facility. Use only DOT 4 brakefluid to fill the reservoir.

The hydraulic clutch provides smooth, quiet, and reli-able clutch actuation with a minimum of mainte-nance.

Pressure builds up in the master cylinder when theclutch pedal is pressed. This pressure is transmittedthrough the brake fluid in the hose to the slave cylin-der, where it acts directly on the clutch release fork.

Drivetrain

8.2

Allison On-HighwayTransmissionsThe Allison on-highway transmissions are fully auto-matic and include the 1000 Series™, 2000 Series™,and 2400 Series™. Refer to the Allison website foradditional information, www.allisontransmission-.com .

Safety Precautions

WARNINGDo not leave the vehicle unattended with the en-gine running. If you leave the vehicle and the en-gine is running, the vehicle can move suddenly,which could result in personal injury or propertydamage.

1000 SeriesOn vehicles with Allison 1000 series transmissions,do the following steps if you have to leave the cabwith the engine running (for example, when checkingthe transmission fluid):

Without Park Position1. Bring the vehicle to a complete stop using the

service brake.

2. Ensure that the engine is at low idle rpm.

3. Put the transmission in neutral.

4. Apply the parking brake, and make sure it isproperly engaged.

5. Chock the rear tires and take any other stepsnecessary to keep the vehicle from moving.

With Park Position1. Bring the vehicle to a complete stop using the

service brake.


3. Put the transmission in P (park).

4. Apply the parking brake (if equipped), and makesure it is properly engaged.

5. Engage the park range by slowly releasing theservice brake.


2000 SeriesOn vehicles with Allison 2000 series transmissions,do the following steps if you have to leave the cabwith the engine running (for example, when checkingthe transmission fluid):

Without Auto-Apply Parking BrakeFollow the instructions for vehicles with 1000 seriestransmissions, under the heading "Without Park Posi-tion."

With Auto-Apply Parking Brake1. Bring the vehicle to a complete stop using the

service brake.


3. Put the transmission in PB (auto-apply parkingbrake).

4. Apply the parking brake (if equipped), and makesure it is properly engaged.


2400 SeriesOn vehicles with 2400 series transmissions, followthe instructions for vehicles with 1000 series trans-missions.

Range Inhibit Indicator, 2000 and2400 SeriesA RANGE INHIBIT indicator is a standard feature ofthe 2000 series and 2400 series transmissions. TheRANGE INHIBIT indicator comes on to alert thedriver that transmission operation is being inhibitedand that the range shifts being requested by thedriver may not occur. When certain operating condi-tions are detected by the TCM (transmission controlmodule), the controls will lock the transmission in thecurrent operating range.

Shift inhibits occur under the following conditions:

• Shifts from neutral to reverse or from neutral toa forward range when the engine is above idle,greater than 900 rpm.

Drivetrain

8.3

www.allisontransmission.com


• Forward/reverse directional shifts are typicallynot permitted if appreciable output shaft speedis detected.

• When some types of unusual transmission op-erating conditions are detected by the TCM,the TCM temporarily limits transmission opera-tion until the vehicle can be driven to a servicelocation. When this type of situation is de-tected, the TCM will lock the transmission in asafe gear range.

• The TCM will prevent shifts from park or neu-tral to range when auxiliary equipment, such asa power takeoff unit (PTO), is in operation.

Operating Instructions, On-HighwayTransmissionsAllison automatic transmissions are electronicallycontrolled. The shift selector provides five or six for-ward ranges and one reverse range.

P (Park, optional on 1000 and 2400Series)Use park when turning the engine on or off, to checkvehicle accessories, to operate the engine in idle forlonger than 5 minutes, and for stationary operation ofthe power takeoff, if equipped. This position placesthe transmission in neutral and engages the parkpawl of the transmission.

NOTE: This does not apply the parking brake.

PB (Auto-Apply Parking Brake, optionalon 2000 Series)The auto-apply parking brake places the transmis-sion in neutral and applies the parking brake.

R (Reverse)Reverse is used to back the vehicle. When the selec-tor is in reverse, the reverse warning signal willsound. Always bring the vehicle to a complete stopbefore shifting from a forward range to reverse, orfrom reverse to a forward range.

CAUTIONExtended idling in reverse may cause transmis-sion overheating and damage.

Do not idle in reverse for more than 5 minutes. Se-lect P (park), PB (auto-apply parking brake), or N(neutral) when time at idle exceeds 5 minutes.

NOTE: The shift into reverse may not succeed ifa range inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.

N (Neutral)The neutral position places the transmission in neu-tral. This position is used when starting the engineand for stationary operation.

WARNINGFailure to apply the vehicle parking brakes whenthe transmission is in neutral may allow the ve-hicle to move unexpectedly, possibly causingproperty damage or personal injury.

When neutral is selected, the vehicle service brakes,parking brake, or emergency brake must be applied.Selecting neutral does not apply vehicle brakes un-less an auxiliary system to apply the parking brake isinstalled.

WARNINGDo not coast in neutral. Coasting in neutral cancause an accident, possibly resulting in severepersonal injury or death.

Do not let the vehicle coast in neutral. If the vehicleis allowed to coast in neutral, the engine brake willnot work and you could lose control of the vehicle.

CAUTIONCoasting in neutral can cause severe transmis-sion damage.

D (Drive)

WARNINGWhen going downhill, use a combination ofdownshifting, braking, and other retarding de-vices to control vehicle speed and the engine’srated governed speed. Failure to do so could re-duce vehicle braking, possibly causing loss ofvehicle control and resulting in personal injury orproperty damage.

Drivetrain

8.4

In the drive position, the transmission will initially gointo first range when drive is selected. As vehiclespeed increases, the transmission will upshift auto-matically through each available range up to fourthrange or fifth range. As the vehicle slows, the trans-mission will downshift automatically.

When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, thetransmission may upshift to the next higher range, ifthe engine is exceeding its governed speed in thelower range.

CAUTIONDo not idle in drive for more than 5 minutes. Ex-tended idling in drive may cause transmissionoverheating and damage. Always select PB (auto-apply parking brake) or P (park) if time at idle islonger than 5 minutes.

NOTE: The shift into drive may not succeed if arange inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.

4 and 3 (Fourth and Third Ranges,optional)Use the fourth or third range for city traffic and forbraking on steep downgrades.

3 and 2 (Third and Second Ranges,standard)Use the third or second range for heavy city trafficand for braking on steeper downgrades.

1 (First Range)Use first range when pulling through mud or deepsnow, when maneuvering in tight spaces, or whendriving up or down very steep grades. First rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect.

NOTE: To have the transmission select theseranges automatically, leave the selector lever inD (drive).

Allison MD SeriesRefer to the Allison website for additional information,www.allisontransmission.com .

Safety Precautions

WARNINGDo not leave the vehicle unattended with the en-gine running. If you leave the vehicle and the en-gine is running, the vehicle can move suddenly,which could result in personal injury or propertydamage.

On vehicles with MD series transmissions, do thefollowing steps if you have to leave the cab with theengine running (for example, when checking thetransmission fluid):

1. Bring the vehicle to a complete stop using theservice brake.

2. Put the transmission in N (neutral).

3. Ensure that the engine is at low idle (500 to 800rpm).

4. Apply the parking brake and emergency brakes,and make sure they are properly engaged.


Operating Instructions, MD SeriesThe Allison MD transmission is electronically con-trolled and comes with a push-button shift controlthat provides five or six forward ranges and one re-verse range. The push-button shift selector has an R(reverse), an N (neutral), a D (drive), an up arrow, adown arrow, a mode button, and a digital display.

New shift controls — known as "fourth generation" —were introduced in mid-2006. They replaced the pre-vious units that are commonly referred to as "WTECIII". See Fig. 8.1 and Fig. 8.2 .

R (Reverse)Press the R button to select reverse. The digital dis-play will show R when reverse is selected. Alwaysbring the vehicle to a complete stop and let the en-gine return to idle before shifting from a forwardrange to reverse, or from reverse to a forward range.

Drivetrain

8.5


CAUTIONExtended idling in reverse may cause transmis-sion overheating and damage.

Do not idle in reverse for more than 5 minutes. Se-lect neutral when time at idle exceeds 5 minutes.

NOTE: The shift into reverse may not succeed ifa range inhibitor is active. When reverse is se-lected, always be sure that R is not flashing.

N (Neutral)

WARNINGWhen starting the engine, make sure that the ser-vice brakes are applied. Failure to apply the ser-vice brakes may result in unexpected vehiclemovement, which could cause severe personalinjury or death. Failure to apply the vehicle park-ing brakes when the transmission is in neutralmay allow the vehicle to move unexpectedly, pos-sibly causing property damage or personal injury.

Press the N button to select neutral. The digital dis-play will display N when neutral is selected. It is notnecessary to press neutral before starting the ve-hicle. The ECU (electronic control unit) or TCM(transmission control module) automatically placesthe transmission in neutral at start-up.

WARNINGFailure to apply the vehicle parking brakes whenthe transmission is in neutral may allow the ve-hicle to move unexpectedly, possibly causingproperty damage or personal injury.

When neutral is selected, the vehicle service brakes,parking brake, or emergency brake must be applied.Selecting neutral does not apply vehicle brakes un-less an auxiliary system to apply the parking brake isinstalled.


Do not let the vehicle coast in neutral. If the vehicleis allowed to coast in neutral, the engine brake willnot work and you could lose control of the vehicle.

Always select neutral before turning off the engine.Neutral is also used during stationary operation ofthe power takeoff if your vehicle is equipped with aPTO.

N

R

D

f270113

1

2

3

07/27/2006

4

1. Digital Display2. Mode Identification

Label

3. Mode Indicator LED4. Mode Button

Fig. 8.1, WTEC III Push-Button Shift Selector

1

2

3

f61080407/27/2006

4

1. Digital Display2. Mode Identification

Label

3. Mode Indicator LED4. Mode Button

Fig. 8.2, Fourth Generation Push-Button Shift Selector

Drivetrain

8.6

D (Drive)When the D button is pushed, the highest forwardrange will appear in the display. The transmission willnormally go into first range when drive is selected(except for those units programmed to start in sec-ond range). As vehicle speed increases, the trans-mission will upshift automatically through each range.As the vehicle slows, the transmission will downshiftautomatically.

CAUTIONDo not idle in drive for more than 5 minutes. Ex-tended idling in drive may cause transmissionoverheating and damage. Always select neutral iftime at idle is longer than 5 minutes.

NOTE: The shift into drive may not succeed if arange inhibitor is active. When drive is selected,always be sure that D is not flashing.

5, 4, 3, and 2 (Fifth, Fourth, Third, andSecond Ranges)Occasionally, road conditions, load, or traffic condi-tions will make it desirable to restrict automatic shift-ing to a lower range. Lower ranges provide greaterbraking for going down grades. The lower the range,the greater the braking effect.

Push the up or down arrows on the push-button shiftselector to select individual forward ranges. The digi-tal display will display your choice of range. When alower range is selected, the transmission may notdownshift until the vehicle speed or engine RPM (en-gine governed speed) is reduced.

WARNINGWhen going downhill, use a combination ofdownshifting, braking, and other retarding de-vices to control vehicle speed and the engine’srated governed speed. Failure to do so could re-duce vehicle braking, possibly causing loss ofvehicle control and resulting in personal injury orproperty damage.

When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, if the

engine governed speed is exceeded in the lowerrange, the transmission may upshift to the nexthigher range.

1 (First Range)Use the first range when pulling through mud ordeep snow, when maneuvering in tight spaces, orwhen driving up or down steep grades. First rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect. Push the downarrow until the first range appears on the display.

Up and Down ArrowsWhen a lower range is desired, after D has beenpressed, press the down arrow until the desiredrange is shown on the display. Pressing the downarrow continuously causes the range position to con-tinue to go down until the button is released or thelowest range is attained.

When the transmission is in drive and the downarrow has the transmission in a lower range position,press the up arrow to shift to a higher selector posi-tion. Pressing the up arrow continuously causes therange position to continue to rise until the button isreleased or the highest available position is attained.

Pressing the up or down arrows does not overridethe transmission automatic shifting operation. If ahigher or lower position is selected, the transmissioncontinues shifting through the ranges according tothe vehicle operating characteristics until the highestor lowest selected position is reached.

Mode ButtonThe MODE button starts a specialized input or outputfunction that has been previously programmed intothe ECU or TCM. Pressing the MODE buttonchanges transmission operation for a specific func-tion.

Mode Indicator LEDWhen the MODE button is pressed, the mode indica-tor LED illuminates. A mode identification label, lo-cated above the MODE button, identifies the functionassociated with a mode change.

Drivetrain

8.7

Digital DisplayThe dual digital display shows both the selectedrange (SELECT) and actual range attained (MONI-TOR). The single digital display shows the selectedrange.

Oil Level SensorAllison MD Series transmissions have an electronicoil level sensor to read fluid level information. Thefluid level diagnostic will display whether the oil levelis OK, too low, or too high. It will also display a de-fault code and indicate if the preconditions (of receiv-ing the fluid level information) are not met.

IMPORTANT: Maintain the the proper fluid levelat all times. If the fluid level is too low, the con-verter and clutch do not receive an adequatesupply of fluid. If the level is too high, the trans-mission may shift erratically or overheat.

To access the oil level display mode, park the vehicleon a level surface, shift to N (Neutral), apply theparking brake, and idle the engine. Then simulta-neously press both the up and down arrows once.The oil level will display at the end of a two-minutecountdown.

Diagnostic CodesDiagnostic codes are numerical indications relating toa malfunction in transmission operation. These codesare logged in the TCM/ECU memory. The most se-vere or most recent code is listed first. A maximum offive codes (numbered d1-d5) may be listed inmemory at one time. If the mode indicator LED isilluminated, the displayed code is active. If it is notilluminated, the displayed code is not active.

NOTE: During normal operation, an illuminatedmode indicator LED signifies the specializedmode operation is in use.

To enter diagnostics mode, first park the vehicle andapply the parking brake. Then simultaneously pressboth the up and down arrows twice.

Eaton ® Fuller ® Straight-ShiftTransmissionsRefer to the Eaton website for additional information,www.roadranger.com .

General Information, Straight-ShiftEaton Fuller 5-speed FS models are fully synchro-nized. They have five forward speeds and one re-verse. See Fig. 8.3 for the shift pattern.

Eaton Fuller 6-speed FS and FSO models are fullysynchronized. They have six forward speeds and onereverse. See Fig. 8.4 for the shift pattern.

Eaton Fuller 7-speed T models are not synchronized.They have seven forward speeds and one reverse.See Fig. 8.5 for the shift pattern.

These transmissions are designed for use with on-highway, fuel economy engines where a minimum ofshifting is desired and less gear reduction is accept-able.

Operation, Straight-Shift1. Always use first gear when starting to move the

vehicle forward.

IMPORTANT: Do not rest your foot on the clutchpedal while driving. This causes partial clutch

1

2

3

R 4

5

05/21/2008 f261049

N

Fig. 8.3, Shift Pattern, 5-Speed FS Models

1

2

3 5

4 6

05/21/2008 f261048

N

R

Fig. 8.4, Shift Pattern, 6-Speed FS and FSO Models

Drivetrain

8.8

www.roadranger.com

disengagement which could cause prematureclutch wear.

2. On synchronized models, press the clutch pedalto the floor when shifting gears. Double-clutchingis unnecessary.

On unsynchronized models, press the clutchpedal to the floor to contact the clutch brake onlywhen engaging the first or reverse gears.

NOTE: If the vehicle is moving when shifting,press the clutch pedal just far enough to disen-gage the clutch. Pressing it to the floor will en-gage the clutch brake, if so equipped, causingpremature clutch brake wear.

3. To upshift, do the following steps:

3.1 Accelerate to engine governed speed.

3.2 On synchronized models, disengage theclutch and move the shift lever to secondgear.

On unsynchronized models, disengage theclutch and move the shift lever to neutral.Engage the clutch again. With the shiftlever in neutral, disengage the clutch andmove the shift lever to second gear.

3.3 Engage the clutch and note the drop inengine rpm before accelerating up to en-gine governed speed again.

3.4 Continue upshifting using the same se-quence described in the previous step.Follow the pattern on the shift lever.

4. To downshift, do the following steps:

4.1 Wait until the engine speed drops to therpm noted immediately after the upshift.

4.2 On synchronized models, disengage theclutch and move the shift lever to the nextlower gear.

On unsynchronized models, disengage theclutch and move the shift lever to neutral.Engage the clutch again. With the shiftlever in neutral, disengage the clutch andmove the shift lever to the next lowestgear.

4.3 Engage the clutch smoothly.

4.4 Use the sequence described above toshift progressively down through eachsuccessive lower gear, as driving condi-tions require.

Eaton Fuller Range-ShiftTransmissionsRefer to the Eaton website for additional information,www.roadranger.com .

General Information, Range-ShiftEaton Fuller 9-Speed ModelsEaton Fuller 9-speed range-shift models are not syn-chronized. They have nine forward speeds and tworeverse speeds. The shift lever controls five forwardgears and one reverse gear in the transmission frontsection, and the range lever controls a LO and HIrange in the two-speed auxiliary section. The firstposition in the front section is used only as a startinggear. The other four ratios are used once in LOrange and once again in HI range. See Fig. 8.6 forthe shift patterns.

After shifting out of the first gear position, use theRoadranger® "repeat H" shift pattern. Select both LOrange and HI range with the range lever (rangeknob). It is used once during the upshift sequenceand once during the downshift sequence.

Always preselect the range shift. After preselection,the transmission will automatically make the synchro-nizer range shift as the shift lever passes throughneutral.

Eaton Fuller 10-Speed ModelsEaton Fuller 10-speed range-shift models are notsynchronized. They have ten forward speeds and

1

4

3 5

6

7

05/21/2008 f261051

N

R 2

Fig. 8.5, Shift Pattern, 7-Speed T Models

Drivetrain

8.9

www.roadranger.com

two reverse speeds. The shift lever controls five for-ward gears and one reverse gear in the transmissionfront section, and the range lever controls a LO andHI range in the two-speed auxiliary section. The fiveforward gears selected in LO range are used againin HI range to provide the 10 progressive forwardgears. See Fig. 8.7 for the shift patterns. SeeTable 8.1 for the shift progressions.

Once the highest shift lever position (fifth gear) isreached in LO range, the driver preselects the rangeshift lever for HI range. The range shift occurs auto-matically as the shift lever is moved from fifth gearposition to the sixth gear position.

Eaton Fuller Shift Progressions

ModelLO Range

HI RangeOff-Highway On-Highway

9-SpeedDirect orOverdrive

1

2

3

4

f260322

R

LOW

1

2

3

4

f260323

R

7

6 8

5

f260324

R

10-SpeedDirect orOverdrive

2

3

4

1

f260329

R

5

2

3

4

1

f260329

R

5

9

8 10

7

f260330

R

6

Table 8.1, Eaton Fuller Shift Progressions

When downshifting, the driver preselects the rangelever for LO range and the range shift occurs auto-matically during the shift lever movement to the nextgear position.

Eaton Fuller Deep-Reduction ModelsEaton Fuller deep-reduction models are not synchro-nized. They have a five-speed front section and atwo-speed auxiliary section which has an extra deepreduction gear. The LO gear in the front section isused only as a starting gear. The other four ratiosare used once in LOW RANGE and once in HIGHRANGE giving eight highway ratios. LO-LO is se-lected by the DEEP REDUCTION lever on the dash-board. See Fig. 8.8 for the shift pattern.

Operation, Range-Shift1. When operating off-highway or under adverse

conditions, always use low gear when starting tomove the vehicle.

1

4

5

86

73

2

A

B

N

LO

LO

HI

11/23/99 f261047

Move the range lever up for HI range, down for LOrange.

A. HI Range B. LO Range

Fig. 8.6, Shift Pattern, 9-Speed Models

4

N

7 2

9

6 1

8 3

10 5

R HI

LO

f261053

A

B

12/15/1999

A. HI Range B. LO Range

Fig. 8.7, Shift Pattern, 10-Speed Models

1

2

3

4LO

5

6

7

8

R RR

LO−LO

03/12/96 f260123a

N

Fig. 8.8, Shift Pattern, Deep Reduction

Drivetrain

8.10

When operating on-highway, with no load orunder ideal conditions, use first gear when start-ing to move the vehicle.

For all conditions, use the highest gear that isstill low enough to start the vehicle moving withthe engine idling and without excessively slippingthe clutch.

2. Use the clutch brake to stop gear rotation whenshifting into low (or first) or reverse when the ve-hicle is stationary. The clutch brake is applied bypressing the clutch pedal all the way to the floor.

For normal upshifts and downshifts, only a partialdisengagement of the clutch is necessary tobreak engine torque.

3. Do not make range shifts with the vehicle movingin reverse gear.

4. Never attempt to move the range preselectionlever with the gear shift lever in neutral while thevehicle is moving. Preselection with the rangepreselection lever must be made prior to movingthe shift lever out of gear into neutral.

5. Do not shift from high range to low range at highvehicle speeds.

6. Use double-clutching between all upshifts anddownshifts.

7. After your shifting ability improves, you may wantto skip some of the ratios. This may be doneonly when operating conditions such as load,grade, and road speed permit.

Upshifting1. Position the gear shift lever in neutral. Start the

engine and bring the air system pressure up to100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down intolow range.

3. Press the clutch pedal to the floor. Shift into lowor first gear, then engage the clutch with the en-gine at or near idle speed to start the vehiclemoving. Accelerate to 80 percent of engine gov-erned speed.

4. Shift progressively up from low or 1st gear to thetop gear in low range, double-clutching betweenshifts and accelerating to 80 percent of enginegoverned speed.

5. While in the top gear of the low-range shift pat-tern and ready for the next upshift, flip the rangepreselection lever up into high range. Double-clutch through neutral and shift into the bottomgear in high range. As the shift lever passesthrough neutral, the transmission will automati-cally shift from low range to high range.

6. With the transmission in high range, shift pro-gressively up through each of the high rangegears, double-clutching between shifts.

Downshifting1. With the transmission in high range, shift pro-

gressively down to the bottom gear in highrange, double-clutching between shifts.

2. When in the bottom gear of the high-range shiftpattern and ready for the next downshift, pushthe range preselection lever down into low range.Double-clutch through neutral and shift into thetop gear of the low-range shift pattern. As theshift lever passes through neutral, the transmis-sion will automatically shift from high range tolow range.

3. With the transmission in low range, downshiftthrough the low range gears as conditions re-quire.

Never use the clutch brake when downshifting oras a brake to slow the vehicle.

Operation, Deep-Reduction ModelsUpshifting1. Position the gear shift lever in neutral. See

Fig. 8.8 for the shift pattern. Start the engine,and bring the air system pressure up to 95 to125 psi (655 to 862 kPa).

2. Position the range preselection lever down, intolow range.

NOTE: If conditions are difficult, start out in LO-LO. Move the DEEP REDUCTION lever on thedashboard to the IN position. Otherwise startout in LO with the DEEP REDUCTION lever inthe OUT position.

Drivetrain

8.11

3. Depress the clutch pedal to the floor. Shift intoLO gear; then, engage the clutch, with the en-gine at or near idle rpm to start the vehicle mov-ing. The vehicle will start in LO or LO-LO de-pending on the DEEP REDUCTION leverposition.

4. To upshift if in LO-LO, move the DEEP REDUC-TION lever to the OUT position and immediatelyrelease the accelerator, depress the clutch pedalonce to break torque, and reengage the clutch.The auxiliary section will shift from LO-LO to LOwhen the gears reach the same speed.

5. Shift progressively upward from LO through 1st,2nd, 3rd, and 4th gears while the range prese-lection lever is in LO. Always double-clutch be-tween gears.

6. When in 4th gear and ready for the next upshift,pull up the range preselection lever and movethe shift lever, double-clutching, to the 5th gearposition. As the shift lever passes through neu-tral, the auxiliary section will automatically shiftfrom low to high range.

CAUTIONNever move the shift lever into the LO gear posi-tion after high range preselection or anytime theauxiliary section is in high range. Transmissiondamage could result.

7. Continue upshifting from 5th gear through 8thgear, always double-clutching between gears.

Downshifting1. While in high range, move the gear shift lever

from 8th gear through 5th gear as conditions re-quire, always double-clutching between gears.

2. When in 5th gear and ready for the next down-shift, push down the range preselection lever andmove the shift lever to the 4th gear position,being sure to double-clutch. As the shift leverpasses through neutral, the auxiliary section willautomatically shift from high to low range.

3. While in the low range, continue downshiftingfrom 4th through LO as conditions require, al-ways double-clutching between gears.

4. Do not downshift into LO-LO from LO unless op-erating conditions make it necessary. If it is nec-essary, make sure that the shift lever is in the LO

gear position and the auxiliary section is in thelow range. Then, move the DEEP REDUCTIONlever on the dashboard to the IN position. Imme-diately release the accelerator, depress theclutch pedal once to break torque, engage theclutch, and accelerate. The auxiliary section willautomatically shift from LO to LO-LO when thegears reach the same speed.

CAUTIONNever use the clutch brake when downshifting, oras a brake to slow the vehicle. This will causepremature clutch brake wear.

Eaton Fuller AutoShift ™

Refer to the Eaton website for additional information,www.roadranger.com .

IMPORTANT: Before starting the vehicle, alwaysdo the following:

• Be seated in the driver’s seat.

• Place the transmission in neutral.

• Set the parking brakes.

• Press the clutch pedal (if equipped) down tothe floor.

The AutoShift ASW is an automated 6-speed EatonFuller transmission. No clutch is necessary to oper-ate the vehicle.

The AutoShift AS2 is a partially automated 10-speedEaton Fuller transmission. The driver must use theclutch and put the transmission in neutral to start andstop the vehicle. A push-button shift selector(Fig. 8.9 ) is used with AutoShift AS2 and ASWtransmissions.

IMPORTANT: If you have to leave the cab withthe engine running:



• Chock the tires.

Push-Button Shift SelectorGear information is presented to the driver on thepush-button shift selector, usually mounted on the

Drivetrain

8.12

www.roadranger.com

right-hand control panel. On this display, the informa-tion is presented as follows:

• To select neutral, press the N button. Whenneutral is engaged, the telltale LED will light upnext to the N button.

• To select reverse, press the R button. Whenreverse is engaged, the telltale LED will lightup next to the R button.

• To select drive, press the D button. When driveis engaged, the telltale LED will light up next tothe D button.

• To select low gear, press the LOW button.When low is engaged, the telltale LED will lightup next to the LOW button.

• To change gears manually, press the MANUALbutton. When the manual mode is engaged,the telltale LED will light up next to theMANUAL button.

• Use the shift buttons (upshift/downshift) tochange the current starting gear selection in R,D, and LOW. In MANUAL, the shift buttons canbe used to select gears.

• In automatic mode, the number of the forwardgear currently engaged appears continually onthe mode indicator when in drive. In MANUAL,the last gear selected appears on the modeindicator.

• If the SERVICE indicator illuminates, take thevehicle as soon as possible to an authorizedFreightliner service facility.

• The mode button is reserved for future use.

IMPORTANT: To prevent engine overspeed, thetransmission software will override bothMANUAL and LOW if necessary. The systemwill not respond to gear selection requests thatwill either overspeed or excessively lug theengine.

Automatic ModeThe AutoShift AS2 transmission is normally operatedin an automatic mode. To select MANUAL mode,press the MANUAL button on the push-button shiftselector.

When the transmission is in automatic mode, thetransmission automatically selects and engages thegears, although the transmission will respond to up-shift and downshift requests as though in manualmode. See the instructions for shifting under heading"Manual Mode" below.

Manual ModeWhen the transmission is in manual mode, the drivermust select the appropriate gear, using the shift but-tons on the push-button shift selector.

11/14/2001

1

2

3

4

5

6

10

8

7

9

f261145

1. Not Used2. R (reverse)3. N (neutral)4. D (drive)5. MANUAL Mode6. Low Gear Hold

7. Upshift/DownshiftArrows

8. SERVICE Light9. Mode Indicator10. Mode Button

Fig. 8.9, Eaton Push-Button Shift Selector

Drivetrain

8.13

To upshift in MANUAL, press the upshift button (uparrow), and release. The number of the gear will ap-pear on the mode indicator. If the requested gear isavailable, the transmission will shift up.

CAUTIONDo not attempt to upshift until the vehicle hasreached a sufficient speed. The clutch absorbsthe speed difference by generating heat, whichcauses the clutch to wear out too soon.

Many drivers upshift into the next gear or even skip-shift into a higher gear before the vehicle hasreached the correct speed. This type of shifting isalmost as bad as starting off in a gear that is toohigh. When the engine speed (rpm) and the vehiclespeed (mph or km/h) are too far apart, the clutchmust absorb the difference in speed by generatingheat.

To downshift in MANUAL, press the downshift button(down arrow), and release. The number of the gearwill appear on the mode indicator. If the requestedgear is available, the transmission will shift down.

If any requested gear is not available, an audiblewarning will sound and the digital display will indicatethat the gear is not available.

Selecting GearsR (Reverse)Reverse (R) is used to back the vehicle. Make surethe vehicle comes to a full stop and the clutch pedalhas been pressed before shifting into reverse.

To select reverse, press the clutch pedal to the floor.Then press the R button.

N (Neutral)Neutral (N) is used for starting, parking, or any sta-tionary operation. No gear is selected. The transmis-sion must be in neutral to start the engine.

IMPORTANT: If the vehicle starts up in any gearbut neutral, bring the vehicle to an authorizedFreightliner service facility as soon as possible.

To select neutral, press the clutch pedal to the floor.Then press the N button. Set the parking brakes andslowly release the clutch pedal.

NOTE: Neutral is always available during ve-hicle operation. When in neutral, requests toupshift or to downshift are ignored.

D (Drive)Drive (D) is used for normal highway driving. In drive,the transmission shifts into the proper gear for start-ing, and then automatically selects additional gearsas needed, in a range between the starting gear andthe highest gear.

To select drive, press the clutch pedal to the floor.Then press the D button. Slowly release the clutchpedal and drive the vehicle.

To start up in a gear other than the normal startinggear, push the upshift arrow with D selected, andwhile the vehicle is stopped.

IMPORTANT: AutoShift will not start up in anygear higher than third gear.

The number of the gear selected will flash on theauxiliary display until the driver presses the clutchpedal. This gear will be stored in memory as the de-fault starting gear until a different starting gear is se-lected by the driver, or until the engine is shut down.

NOTE: The transmission may be programmedso that it is not possible to select a starting gearother than the preprogrammed starting gear.

L (Low)LOW is used to hold the transmission in low gearwhen descending steep hills. If LOW is selectedwhen the vehicle is stopped, the transmission re-mains in low gear until drive is selected. If LOW isselected while the vehicle is moving, the transmis-sion downshifts at a higher engine speed than nor-mal, in order to maximize the engine braking effect.

To select LOW, press the clutch pedal to the floor.Then press the LOW button. Slowly release theclutch pedal and drive the vehicle.

IMPORTANT: Before parking the vehicle, alwaysdo the following:



• Chock the tires, if parking on an incline.

Drivetrain

8.14

Freightliner SmartShift ShiftControlGeneral Information, SmartShiftThe SmartShift transmission control is an electronictransmission control device. It is installed with thefollowing transmissions:

• Eaton Fuller UltraShift™

• Mercedes-Benz Automated Gear Shift (AGS)

It replaces the typical floor-mounted shift lever ordash-mounted push button control.

SmartShift accepts driver requests for transmissionfunctions and transmits them through hard wiring tothe transmission control unit (TCU). SmartShift is atrue shift-by-wire system.

SmartShift offers two main advantages over conven-tional transmission control devices. Without a floor-mounted shift control, usable cab space is increased.The SmartShift control mounts to the right-hand sideof the steering column and is operated by the fingersof the driver’s right hand, allowing both hands to re-main on the steering wheel.

A two-position slide switch (Fig. 8.10 ) is mounted onthe body of the control lever just before the paddlewidens out. The slide switch allows the driver tochoose automatic (AUTO) or manual (MAN) mode.

In AUTO mode, gears shift automatically, withoutdriver interaction. Manual gearshifts are accom-plished by a momentary pull or push on the control inthe plane perpendicular to the steering wheel. Pullupward (toward you) on the control to upshift andpush downward (away from you) to downshift. Thecontrol is spring-loaded and returns to mid-positionwhen released after an upshift or downshift.

For Eaton Fuller UltraShift (Fig. 8.10 ), a four-position(R, N, D, L) selector switch is located at the end ofthe lever. For the Mercedes-Benz AGS (Fig. 8.11 ), athree-position (R, N, D) selector switch is located atthe end of the lever.

Embedded in the selector switch is a small neutrallock button to prevent accidental shifts into gear fromneutral. Any time you shift through N, press down onthe neutral lock button to move the switch from neu-tral (N) to another gear, such as drive (D), low (L), orreverse (R). When shifting to N, it is not necessary topress the neutral lock button.

Eaton Fuller UltraShiftThe Eaton® Fuller® UltraShift™ transmission uses thefour-position SmartShift control lever on the steeringcolumn to change gears, combined with a gear indi-cator on the right-hand control panel as shown inFig. 8.12 . All forward shifts can be made eithermanually or automatically, at the driver’s choice. Noclutch pedal is required to operate the vehicle.

General Information, UltraShift ASWUltraShift ASW is a six-speed medium-duty fully au-tomated transmission used on the M106 only. Six-speed UltraShift ASW uses a "wet" clutch system inwhich the drive and driven discs rotate in a bath oftransmission fluid (Dexron III).

General Information, UltraShift DMUltraShift DM is a ten-speed heavy-duty fully-automated transmission used on the M112 only. Ten-speed UltraShift DM uses a dry clutch system which

01/24/2003

12

3 4

5 6

8

9

10

1112

f270120

7

To upshift manually, pull the lever up (towards you). Todownshift manually, push the lever down (away fromyou).1. SmartShift Control Lever2. Slide Switch (forward driving mode switch)3. MAN Mode (of slide switch)4. AUTO Mode (of slide switch)5. Upshift Direction6. Reverse Position (of selector switch)7. Selector Switch8. Neutral Lock Button9. Neutral Position (of selector switch)10. Drive Position (of selector switch)11. Low Position (of selector switch)12. Downshift Direction

Fig. 8.10, SmartShift Control (with Eaton FullerUltraShift)

Drivetrain

8.15

is offered only on this automated transmission sys-tem.

Operation, UltraShiftPower Up

NOTE: These operating instructions applyequally to six-speed UltraShift ASW and ten-speed UltraShift DM, with the exceptions ex-plained below.

1. With the parking brake set, select neutral (N) bymoving the selector switch to the N position.

2. With the transmission in neutral, turn on the igni-tion switch. The "CHECK TRANS" and "TRANSTEMP" telltale lights come on and go out again(bulb check). See Fig. 8.13 .

3. After the ignition is turned on, the current gearindicator shows the dot display, arranged in asquare pattern. All dots in the pattern should lightup, without gaps or spaces. See Fig. 8.14 .

4. Wait for the current gear indicator to show a solid"N." When the "N" is solid, rather than flashing,the UltraShift transmission control unit (TCU) ispowered up. Apply the service brake and startthe engine.

5. Select drive (D) by pressing in the neutral lockbutton and moving the selector switch downwardto the position below neutral. Release the park-ing brake. The gear is displayed on the currentgear indicator.

11/11/2002

12

3 4

5 67

9

10

11f270080

8

To upshift manually, pull the lever up (towards you). Todownshift manually, push the lever down (away fromyou).1. SmartShift Control Lever2. Slide Switch3. MAN Position (of slide switch)4. AUTO Position (of slide switch)5. Upshift Direction6. Reverse Position (of selector switch)7. Selector Switch8. Neutral Lock Button9. Neutral Position (of selector switch)10. Drive Position (of selector switch)11. Downshift Direction

Fig. 8.11, SmartShift Control (with Mercedes-Benz AGS)

10/13/2003 f270079

1

2

To know what gear the transmission is in, look at thecurrent gear indicator.1. Gear Indicator2. SmartShift Control

Fig. 8.12, Shift Controls and Indicators, UltraShiftTransmissions

BRAKE

CHECKTRANS

f610677

1

TRANSTEMP

10/27/2003

2

1. "CHECK TRANS" Light2. "TRANS TEMP" Light

Fig. 8.13, Telltale Lights, UltraShift Transmission

Drivetrain

8.16

NOTE: When D is selected, the transmissioncontroller starts up in second gear. On both six-speed Ultrashift ASW and ten-speed UltrashiftDM, the driver can select to start up in first. Noother start gear is available.

6. On a level grade, release the service brake andpress down on the throttle pedal to allow the ve-hicle to move forward.

WARNINGWhen starting or stopping on hills and grades,use extra care to prevent the vehicle from rollingback. A rollback accident could cause death, seri-ous personal injury, or property damage.

7. Prevent the vehicle from rolling backward whenstopped on a hill or grade, or when the vehicle isstarting from a stop on a hill or grade.

7.1 To start from a full stop on a hill or grade,quickly move your foot from the brakepedal and press firmly on the throttlepedal.

On steep hills, set the parking brake andrelease it only when there is enough en-gine power to prevent rollback.

7.2 To stop on a hill or grade, press and holdthe brake pedal to keep the vehicle frommoving.

On steep hills, set the parking brake.When parking, chock the tires, front and/orrear. Never hold a hill with the throttlepedal. This will cause the clutch to over-heat.

Power Down1. Apply the service brake.

2. Select neutral (N) by moving the selector switchto the N position. When the "N" on the gear indi-cator is solid, rather than flashing, the UltraShiftTCU is ready to power down. See Fig. 8.13 .

3. With the transmission in neutral, set the parkingbrake.

4. Turn off the ignition key and shut down the en-gine.

Automatic and Manual ModesThe SmartShift control has a slide switch located onthe body of the control lever just before the paddlewidens out. See Fig. 8.15 . The slide switch controlsthe forward driving mode, automatic or manual.

10/13/2003 f610678

Fig. 8.14, Power-Up Dot Display

01/21/2004 f270079c

1 2

3

1. Slide Switch (controls forward driving mode)2. Selector Switch (controls gear selection)3. Neutral Lock Button (prevents accidental shift into

gear)

Fig. 8.15, Switches, Ultrashift Transmission

Drivetrain

8.17

To change mode at any time, move the slide switchin the desired direction. This allows the driver to re-spond to a wide range of driving conditions, such asblind corners, tight curves, and steep hills.

IMPORTANT: Whatever the mode, it is alwayspossible to shift manually by moving the leverup or down as needed. When the engine speedis within 75 revolutions per minute (rpm) of theload-based shift point for an automatic shift, theUltraShift TCU will advance the shift.

In either mode, the gear indicator displays the cur-rent gear. See Fig. 8.16 .

At the start of a shift, the current gear continues todisplay until the transmission has been pulled intoneutral. At this point, as the transmission is synchro-nizing for the new (target) gear, the gear indicatorflashes the number of the new gear.

When the shift is complete, the new gear displayssolid, without flashing.

Automatic Mode (AUTO)In automatic drive mode (AUTO), upshifts and down-shifts are made by the transmission without driverintervention. Press in the neutral lock button, movethe selector switch to drive (D), and press down onthe throttle pedal. The transmission will shift auto-matically.

If driving conditions require, it is still possible to re-quest a manual shift. The transmission will make the

shift if the engine speed is within 75 rpm of the load-based shift point for that gear.

If the driver presses down on the throttle pedal aftera manual downshift in automatic mode, the transmis-sion will upshift again if the UltraShift TCU requiresit.

Manual Mode (MAN)In manual drive mode (MAN), upshifts and down-shifts are made by the driver:

• To shift up, pull the lever up (towards you).

• To shift down, push the lever down (away fromyou).

The system will hold the current gear until the driverrequests a shift. In downhill situations in particular,the driver must be alert to vehicle speed by down-shifting and/or using the service brake.

A shift request will still be refused if the selected gearwould cause engine overspeed or excessive lugging.

Selecting GearsReverseReverse (R) is at the upper end of the four-positionselector switch located at the end of the SmartShiftcontrol lever. To select R, press in the neutral lockbutton and move the selector switch upward to theposition above neutral.

Six-speed UltraShift ASW has one reverse gear.When reverse is selected, the letter "R" displays onthe gear indicator. See Fig. 8.17 .

10/13/2003 f610680

NOTE: The gear indicator displays the current gear. Inthis example, it displays first gear.

Fig. 8.16, Current Gear Display

10/14/2003 f610681

Fig. 8.17, Reverse Gear Display

Drivetrain

8.18

Ten-speed UltraShift DM has two reverse gears, re-verse low and reverse high. To shift manually be-tween them, use the shift lever as described for MANmode. There is no AUTO mode for reverse.

When reverse low is selected, the letter "R" displayson the current gear indicator. When reverse high isselected, the letter "H" displays on the current gearindicator.

IMPORTANT: Under normal conditions, do notselect reverse with the vehicle moving forward.

The vehicle must be moving at less than two milesper hour (3 km/h) before selecting reverse. If reverseis selected when the vehicle is moving faster, an au-dible alert will sound and continue sounding at three-second intervals until the control lever is returned tothe D position. When the vehicle is moving at theproper speed, reverse can be engaged.

On ten-speed UltraShift DM only, if necessary to rockthe vehicle, use the selector switch to shift back andforth at low speed between reverse and drive.

Neutral

IMPORTANT: Always start the engine with thetransmission in neutral, the parking brake set,and the service brakes applied.

Neutral (N) is directly below R on the four-positionselector switch located at the end of the SmartShiftcontrol lever. To select N, move the selector switch tothe position below R. When neutral is selected, theletter "N" displays on the gear indicator. SeeFig. 8.18 .


Neutral is always available during operation, what-ever the vehicle speed. When in neutral, requests toupshift or downshift are ignored. If the selector switchis moved from neutral to drive while the vehicle ismoving, the transmission will shift into a gear withinthe engine’s operating speed range.

When shifting from neutral, always press on thebrake pedal. If the brake pedal is not pressed, thetransmission will not shift, the current gear displaywill flash "N," and an audible alert will sound.

NOTE: To reset the transmission, return the se-lector switch on the SmartShift lever to N andattempt the shift again, this time with the brakepedal pressed.

Before shutting down the engine, return the selectorswitch to "N." When the ignition is turned off, thetransmission will reset to neutral in a few minutesregardless of the position of the shift lever.

DriveDrive (D) is directly below N on the four-position se-lector switch located at the end of the SmartShiftcontrol lever. To select D, press in the neutral lockbutton and move the selector switch to the positionbelow N. When drive is selected, the number of thecurrently selected forward gear (1 through 6 on six-speed UltraShift ASW; 1 through 10 on ten-speedUltraShift DM) displays on the gear indicator. SeeFig. 8.16 .

When in drive, requests to upshift or downshift areenabled. Either manual or automatic mode can beselected on the slide switch.

Two starting gears are available, first and second.The default starting gear is second, but first can beselected by the driver, if desired. To change the start-ing gear, press the brake pedal and select D with thevehicle stopped. The current gear indicator will dis-play the starting gear. Move the shift lever up ordown until the desired starting gear is displayed.

The UltraShift TCU adapts to the working conditionsof each vehicle and its driver. After power-up or aload change, it needs to learn the new conditions.

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Fig. 8.18, Neutral Display

Drivetrain

8.19

While learning, it may hold a gear too long beforeupshifting. Start the upshift manually. It may takethree or four shifts before UltraShift succeeds inlearning the new load-based shift points, but afterthat it will handle the shifting automatically.

LowLow (L) is located at the lower end of the four-position selector switch located at the end of theSmartShift control lever. To select L, press in theneutral lock button and move the selector switch tothe position below D.

When in low, the current gear is maintained. Re-quests to upshift are not enabled.

IMPORTANT: If the engine is approaching over-speed, the UltraShift TCU will override the cur-rent gear setting and upshift to prevent enginedamage.

To enhance engine braking, downshifts are per-formed at higher rpm than normal.

If L is selected from neutral while stopped, the ve-hicle starts up in first gear and stays there until theengine approaches overspeed.

UpshiftingTo request an upshift with the transmission in drive,pull the control lever up (towards you). If the gear isavailable, the transmission upshifts and the new geardisplays on the gear indicator. No skip shifts areavailable while upshifting.

No upshifts are available in low, except to preventengine overspeed.

If the transmission does not upshift quickly enoughafter power-up or a load change, begin the shiftmanually. The UltraShift TCU will learn the new load-based shift conditions after three or four shifts.

If the gear requested is unavailable, a tone willsound. An unavailable request to upshift is not storedin memory. The upshift must be requested again.

Downshifting

NOTE: The driver can manually downshift atany time, even when the slide switch is set toAUTO mode.

To request a downshift with the transmission in driveor low, push the control lever down (away from you).

If the gear is available, the transmission downshiftsand the new gear displays on the gear indicator. Skipshifts are available while downshifting.

For best engine braking, select low while moving. Inlow, downshifts are performed at higher rpm than indrive.

IMPORTANT: If the engine is approaching over-speed, the UltraShift TCU will override the cur-rent gear setting and upshift to prevent enginedamage.

If the gear requested is unavailable, a tone willsound. An unavailable request to downshift is notstored in memory. The downshift must be requestedagain.

When coasting to a stop, the UltraShift TCU may notfinish the downshift until the driver presses down onthe throttle pedal again.

IMPORTANT: A downshift request can neverresult in a shift into neutral, even if the vehicle isin the drive position in the lowest possible gear.

Before starting down a hill, slow down. Downshift toa speed that you can control without hard pressureon the service brakes.

Before entering a curve, slow down to a safe speed.Downshift if necessary. This lets you use somepower through the curve to help the vehicle be morestable on the turn. It also allows you to regain speedfaster as you come out of the curve.

UltraShift DiagnosticsClutch Calibration

NOTE: Clutch calibration only occurs on six-speed UltraShift ASW.

The UltraShift TCU automatically adjusts for clutchwear. The calibration takes place whenever the fol-lowing conditions are met:

• The engine is at normal operating temperature

• The vehicle is stopped

• The engine is at idle speed

• The selector switch on the control lever is inneutral

Drivetrain

8.20

Calibration may take up to two minutes to complete.The engine may slow and return to normal idle sev-eral times during calibration.

To stop calibration at any time, select one of thedrive positions on the selector switch (R, D, or L).

Clutch Protection FaultExcessive clutch slippage creates heat and reducesthe life of the clutch. These are some conditionswhich lead to clutch abuse:

• Using the throttle to hold the vehicle on agrade

• Starting the vehicle in too high a gear

• Overloading the vehicle

• Using high idle with the vehicle in gear

The UltraShift TCU is programmed to prevent clutchabuse. When the clutch overheats, the followingalerts take place:

• The "TRANS TEMP" light comes on

• The gear indicator displays "CA"

• A warning tone sounds at one second intervals

The alerts continue until the clutch cools, the throttleis released, or the clutch is fully engaged.

System ProblemIn the event of a problem, do the following steps:

1. Note the driving conditions at the time the prob-lem occurred.

2. Record the status of the transmission at the timeof the problem (AUTO or MAN mode, gear set-ting R, N, D, or L, current gear, engine speed,etc.)

3. Reset the system, using the procedure below.

Reset ProcedureTransmission operation can sometimes be restoredby doing the following reset procedure:

1. Stop the vehicle when it is safe to do so.

2. Place the selector switch in neutral and turn offthe ignition.

3. Check all harness connectors as described inChapter 11 .

4. Wait at least two minutes with the engine shutdown.

5. Restart the engine.

If the problem continues, contact an authorizedFreightliner or Eaton service facility.

Locked In GearIf the transmission becomes locked in gear, a dash(–) will appear on the gear indicator when the vehicleis restarted during the reset procedure.

NOTE: If the transmission becomes locked ingear while the vehicle is moving, increasedbraking effort may be required to stop the ve-hicle.

If the current gear indicator displays a dash duringpower-up with the selector switch in neutral, do thefollowing steps:

1. Make sure the parking brake is set.

2. Turn off the ignition and wait at least two min-utes.

3. Apply the service brakes.

4. With the service brakes applied, release theparking brake.

5. Make sure the selector switch is in neutral andturn on the ignition key. Do not attempt to startthe engine at this time.

6. If necessary to get the transmission to shift intoneutral, release the pressure on the brake pedalslightly.

7. Once the UltraShift TCU reaches neutral, a solid"N" will appear on the current gear indicator andthe vehicle will start. Make sure the servicebrakes are applied and the parking brake is set.

If the gear indicator continues to display a dash, con-tact an authorized Freightliner or Eaton service facil-ity.

Drivetrain

8.21

Mercedes-Benz ManualTransmissions

CAUTIONOperating a manual transmission with the fluidlevel higher or lower than recommended can re-sult in transmission damage.

Mercedes-Benz transmissions use a simple 6-speedgear pattern as shown in Fig. 8.19 .

Always use first gear when starting to move the ve-hicle forward.

IMPORTANT: Do not rest your foot on the clutchpedal while driving. This causes partial clutchdisengagement which could cause prematureclutch wear.

While traveling, check the tachometer regularly to besure the engine speed is within the most economicalrange (1400 to 2000 rpm).

On level roads, drive in the highest usable gear,keeping engine speed down.

CAUTIONDo not rest your hand on the gear shift leverwhile driving. This can cause synchronizer dam-age.

When approaching an uphill grade, shift down aheadof time to prevent loss of engine rpm. When ap-proaching a downhill grade, shift down ahead of timeto prevent runaway speed. For information aboutshift points and "progressive shifting," see Chap-ter 7 .

Change gears only when absolutely necessary. Skipgears if needed.

When shifting, always press the clutch pedal all theway down. Do not force the gear lever.

Before shifting into reverse, be sure the engine isidling and the vehicle is not moving.

CAUTIONIf the transmission locks up while driving, mak-ing further shifting impossible, continue drivingin the gear already selected to reach service as-sistance, as circumstances allow. Or, safely parkthe vehicle off the roadway and contact yournearest Freightliner dealer or other qualified ser-vice provider for roadside assistance. To preventfurther transmission damage, do not move thevehicle from a standing start unless this can beaccomplished safely, taking into account the gearthat is engaged and the load on the vehicle.

Mercedes-Benz AutomatedTransmissionsGeneral Information, AGSThe AGS Automated Gear Shift is a fully automated6-speed medium-duty transmission. The clutch is ac-tivated by a hydraulic system that is integral to thetransmission. No clutch pedal is needed to operatethe vehicle.

AGS transmissions use the SmartShift control leveron the steering column to select gears. A manualshift is possible at any time by moving the SmartShiftlever up or down as needed.

The transmission control unit (TCU) can direct allforward shifts in response to driving conditions andthe driver’s pressure on the brake and throttle ped-als. To know which gear the transmission is in, lookat the round current gear indicator on the right-handcontrol panel as shown in Fig. 8.20 .

The TCU always selects first gear to start the vehiclein motion. It is possible, in manual mode, to start anunloaded or lightly loaded vehicle in second gear. Inmost cases, second gear is acceptable for downhillstarts. In other situations, for best results always startmoving in first gear. Loaded vehicles, or vehicles onsubstantial grades, must start moving only in firstgear.

f261098

1

62 4

3 5

R

05/03/2001

N

05/03/2001

Fig. 8.19, Shift Pattern, M-B Transmissions

Drivetrain

8.22

CAUTIONAt the first sign of a transmission malfunction,take the vehicle out of service immediately. De-pending on the type of problem, further shiftingmay not be possible, and driveline torque may beinterrupted.

Operation, AGSPower Up1. With the parking brake set and/or the brake

pedal pressed down, select neutral (N) by mov-ing the selector switch to the center position.

2. With the transmission in neutral, turn on the igni-tion switch. The "CHECK TRANS" and "TRANSTEMP" telltale lights come on and go out again(bulb check). See Fig. 8.21 .

3. On power up, the current gear indicator showsthe dot display, arranged in a square pattern. Alldots in the pattern should light up, without gapsor spaces. See Fig. 8.22 .

4. When the current gear indicator shows "N," startthe engine.

NOTE: No matter what the circumstances, donot start the engine unless the current gear indi-cator shows "N." See Chapter 13 for jump start-ing information.

5. Select drive (D) by pressing in the neutral lockbutton and moving the selector switch downwardto the position below neutral. Release the park-ing brake and/or service brake pedal. The gear isdisplayed on the current gear indicator.

NOTE: When D is selected, the transmissionstarts up in first gear. To start up in second gear(downhill start, vehicle unloaded or lightlyloaded), pull up on the SmartShift lever whenthe current gear indicator displays "1."

10/13/2003 f270079

1

2

To know which gear the transmission is in, look at thecurrent gear indicator.1. Current Gear Indicator2. SmartShift Control

Fig. 8.20, Shift Controls and Indicators, AGSTransmissions

BRAKE

CHECKTRANS

f610677

1

TRANSTEMP

10/27/2003

2

1. "CHECK TRANS" Light2. "TRANS TEMP" Light

Fig. 8.21, Telltale Lights, AGS Transmissions

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Fig. 8.22, Power-Up Dot Display

Drivetrain

8.23

6. On a level grade, press down on the throttlepedal to allow the vehicle to move forward. Thevehicle will not move until the pedal is de-pressed.

WARNINGWhen starting or stopping on hills and grades,use extra care to prevent the vehicle from rollingback. A rollback accident could cause death, seri-ous personal injury, or property damage.

7. Prevent the vehicle from rolling backwards whenstopped on a hill or grade, or when the vehicle isstarting from a stop on a hill or grade.

7.1 To start from a full stop on a hill or grade,quickly move your foot from the brakepedal and press firmly on the throttlepedal.

On steep hills, set the parking brake andrelease it only when there is enough en-gine power to prevent rollback.

7.2 To stop on a hill or grade, press and holdthe brake pedal to keep the vehicle frommoving.

On steep hills, set the parking brake.Never hold a hill with the throttle pedal.This will cause the clutch to overheat.

Power Down1. Bring the vehicle to a complete stop.


3. Move the selector switch to N. Wait until "N" ap-pears on the current gear indicator.

WARNINGAlways apply the parking brake before shuttingdown the engine. AGS will shift into neutral aftershutdown, regardless of the position of the shiftlever. If you do not set the parking brake, the ve-hicle could roll and cause an accident resultingin death, serious personal injury, or propertydamage.

4. Turn the ignition switch off and shut down theengine.

5. If the current gear indicator flashes "PB" whenthe engine is shut down, set the parking brakeand move the selector switch to "N."

Automatic and Manual ModesThe SmartShift control has a slide switch located onthe body of the lever just before the paddle widensout. See Fig. 8.23 . The slide switch controls the for-ward driving mode, automatic or manual.

To change mode at any time, move the slide switchin the desired direction. This allows the driver to re-spond to a wide range of driving conditions, such asblind corners, tight curves, and steep hills.

IMPORTANT: Whatever the mode, it is alwayspossible to shift manually by moving the leverup or down as needed.

In either mode, the gear indicator displays the cur-rent gear. See Fig. 8.24 .

Automatic Mode (AUTO)Automatic drive mode (AUTO) is recommended formost driving conditions. For the best fuel economy,always use AUTO mode.

In AUTO mode, upshifts and downshifts are made bythe transmission without driver intervention. Press in

01/19/2004 f270079b

1 2

3

1. Slide Switch (controls forward driving mode)2. Selector Switch (controls gear selection)3. Neutral Lock Button (prevents accidental shift into

gear)

Fig. 8.23, Switches, AGS Transmissions

Drivetrain

8.24

the neutral lock button, move the selector switch todrive (D), and press down on the throttle pedal. Thetransmission will shift automatically through the for-ward gears.

If driving conditions require, it is still possible to re-quest a manual shift. The transmission will make theshift unless the selected gear would cause engineoverspeed.

If the driver presses down on the throttle pedal aftera manual downshift in automatic mode, the transmis-sion will upshift again if the TCU requires it.

On downgrades, the transmission holds the currentgear until the driver requests a shift, or presses thethrottle pedal.

WARNINGWhile driving off-road or with locked differentialin AUTO mode, use extra caution. Shifts of theAGS could interrupt power to the drive wheels,causing a rollback accident while climbing steepgrades at low speeds. A rollback accident couldcause death, serious personal injury, or propertydamage.

Manual Mode (MAN)Manual mode may be required under certain condi-tions, such as:

• In difficult or slippery conditions

• On hills, steep grades, or other situationswhere driveline torque interruption is not desir-able

• During off-road driving or driving with a lockeddifferential

• In downhill driving where control of enginebraking is needed

• If necessary to hold a specific gear on a down-grade

In manual drive mode (MAN), upshifts and down-shifts are made by the driver:

• To shift up, pull the lever up (towards you).

• To shift down, push the lever down (away fromyou).

The system will hold the current gear until the driverrequests a shift. In downhill situations in particular,the driver must be alert to vehicle speed and main-tain vehicle control by downshifting and/or using theservice brakes as needed.

When braking or slowing in MAN, downshift as nec-essary to prevent lugging the engine when speed isresumed. If the vehicle comes to a complete stop,the TCU resets the transmission to neutral.

NOTE: A downshift request will be refused if theselected gear would cause engine overspeed.

Cruise ControlCruise control is fully functional with AGS transmis-sion in either AUTO or MAN mode.

In AUTO, the TCU will adjust the gear selections tomaintain the speed settings as desired. No driveraction is necessary.

In MAN, the vehicle speed settings must be withinthe engine speed range for the gear selected. If theengine cannot maintain set speed due to changes inroad grade, the driver must downshift or upshift asnecessary.

For vehicles equipped with a power take-off (PTO)unit, two modes of operation are possible, stationaryand mobile. For PTO operation, see Chapter 7 .

10/13/2003 f610680

NOTE: The gear indicator displays the current gear. Inthis example, it displays first gear.

Fig. 8.24, Current Gear Display

Drivetrain

8.25

Selecting GearsReverseReverse (R) is at the upper end of the three-positionselector switch located at the end of the SmartShiftcontrol lever. To select reverse (R), press in the neu-tral lock button and move the selector switch upwardto the position above neutral. When reverse is se-lected, the letter "R" displays on the gear indicator.See Fig. 8.25 .

IMPORTANT: The vehicle must come to a com-plete stop before selecting reverse. If reverse isselected with the vehicle moving forward, anaudible alert will sound and continue soundingat three-second intervals until the selectorswitch is returned to N or D.

Once the vehicle has come to a complete stop, re-verse can be engaged.

NeutralNeutral (N) is in the center of the three-position se-lector switch located at the end of the SmartShiftcontrol lever. Always start the engine in neutral. Toselect neutral, move the selector switch to the centerposition. When neutral is selected, the letter "N" dis-plays on the gear indicator. See Fig. 8.26 .


Neutral is always available during operation, what-ever the vehicle speed. When in neutral, requests toupshift or downshift are ignored. If the selector switchis moved from neutral to drive while the vehicle ismoving, the transmission will shift into a gear withinthe operating torque range of the engine.

WARNINGAlways apply the parking brake before shuttingdown the engine. AGS will shift into neutral aftershutdown, regardless of the position of the shiftlever. If you do not set the parking brake, the ve-hicle could roll and cause an accident resultingin death, serious personal injury, or propertydamage.

Before shutting down the engine, return the selectorswitch to "N." When the ignition is turned off, thetransmission will reset to neutral during power down.

Drive

IMPORTANT: The vehicle must come to a com-plete stop before selecting drive. If drive is se-lected with the vehicle moving in reverse, anaudible alert will sound and continue soundingat three-second intervals until the selectorswitch is returned to N or R.

Drive (D) is at the lower end of the three-position se-lector switch located at the end of the SmartShiftcontrol lever. To select drive, press in the neutral lockbutton and move the selector switch to the positionbelow neutral. When drive is selected, the number of

10/14/2003 f610681

Fig. 8.25, Reverse Gear Display

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Fig. 8.26, Neutral Display

Drivetrain

8.26

the currently selected forward gear (1, 2, 3, 4 , 5, or6) displays on the gear indicator. See Fig. 8.24 .

Upshifting

NOTE: The driver can manually upshift at anytime, even when the slide switch is set to AUTOmode.

To request an upshift with the transmission in drive,pull the control lever up (towards you). If the gear isavailable, the transmission upshifts and the new geardisplays on the gear indicator.

As in a manual transmission, upshifting too earlycauses engine lugging and uneven operation.

To achieve smooth operation in MAN mode, upshiftwhen the engine speed reaches approximately 2000revolutions per minute (rpm). Heavy loads or steepgrades require higher rpm; lighter loads require lowerrpm.

An unavailable request to upshift is not stored inmemory. The upshift must be requested again.

Downshifting

NOTE: The driver can manually downshift atany time, even when the slide switch is set toAUTO mode.

To request a downshift with the transmission in drive,push the control lever down (away from you). If thegear is available, the transmission downshifts andthe new gear displays on the gear indicator.

Downshifts are not available if the engine speed afterthe shift would exceed 2700 rpm. If the gear re-quested is unavailable, an audible alert will sound.An unavailable request to downshift is not stored inmemory. The downshift must be requested again.

To achieve smooth operation in MAN mode, down-shift when the engine speed reaches approximately1200 rpm.

Before starting down a hill, slow down. Downshift toa speed that you can control without hard pressureon the service brakes.

Before entering a curve, slow down to a safe speed.Downshift if necessary. This lets you use somepower through the curve to help the vehicle be morestable when turning. It also allows you to regainspeed faster as you come out of the curve.

AGS Diagnostics

CAUTIONAt the first sign of a transmission malfunction,take the vehicle out of service immediately. De-pending on the type of problem, further shiftingmay not be possible, and driveline torque may beinterrupted.

System MalfunctionIf the "CHECK TRANS" telltale light comes on whiledriving, the audible alert sounds, and the currentgear indicator begins to flash between the currentgear and "SM" (system malfunction), there is a prob-lem which may or may not be apparent to the driver.Bring the vehicle at once to a safe stopping placeand call an authorized Freightliner service facility forassistance.

Clutch OverloadIf the "TRANS TEMP" telltale light comes on whiledriving and the current gear indicator begins to flashbetween the current gear and "CO" (clutch overload),the clutch has begun to overheat.

The clutch overload may have been caused by im-proper driving practices such as frequent and rapidstart/stop driving, or hillholding with the throttle pedal.In this case, allow the clutch to cool, and continueon, but cease the improper driving practices.

If the clutch overload message returns or continues,the clutch is worn or damaged. Bring the vehicle atonce to a safe stopping place and call an authorizedFreightliner service facility for assistance.

Low Hydraulic Fluid Level

IMPORTANT: The only hydraulic fluid permittedin this system is Pentosin CHF 11S. No otherfluid can be substituted.

If the "CHECK TRANS" telltale light comes on whiledriving and the current gear indicator begins to flashbetween the current gear and "FL" (fluid level), therehas been an unusual loss of hydraulic fluid. Bring thevehicle at once to a safe stopping place and call anauthorized Freightliner service facility for assistance.The hydraulic reservoir holds about 1.05 quarts (oneliter) of Pentosin CHF 11S.

Drivetrain

8.27

NOTE: After hydraulic fluid loss, a special pro-cedure is required to fill the hydraulic reservoir.This procedure must be carried out by an autho-rized Freightliner service facility.

Meritor ™ Drive AxlesRefer to the Meritor website for additional informa-tion, www.arvinmeritor.com .

Drive Axles With Differential LockThe Meritor driver-controlled differential lock feature(side-to-side wheel lock, traction control, or tractionequalizer) is available on single-drive or dual-driverear axles. It is available on both axles of a dual-drive vehicle, or on one only. It is only available ondrive axles. Differential lock must only be used underadverse road conditions where greater traction isneeded. With differential lock on, the turning radius isincreased and vehicle handling is affected. The differ-ential lock switch (Fig. 8.27 ) allows the driver to lockthe wheels on the same axle together. The red differ-ential lock warning light illuminates on the dash mes-sage center when differential lock is engaged.

Differential lock provides maximum traction underslippery conditions. When the differential lock is en-gaged, the clutch collar completely locks the differen-tial case, gearing, and axle shafts together, maximiz-ing the traction of both wheels and protecting againstspinout.

Under normal traction conditions, do not use the dif-ferential lock feature.

Differential Lock Switch

CAUTIONDifferential lock should only be engaged whenthe vehicle is stopped or moving slowly at lowthrottle. This will prevent internal axle damage.

Normally, when differential lock is available on dual-drive vehicles, one switch activates the lock on bothrear drive axles. As an option, it possible to have twodifferential lock switches, one for the forward rearand one for the rearmost drive axle. It is also pos-sible for some vehicles to have differential lock ononly one of the drive axles.

A two-position guarded rocker switch (Fig. 8.27 ) con-trols differential lock, causing the wheels on eachaxle governed by the switch to rotate together. Tolock the wheels together, press the upper half of therocker momentarily (at the red LED). To unlock thewheels, press the upper half of the rocker again.

IMPORTANT: The differential lock rocker switchis guarded to prevent unintentional switch acti-vation. If the LED in the switch begins to blinkduring normal operation, when the switch hasnot been activated, this indicates an error condi-tion. Bring the vehicle to an authorized Freight-liner service facility as soon as possible.

When the differential lock switch is pressed, threeresponses are possible: a normal response, a slowresponse, and an abnormal response.

Normal Response: The LED in the switch blinks untilthe axle has responded to the request to lock thewheels. At this point, the LED comes on steady andstays illuminated. In normal operation, the wheelsmay lock so quickly that the blinking of the switch isbarely noticeable.

If operation of the switch is not possible for any rea-son (ignition is turned off, vehicle is moving fasterthan 25 mph, etc.), the LED will stop blinking andturn off.

Slow Response: If operation of the switch is slowedfor any reason (vehicle moving too fast, low air pres-sure, etc.), the switch will continue to blink until thewheels are able to lock. As in the normal response,the LED comes on steady and stays illuminated oncethe wheels have locked.

10/26/2001 f610596

Fig. 8.27, Differential Lock Switch

Drivetrain

8.28

www.arvinmeritor.com

NOTE: If the vehicle is moving too fast, let upslightly on the accelerator. As the vehicle slows,the wheels will lock.

Abnormal Response: If the LED blinks for more than30 seconds, the lock mechanism may not be fullyengaged/disengaged. Bring the vehicle to an autho-rized Freightliner service facility for testing.

Differential Lock Operation

WARNINGLocking the wheels when the vehicle is travelingdown steep grades or when the wheels are slip-ping could damage the differential and/or lead toloss of vehicle control, causing personal injuryand property damage.

Lock the wheels only when the vehicle is standingstill or moving at very low speed, less than 5 mph (8km/h). Never lock the wheels when the vehicle istraveling down steep grades or when the wheels areslipping.

NOTE: On some vehicles, the differential locksystem is connected through the low speedrange of the transmission. If this system is used,the transmission must be in the low speedrange for the wheels to fully lock.

WARNINGA vehicle with locked wheels can still slip side-ways, causing possible loss of vehicle control,personal injury, and property damage.

Be especially careful when driving under slipperyconditions with the wheels locked. Though forwardtraction is improved, the vehicle can still slip side-ways.

If the vehicle is moving, maintain a constant vehiclespeed when the differential lock is turned on. Brieflylet up on the accelerator to relieve torque on thegearing, allowing the wheels to lock completely.When the wheels are fully locked, the turning radiuswill increase because the vehicle understeers. SeeFig. 8.28 . Drive cautiously and do not exceed 25mph (40 km/h).

To disengage differential lock after leaving poor roadconditions, operate the differential lock switch as dis-cussed above while maintaining vehicle speed. Let

up momentarily on the accelerator to allow thewheels to fully unlock, then resume driving at normalspeed.

NOTE: If the differential lock system is con-nected with the transmission in its low speedrange, shifting out of the low speed range willalso disengage the differential lock function. Theswitch will blink until the wheels unlock, andthen go out.

Tandem Drive Axles With InteraxleLock

CAUTIONThe interaxle lock should not be engaged on avehicle with obviously spinning wheels. Engage-ment at high speed or power can damage theaxle(s).

Meritor has an interaxle lock (axle lock, interaxle dif-ferential lockout) feature that is standard on all dual-drive (tandem-drive) vehicles. Interaxle lock is recom-mended for use under adverse road conditionswhere greater traction is needed. See the axle manu-facturer’s manual provided with the vehicle for moreinformation.

The interaxle lock switch (Fig. 8.29 ) allows the driverto lock both rear axles together. The red interaxlewarning light illuminates on the dash message centerwhen interaxle lock is engaged.

02/09/96 f350079a

A

B

A. Turning Radius When the Differential Lock isEngaged (understeer condition)

B. Turning Radius When the Differential Lock isDisengaged

Fig. 8.28, Turning Radii

Drivetrain

8.29

When the interaxle lock is not engaged, there is dif-ferential action between the two axles. The differen-tial compensates for different wheel speeds andvariations in tire size. Keep the interaxle lock disen-gaged when driving on roads where traction is good.

When the interaxle lock is engaged, the differentialaction between the two axles is locked. Both driveaxles now share the power. Both axles, and bothsets of wheels, turn together at the same speed. Theinteraxle lock should be used when the vehicle en-counters poor traction conditions; however, it alsoincreases drivetrain and tire wear and should beused only when improved traction is required.

Interaxle Lock SwitchA two-position guarded rocker switch (Fig. 8.29 ) con-trols interaxle lock, causing both axle shafts to rotatetogether. To lock the axles together, press the upperhalf of the rocker momentarily (at the red LED). Toturn off interaxle lock, press the lower half of therocker (at the double-axle icon).

IMPORTANT: The interaxle lock rocker switch isguarded to prevent unintentional switch activa-tion. This switch does not have a diagnosticblink function when inactive.

When the interaxle lock switch is pressed, three re-sponses are possible: a normal response, a slow re-sponse, and an abnormal response.

Normal Response: The LED in the switch blinks untilthe interaxle lock is engaged. At this point, the LEDcomes on steady and stays illuminated. In normaloperation, the interaxle may lock so quickly that theblinking of the switch is barely noticeable.

If operation of the switch is not possible for any rea-son (ignition is turned off, vehicle is moving too fast,etc.), the LED will stop blinking and turn off.

Slow Response: If operation of the switch is slowedfor any reason (by cold weather, low air pressure,etc.), the switch will continue to blink until the axleslock together, or for a maximum of 10 seconds. As inthe normal response, the LED comes on steady andstays illuminated.

Abnormal Response: If the LED blinks for more than30 seconds, the lock mechanism may not be fullyengaged/disengaged. Bring the vehicle to an autho-rized Freightliner service facility for testing.

Interaxle Lock OperationTo engage interaxle lock and achieve maximum pull-ing power in slippery or hazardous road conditions,operate the interaxle lock switch as discussed above,while maintaining vehicle speed. Let up momentarilyon the accelerator until the axle lock engages. Pro-ceed over poor road conditions with caution. Do notwait until traction is lost and the tires are spinningbefore engaging the interaxle lock.

CAUTIONDo not turn on the interaxle lock switch when thetires are slipping. Do not continuously operatethe vehicle with the interaxle lock engaged dur-ing good road conditions. To do so could resultin damage to the axle gearing and excessive tirewear.

To disengage the interaxle lock after leaving poorroad conditions, operate the interaxle lock switch asdiscussed above while maintaining vehicle speed.Let up momentarily on the accelerator to allow theaxles to fully unlock, then resume driving at normalspeed.

Axle Shift

CAUTIONTo prevent transmission and axle damage, makesure the automatic transmission is in high rangewhen performing an axle shift with the vehiclemoving.

Axle shift is a function installed on vehicles with two-speed axles to allow the use of the low speed range

10/26/2001 f610595

Fig. 8.29, Interaxle Lock Switch

Drivetrain

8.30

when greater traction and maximum pulling power isneeded at low engine speed (rpm).

Under normal operating conditions, the vehicle is op-erated using the high-speed gear ratios of the axle.Under extreme weather or off-road conditions, at lowspeed and rpm and/or to pull heavy loads, the ve-hicle must be operated using the low-speed, or re-duction, gear ratios of the axle.

Axle Shift SwitchThe axle shift switch is a two-position guarded rockerswitch (Fig. 8.30 ) installed on vehicles with two-speed axles.

To shift the axle from low speed to high speed, pressthe upper half of the rocker momentarily (at theLED). To turn the axle shift off (switch from highspeed back to low speed), press the upper half ofthe rocker again. When the axle has shifted speed,the LED turns off.

When the panel lights are on, the AXLE SHIFT leg-end is backlit in green.

IMPORTANT: The axle shift rocker switch isguarded to prevent unintentional switch activa-tion. If the LED in the switch begins to blink dur-ing normal operation, when the switch has notbeen activated, this indicates an error condition.Bring the vehicle to an authorized Freightlinerservice facility as soon as possible.

When the axle shift switch is pressed, three re-sponses are possible: a normal response, a slow re-sponse, and an abnormal response.

Normal Response: The LED in the switch blinks untilthe axle shifts speed. At this point, the LED comeson steady and stays illuminated. In normal operation,

the axle may shift so quickly that the blinking of theswitch is barely noticeable.

If operation of the switch is not possible for any rea-son (interaxle lock is on, ignition is turned off, etc.),the LED will stop blinking and turn off.

Slow Response: If operation of the switch is slowedfor any reason (by cold weather, low air pressure,etc.), the switch will continue to blink until the axleshifts. As in the normal response, the LED comes onsteady and stays illuminated.

Abnormal Response: If the LED blinks for more than30 seconds, the axle shift function/mechanism maynot be operating correctly. Bring the vehicle to anauthorized Freightliner service facility for testing.

Axle Switch Interlock

NOTE: On vehicles with tandem drive axles,there is an interlock that prevents an axle fromshifting speed whenever the interaxle lock is on.

If the axle shift switch is pressed when the interaxlelock is on, the axle shift will not be completed. TheLED does the following:

• If the LED is off, the LED comes on briefly andturns off again.

• If the LED is on, it stays on.

To complete the axle shift, turn off the interaxle lockand press the axle shift switch again. If still needed,the interaxle lock can then be reactivated.

10/26/2001 f610594

Fig. 8.30, Axle Shift Switch

Drivetrain

8.31

9

Steering and Brake SystemsSteering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

Steering SystemSteering Wheel AdjustmentTwo steering wheels are available: a standard 18-inch (450-mm) steering wheel and an optional 20-inch (500-mm) steering wheel.

When there is no load on the vehicle and the fronttires are pointed straight ahead, the standard steer-ing wheel spokes should be at the 3 o’clock and 9o’clock positions or within 10 degrees of these posi-tions. See Fig. 9.1 .

On the optional 20-inch (500-mm) wheel, the steeringwheel spokes should be at the 4 o’clock and 8o’clock positions or within 10 degrees of these posi-tions. For steering wheel adjustment procedures, seeGroup 46 of the Business Class® M2 WorkshopManual.

Power Steering SystemThe power steering system consists of a steeringgear (which includes a manual steering mechanism,a hydraulic control valve, and a hydraulic power cyl-inder), hydraulic hoses, power steering pump, powersteering reservoir, and other components. Somemodels are also equipped with a separate hydraulicpower cylinder on the right side of the front axle.

The power steering pump, driven by the engine, pro-vides the power assist for the steering system. If theengine is not running, there is no power assist.

If the power-assist feature does not work due to hy-draulic fluid loss, steering pump damage, or someother cause, bring the vehicle to a safe stop. Do notdrive the vehicle until the cause of the problem iscorrected.

WARNINGDriving the vehicle without the power-assist fea-ture of the steering system requires much greatereffort, especially in sharp turns or at low speeds,which could result in an accident and possibleinjury.

Drivers should use the power available with a powersteering system carefully. If the front tires becomelodged in a deep chuckhole or rut, drive the vehicleout instead of using the steering system to lift thetires from the hole. Avoid turning the tires when theyare against a curb as this places a heavy load onsteering components and could damage them.

Air Brake SystemA dual air brake system consists of two independentair brake systems that use a single set of brake con-trols. Each system has its own reservoir, plumbing,and brake chambers. The primary air system oper-ates the service brakes on the rear axle; the second-ary air system operates the service brakes on thefront axle. Service brake signals from both systemsare sent to the trailer.

Primary Air Brake SystemLoss of air pressure in the primary air system causesthe rear service brakes to become inoperative. Thefront brakes will continue to be operated by the sec-ondary air system. In addition, the trailer brakes (ifequipped) will be operated by the secondary airsystem.

Secondary Air Brake SystemLoss of air pressure in the secondary air systemcauses the front axle brakes to become inoperative.The rear service brakes will continue to be operatedby the primary air system. In addition, the trailerbrakes (if equipped) will be operated by the primaryair system.

f461923 11/14/2001

1 2

10°

10° 10°

10°

NOTE: The standard steering wheel is shown.

1. 9 o’Clock 2. 3 o’Clock

Fig. 9.1, Steering Wheel Centered

Steering and Brake Systems

9.1

Emergency Braking SystemWhen air pressure is lost in either the primary or sec-ondary air system, the air compressor will operate,but the air supply in the other system, the one that isnot leaking, will not be replenished. There will beenough air in the other system to stop the vehiclesafely. The dual air brake system thus providesemergency braking capability. When the low air pres-sure warning light and emergency buzzer first comeon, stop the vehicle immediately. Do not drive thevehicle until the cause of the problem is corrected.

Parking Brakes, Tractor and TrailerThe yellow diamond-shaped knob (parking brakecontrol valve) on the auxiliary dash panel applies theparking brakes (spring brakes). Pulling out the knobapplies both the tractor and the trailer parking brakesand automatically causes the red octagonal knob(trailer air supply valve) to pop out. See Fig. 9.2 .

The red octagonal-shaped knob on the auxiliary dashpanel operates the trailer air supply valve. After thevehicle and its air hoses are connected to a trailer,and the pressure in the air system is at least 65 psi(448 kPa), the red knob must be pushed in (andshould stay in) to charge the trailer air supply systemand release the trailer parking brakes. Before discon-necting a trailer or when operating a vehicle withouta trailer, the red knob must be pulled out.

If pressure in both air systems drops to 35 to 45 psi(241 to 310 kPa), the red knob automatically popsout, exhausting the trailer air supply and applying thetrailer parking brakes.

If the trailer is not equipped with parking brakes, pull-ing out the yellow knob applies both the tractor park-

ing brakes and the trailer service brakes. When thetractor and trailer parking brakes (or trailer servicebrakes) are both applied, the trailer brakes can bereleased by pushing in the red knob, leaving the trac-tor parking brakes applied.

The trailer brake lever (hand control valve) is usedfor applying the trailer brakes without applying thetruck or tractor service brakes. It is usually mountedon the right-hand control panel. See Fig. 9.3 .

The valve can be partially or fully applied, but in anypartially on position it will be overridden by a full ap-plication of the service brake pedal. Moving the leverdown applies the trailer brakes, while moving it upreleases the trailer brakes. The lever will automati-cally return to the up position when it is released.

On Tractor-TrailersIf both the primary and secondary air systems be-come inoperative on tractor-trailers, the trailer servicebrakes or parking brakes will automatically applywhen the air pressure drops below 35 to 45 psi (241to 310 kPa).

The tractor parking brakes will automatically applywhen the air pressure drops below 20 to 30 psi (138to 207 kPa).

On TrucksTrucks are equipped with spring brake modulation. Ifan air pressure loss occurs in the primary air system,the rear parking brakes will be modulated (appliedand released) in proportion to the service brake ap-plication. There will only be enough air in the sec-ondary system for two to four brake applications, at

f610291

1 2

03/10/99

1. Trailer Air Supply Valve (red knob)2. Parking Brake Control Valve (yellow knob)

Fig. 9.2, Brake Valve Control Knobs

10/17/2001 f610591

Fig. 9.3, Trailer Brake Lever


9.2

which time the parking brake control valve will popout and fully apply the brakes.

On trucks, the parking brakes will apply when the airpressure drops below 20 to 30 psi (138 to 207 kPa).Do not wait for the brakes to apply automatically. Be-fore continuing to operate the vehicle, correct thecause of the air loss.

Automatic Slack AdjustersAutomatic slack adjusters are required on all vehiclesequipped with air brakes manufactured after October20, 1994. Automatic slack adjusters should never bemanually adjusted except during routine maintenanceof the foundation brakes (e.g., replacing shoes), dur-ing slack adjuster installation or in an emergencysituation.

When the brake pushrod stroke exceeds the legalbrake adjustment limit on a vehicle, there likely is amechanical problem with the foundation brake com-ponents, or the adjuster is improperly installed.

Visit a repair facility as soon as possible whenbrakes equipped with automatic slack adjusters aredetermined to be out of adjustment.

WARNINGManually adjusting an automatic slack adjuster tobring the pushrod stroke within legal limits islikely masking a mechanical problem. Adjustmentis not repairing. In fact, continual adjustment ofautomatic slack adjusters may result in prema-ture wear of the adjuster itself. Further, the im-proper adjustment of some automatic slack ad-justers may cause internal damage to theadjuster, thereby preventing it from properlyfunctioning.

Air Brake Operation

WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol resulting in property damage or personalinjury.

Before driving the vehicle, secure all loose items inthe cab so that they will not fly forward during a full

brake application. Make sure all occupants are wear-ing seat belts.

Parking Brake Interlock

CAUTIONDo not continually press down on the parkingbrake control valve (yellow knob) without press-ing down on the service brake pedal. This willdamage the safety interlock.

The service brakes and parking brakes have a safetyinterlock that prevents the unintentional release ofthe parking brake. If the yellow knob is pressed in, itwill pop back out unless the service brake pedal isbeing pressed down.

A decal on the dash alerts you to press down on theservice brake pedal before releasing the parkingbrake. If you do not, the yellow knob will not allowitself to be pressed in, but will return to its old posi-tion.

Operating the BrakesTo ensure safe operation and minimum brake wear,do the following steps when operating the brakes.

1. Monitor the air pressure system by observing thelow air pressure warning light, the emergencybuzzer, and both the primary and secondary airpressure gauges.

When the ignition switch is turned on, the low airpressure warning light (pressure circle icon) illu-minates and the emergency buzzer sounds.

The warning light and buzzer shut off when airpressure in both systems reaches 65 to 75 psi(448 to 517 kPa).

2. Before driving your vehicle, continue to monitorthe air pressure system until the air compressorhas built up a minimum pressure of 95 psi (655kPa) in both the primary and secondary air sys-tems.

3. While driving, the low air pressure warning lightand buzzer come on if air pressure drops below65 to 75 psi (448 to 517 kPa) in either system. Ifthis happens, check the air system pressuregauges to determine which system has low airpressure.


9.3

Although vehicle speed can be reduced usingthe service brake, either the front or rear servicebrakes will not be operating, causing a longerstopping distance.

Bring the vehicle to a safe stop and have the airsystem repaired before continuing.

4. During normal brake stops, depress the servicebrake until braking action slows down the ve-hicle. Increase or decrease the pressure on thepedal so that the vehicle comes to a smooth,safe stop.

IMPORTANT: In the event of a total loss of ser-vice brakes, use the parking brake control valve(yellow knob) to bring the vehicle to a completestop in the safest location possible.

5. When the forward speed of the vehicle has de-creased almost to the idling speed of the engine,press in the clutch pedal (on manual transmis-sions) and shift the transmission to neutral. Applythe parking brakes, if the vehicle is to be parked.

6. If the brakes are wet, drive the vehicle in lowgear and lightly apply the brakes to heat and drythem.

CAUTIONDo not use the spring parking brakes if the ser-vice brakes are hot, such as after descending asteep grade. Also, do not use the spring parkingbrakes during freezing temperatures if the ser-vice brakes are wet. To do so could damage thebrakes if hot, or cause them to freeze during coldweather.

If the brakes are wet, drive the vehicle in lowgear and lightly apply the brakes to heat and drythem. Allow hot brakes to cool before using thespring parking brakes. Always chock the tires.

7. Allow hot brakes to cool before using the parkingbrakes. Always chock the tires.

Parking the Vehicle

WARNINGDo not use the trailer service brakes for parking;they are not designed for this purpose. If airbleeds out of the trailer air tank during parking,

the vehicle could roll causing serious personalinjury or property damage.

IMPORTANT: Air pressure in the primary or sec-ondary reservoir must be at least 65 psi (448kPa) before the tractor parking brakes and thetrailer service brakes (or parking brakes) can bereleased.

On trailers without parking brakes, do the following topark safely:

• To park just the trailer, chock the trailer tiresbefore disconnecting the tractor.

• To park a tractor with a trailer, apply the tractorparking brakes.

Caging the Parking Brakes

WARNINGDo not drive the vehicle with the parking brakescaged. If the vehicle is driven with the parkingbrakes caged, there would be no means of stop-ping the vehicle if a complete loss of air pressureoccurred. This could result in serious personalinjury or vehicle damage.

To move a vehicle with insufficient system air pres-sure, it is necessary to release the parking brakesprings.

There are two ways to do this:

• Apply an external air source at the gladhands;

• Cage (manually release) the parking brakes.

IMPORTANT: Before caging the parking brakes,make the connection to a towing vehicle orchock the tires.

After correcting the brake system problem, uncagethe parking brakes before resuming normal vehicleoperation.

Meritor™ WABCO® Antilock BrakingSystem (ABS) for Air BrakesABS is an electronic wheel-speed monitoring andcontrol system that works with the air brake system.It passively monitors vehicle wheel speed at alltimes, but controls wheel speed during an emer-gency or reduced-traction stop. In normal braking


9.4

applications, the standard air brake system is in ef-fect.

ABS OperationThe Meritor WABCO ABS is a four-sensor system. Itcombines one front-axle control channel with onerear-axle control channel to form one control circuit.

Example: The sensor and solenoid control valve atthe left front wheel form a control circuit with the sen-sor and solenoid valve at the right rear wheel.

ABS includes signal-generating tone wheels and sen-sors located in the wheel hubs of each sensed axle.The sensors transmit vehicle wheel speed informa-tion to an electronic control unit.

IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit. Installing differentsized tires could result in a reduced brakingforce, leading to longer stopping distances.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS system willcontrol all wheels to provide steering control and areduced braking distance.

Although the ABS system improves vehicle controlduring emergency braking situations, the driver stillhas the responsibility to change driving styles de-pending on the existing traffic and road conditions.For example, the ABS system cannot prevent an ac-cident if the driver is speeding or following too closeon slippery road surfaces.

The main circuit of the control unit interprets thespeed sensor signals and calculates wheel speed,wheel retardation, and a vehicle reference speed. Ifthe calculations indicate wheel lockup, the main cir-cuit signals the appropriate solenoid control valve toreduce braking pressure.

The electronic control unit also has a safety circuitthat constantly monitors the wheel sensors, solenoidcontrol valves, and the electrical circuitry. Duringemergency braking, the solenoid control valve alter-nately reduces, increases, or maintains the supply ofair pressure in the brake chamber, thereby prevent-ing front and/or rear wheel lockup.

Even if the ABS system is partially or completely in-operative, normal braking ability is usually main-tained.

IMPORTANT: If a solenoid control valve (orcombination solenoid control valve) is damagedand inoperative, normal braking may be im-paired.

ABS Indicator Lights

IMPORTANT: If any of the ABS indicator lightsdo not work as described below, or come onwhile driving, repair the ABS system immedi-ately to ensure full antilock braking capability.

Tractor ABS LightIf equipped only with the tractor ABS system, theamber TRACTOR ABS indicator light (see Fig. 9.4 )comes on after the ignition switch is turning on. Theindicator light goes out only if all of the tractor ABScomponents are working.

CAUTIONAn accumulation of road salt, dirt, or debris onthe ABS tone wheels and sensors can cause theABS warning light to come on. If the ABS lightdoes come on, the tone rings and sensorsshould be inspected for corrosion and serviced ifnecessary. The service should include cleaning

21 3

10/12/2000 f610454

1. Tractor ABS Indicator2. Wheel Spin Indicator

(optional)

3. Trailer ABS Indicator

Fig. 9.4, ABS Indicator Lights


9.5

of the tone rings and sensors. If any tone ring ona vehicle shows severe corrosion, all tone ringson that vehicle should be replaced.

During winter months in areas where corrosivematerials are used on the highways, periodicallyclean the underside of the vehicle, including thetone rings and sensors, to ensure proper ABSfunction and to protect the components from cor-rosion. Clean more frequently when unusuallycorrosive chemicals are being used.

During vehicle operation, if the safety circuit sensesa failure in any part of the ABS system (a sensor,solenoid control valve, wiring connection, short cir-cuit, etc.), the TRACTOR ABS indicator light comeson and the control circuit where the failure occurredis switched to normal braking action. The remainingcontrol circuit will retain the ABS effect.

Trailer ABS LightThe amber TRAILER ABS indicator light operates asfollows when a compatible trailer is properly con-nected to the tractor:

• When the ignition switch is turned to the onposition, the trailer ABS light will illuminate mo-mentarily, then turn off.

• If the light comes on momentarily during ve-hicle operation, then shuts off, a fault was de-tected and cleared.

• If the light flickers, or comes on and goes offrepeatedly, it could indicate an intermittent wir-ing problem. Bring the vehicle to an authorizedFreightliner service facility for testing and re-pairs.

• If the light comes on and stays on during ve-hicle operation, there is a fault with the trailerABS. Repair the trailer ABS system immedi-ately to ensure full antilock braking capability.

The Trailer ABS light will not illuminate unless a com-patible trailer is connected to the tractor.

IMPORTANT: If a compatible trailer is con-nected, and the light is not illuminating for threeseconds when the ignition switch is turned tothe ON position, it is possible that the light isburnt out.

Wheel Spin LightIf equipped with Automatic Traction Control (ATC),the amber WHEEL SPIN indicator light illuminates ifone of the drive wheels spins during acceleration.When the light illuminates, partially release thethrottle pedal until the light goes out. The light goesout when the wheel stops spinning.

If slippery road conditions continue, turn on the differ-ential lock switch (on dual-drive vehicles, turn on theinteraxle lock switch). See Chapter 8 for axle switchinstructions.

CAUTIONDo not turn the differential lock switch on whilethe WHEEL SPIN indicator light is on. To do socould damage the rear axle.

Automatic Traction Control, OptionalAutomatic Traction Control is an option available onABS-equipped vehicles with air brake systems. It im-proves traction when vehicles are on slippery sur-faces by reducing drive wheel overspin. ATC worksautomatically in two ways.

• If a drive wheel starts to spin, ATC applies airpressure to brake the wheel. This transfers en-gine torque to the wheels with better traction.

• If all drive wheels spin, ATC reduces enginetorque to provide improved traction.

ATC turns itself on and off. Drivers do not have toselect this feature. If drive wheels spin during accel-eration, the WHEEL SPIN indicator comes on, indi-cating ATC is active. It goes out when the drivewheels stop spinning.

Hydraulic Brake SystemGeneral InformationThe hydraulic brake system includes a powerbooster, master cylinder, reservoir, hydraulic lines, abrake rotor on each wheel hub, and a brake caliperand pad assembly at each rotor.

IMPORTANT: Make sure that the fluid level inthe master cylinder reservoir is up to the ridgethat surrounds the reservoir. See Fig. 9.5 . Useonly heavy-duty brake fluid, DOT 3, in the hy-draulic brake system.


9.6

The master cylinder controls braking power to thefront and rear brakes. The Bendix Hydro-Max® powerbooster is attached to the rear of the master cylinderand is connected to the power steering system(which provides pressurized power steering fluid). Anelectrically powered backup pump operates if there isinadequate fluid flow from the power steering pumpto the power booster. The brake system warning lightcomes on if there is a problem within the system.Bring the vehicle to a safe stop and correct the prob-lem before continuing operation of the vehicle. SeeGroup 42 of the Business Class® M2 WorkshopManual for hydraulic brake system troubleshootingand adjustment procedures.

OperationBefore driving the vehicle, secure all loose items inthe cab so that they will not fly forward during a fullbrake application. Make sure that all occupants arewearing seat belts. Check that the brake systemwarning light is off after releasing the parking brake.If the warning light does not go off, correct the prob-lem before continuing operation of the vehicle.

During normal brake stops, depress the foot brakecontrol pedal until braking action slows down the ve-hicle. Increase or decrease the pressure on thepedal so that the vehicle comes to a smooth, safestop. When the forward speed of the vehicle has de-creased to almost the idling speed of the engine,

push the clutch pedal in, and shift the transmissioninto Neutral. Apply the parking brake if the vehicle isto be parked.

Meritor™ WABCO® Antilock BrakingSystem (ABS) for Hydraulic BrakesThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel-speed monitoring and controlsystem that works with the hydraulic brake system.ABS passively monitors vehicle wheel speed at alltimes, but controls wheel speed during an emer-gency or reduced-traction stop. In normal brakingapplications, the standard hydraulic brake system isin effect.

IMPORTANT: For proper hydraulic ABS opera-tion, Meritor WABCO recommends that frontand rear tire sizes be within 16% of each other.Contact the Meritor WABCO Customer SupportCenter at 800-535-5560 if you plan a tire sizedifference greater than ±8%. Installing differentsized tires could result in inaccurate wheelspeed signals to the ECU resulting in a reducedbraking force, which could lead to longer stop-ping distances.

ABS includes signal-generating tone rings and sen-sors located in the wheel hubs of each sensed axle.The sensors transmit vehicle wheel speed informa-tion to the ECU which interprets these signals to cal-culate wheel speed and a vehicle reference speed. Ifthe calculations indicate wheel lockup, the appropri-ate control circuit signals the brake pressure modula-tor to increase or decrease braking pressure.

CAUTIONAn accumulation of road salt, dirt, or debris onthe ABS tone wheels and sensors can cause theABS warning light to come on. If the ABS lightdoes come on, the tone rings and sensorsshould be inspected for corrosion and serviced ifnecessary. The service should include cleaningof the tone rings and sensors. If any tone ring ona vehicle shows severe corrosion, all tone ringson that vehicle should be replaced.

During winter months in areas where corrosivematerials are used on the highways, periodicallyclean the underside of the vehicle, including thetone rings and sensors, to ensure proper ABS

10/31/94 f460513a

A

B

A. Open caps and check fluid level.B. Fill to this level.

Fig. 9.5, Hydraulic Brake Reservoir


9.7

function and to protect the components from cor-rosion. Clean more frequently when unusuallycorrosive chemicals are being used.

The ECU also has a safety circuit that constantlymonitors the wheel sensors, brake pressure modula-tor, and the electrical circuitry. The ABS indicatorlamp comes on after the ignition is switched on andwill go out within three seconds if the system is func-tioning correctly. If the ABS indicator lamp does notcome on, or does not go out after three seconds,have the vehicle serviced before operation.

If, during vehicle operation, the safety circuit sensesa failure in any part of the ABS system (a sensor,brake pressure modulator, wiring connection, shortcircuit, etc.), the warning lamp comes on and thecontrol circuit where the failure occurred is switchedto normal braking action. Even if the ABS system ispartially or completely inoperative, normal brakingability is maintained. An exception would be if thebrake pressure modulator or a hydraulic fluid line isdamaged. Since these components are an integralpart of the hydraulic brake system, normal brakingmay be impaired or inoperative.

IMPORTANT: If any of the ABS warning lightsdo not work as described above, or come onwhile driving, repair the ABS system immedi-ately to ensure full antilock braking capability.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop; do not pump the brake pedal. With thebrake pedal fully depressed, the ABS system willcontrol all wheels to provide steering control and areduced braking distance.

Although the ABS system improves vehicle controlduring emergency braking situations, the driver stillhas the responsibility to change driving styles de-pending on the existing traffic and road conditions.For example, the ABS system cannot prevent an ac-cident if the driver is speeding or following too closeon slippery road surfaces.


9.8

10

Fifth Wheels and TrailerCouplings

Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Fontaine Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1ConMet Simplex® Series Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3Holland Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

Air-Suspension Dump ValveThe air-suspension height switch may be used to aidin connecting or disconnecting from a trailer. Whenthe switch is set to LOWER, the air-suspensiondump valve deflates the air springs to lower the rearof the vehicle. In the AUTO position, the automaticride-control valves operate for normal driving.

NOTICEDo not operate the vehicle over uneven groundsuch as ramps, speed bumps, curbs, etc. withthe air springs deflated. Doing this may lead toair bag separation from the piston, preventing thesuspension air springs from reinflating.

NOTICENever exhaust air from the suspension whiledriving. When the air is exhausted, the suspen-sion will not absorb road shocks, and compo-nents may be damaged.

Fontaine Fifth WheelsOn Fontaine fifth wheels, kingpin release is accom-plished by activating a manual lock control handlelocated on either the right side or left side of the fifthwheel. Kingpin lockup occurs when the kingpin isforced into the jaws and the lock control handlemoves to the locked position.

Fontaine Lock MechanismThe Fontaine fifth wheel lock mechanism for thetrailer kingpin (Fig. 10.1 ) consists of a spring-loadedjaw and a sliding wedge.

The jaw and wedge each have a pin permanentlyattached. The pin on the jaw and the pin on thewedge fit into elongated notches in the lock controlhandle. The notches in the handle control the limit ofmovement for both the jaw and wedge. The notchesare arranged so that the wedge is actuated first dur-ing release of the kingpin.

During lockup, the jaw is moved first with the spring-loaded wedge being allowed to slip in place againstthe jaw. A timing bracket ensures that the wedge andjaw are moved at the proper time.

Placing the lock control handle in the unlocked posi-tion moves the wedge away from the jaw. This actionunlocks the jaw so that it can be moved by the trailerkingpin. When the tractor is moved out from underthe trailer, the kingpin moves the jaw until the kingpinis out of the mechanism. With the jaw in the un-locked position, the lock control handle will remain inthe unlocked position until manually moved by theoperator.

During coupling (Fig. 10.1 ), the motion of the kingpinentering the jaw will actuate the jaw and wedge. Thejaw will move behind the kingpin, followed by thewedge. The purpose of the wedge is to reinforce thejaw and take up slack around the pin. Any wear onthe jaw is immediately taken up by the wedge sothere is no slack in the connection.

Fontaine Locking OperationLocking the Fontaine Fifth Wheel1. Chock the front and rear of the trailer tires to

prevent the trailer from moving.

1

2 A

3

B C

01/04/95 f310184c

A. Unlocked PositionB. Locking

C. Locked

1. Wedge2. Jaw

3. Trailer Kingpin

Fig. 10.1, Fontaine Kingpin Lock Mechanism

Fifth Wheels and Trailer Couplings

10.1

WARNINGKeep the fifth wheel plate lubricated to preventbinding between the tractor and trailer. A bindingfifth wheel could cause erratic steering and lossof vehicle control, possibly resulting in seriouspersonal injury or death.

2. The kingpin lock mechanism must be fully open,the fifth wheel plate must be completely lubri-cated with chassis grease. For lubrication in-structions, see Group 31 of the Business Class®

M2 Maintenance Manual.

3. Position the tractor so that the fifth wheel lockopening is in line (both vertically and horizontally)with the trailer kingpin. The kingpin should be ina position to enter the throat of the lockingmechanism (Fig. 10.1 ). Adjust the trailer landinggear to give enough alignment height for positivekingpin lockup.

4. With the fifth wheel lock opening aligned with thetrailer kingpin, back the tractor slowly toward thetrailer, making sure that the kingpin enters thethroat of the locking mechanism. Continue back-ward motion until positive lockup occurs.

5. Apply the tractor parking brakes.

6. Make a visual and physical check for positivekingpin lockup. When lockup has occurred, thefifth wheel control handle will have moved to thelocked position. Make sure that the safety latchis down over the lock control handle. SeeFig. 10.2 . This will hold the control handle in thelocked position.

7. Release the tractor parking brakes. Test for king-pin lockup by pulling on the trailer against thechocks.

NOTICEAlways make sure the connect-hanger/supportkeeps the trailer air hoses and electrical cablespositioned so that they do not rub on anything.Rubbing may wear through hoses or cables, re-sulting in air leaks, or exposed or broken wires,potentially affecting trailer brake or electrical sys-tems.

8. After lockup is completed, connect the tractor-to-trailer air system lines and the electrical cable to

the trailer. Take care to prevent dirt or foreignmaterial from entering the air system lines.

9. Charge the air brake system with air. Make surethat the air connections do not leak.

WARNINGEliminate slack between the trailer and the trac-tor. Incorrect fifth wheel adjustment could causethe trailer to disconnect, possibly resulting in se-rious personal injury or death.

10. With the trailer wheels chocked and the brakesset, check for clearance between the kingpin andthe fifth wheel jaws by moving the tractor forwardand backward against the locked kingpin. Thereshould be no slack between the tractor and thetrailer. If slack is present, uncouple the trailer.

For adjustment instructions, refer to the appli-cable trailer manufacturer’s service information.

11. Retract the trailer landing gear, and secure theratchet handle. Remove the chocks from thetrailer tires.

1

1

2

2 02/09/95 f310110a

A

B

NOTE: Make sure the safety latch is down when thecontrol handle is locked.

A. Unlocked B. Locked1. Safety Latch 2. Lock Control Handle

Fig. 10.2, Fontaine Fifth Wheel, Locking and Unlocking


10.2

12. The load distribution on the front steering axleand rear drive axle(s) will have a direct effect onthe steering control of the vehicle.

Determine the front and rear axle weights byweighing the vehicle on scales designed for thispurpose.

The maximum axle weight ratings are given onthe Federal Motor Vehicle Safety Standard(FMVSS) label or Canadian Motor Vehicle SafetyStandard (CMVSS) label attached to the left reardoor post of the tractor. The desired load on theaxle is no less than 80 percent of the maximumaxle weight rating, but in no instances should theaxle load exceed the maximum axle weight rat-ing given on the FMVSS or CMVSS label.

WARNINGDo not overload any tractor axle by improperlyloading the trailer. This could cause erratic steer-ing and loss of vehicle control, possibly resultingin serious personal injury or death.

Unlocking the Fontaine Fifth Wheel1. Apply the tractor parking brakes.

2. Pull the trailer air supply valve to cut off the airsupply to the trailer.

WARNINGDo not use the trailer air supply for parking trail-ers not equipped with spring parking brakes.This applies the trailer service brakes only. As airbleeds from the trailer brake system, brake appli-cation is lost. This could allow the unattendedvehicle to roll away, possibly resulting in seriouspersonal injury or death.

3. Chock the front and rear of the trailer tires toprevent the trailer from moving.

4. Lower the trailer landing gear until the weight isremoved from the fifth wheel.

5. Disconnect the tractor-to-trailer air system linesand electrical cable. Plug the air lines to preventdirt or foreign material from entering the lines.

6. Release the kingpin locking mechanism by liftingthe safety latch and pulling the lock controlhandle to the unlocked position. See Fig. 10.2 .

7. Slowly drive the tractor away from the trailer.

Fontaine Fifth Wheel Lubrication


For lubrication instructions, see Group 31 of theBusiness Class® M2 Maintenance Manual.

ConMet Simplex ® Series FifthWheelsThe ConMet Simplex series fifth wheels are used forpulling trailers having the standard 2-inch (51-mm)diameter kingpin. When installed as a stationary fifthwheel (Fig. 10.3 ), they are bracket-mounted to thetractor frame in a position that best distributes thetrailer load over the tractor axles.

Simplex Lock MechanismThe fifth wheel lock mechanism for the trailer kingpinconsists of a rotating jaw that grips the trailer kingpinand a spring-actuated lock. The jaw rotates on a jawpin during coupling and uncoupling operations. King-pin lockup occurs when the kingpin is forced into thejaw and the operating rod handle moves to the

f310353b

12

3

4

11/28/95

1. Lubricant Grooves2. Safety Latch

3. Operating Rod4. Mounting Bracket

Fig. 10.3, Simplex Stationary Fifth Wheel


10.3

locked position. The kingpin is released by activatinga manual operating rod. The air cylinder activates theoperating rod. The operating rod is located on the leftside of the fifth wheel for Simplex II fifth wheels.

The Simplex Series fifth wheel lock mechanism(Fig. 10.4 ) consists of a rotating jaw and a spring-actuated lock that grips the trailer kingpin. The jawrotates on an eccentric pin during coupling and un-coupling operations. The spring-actuated lock holdsthe jaw in the locked position once kingpin lockuphas occurred.

In the locked position, there is approximately 1/16-inch (1.6-mm) clearance between the jaw and king-pin. The jaw eccentric pin can be removed and ro-tated to compensate for wear and maintain anapproximate 1/16-inch (1.6-mm) clearance duringservice.

Placing the operating rod in the lockset positionmoves the lock away from the jaw. This action un-locks the jaw so that it can be rotated by movementof the kingpin. When the tractor is moved out fromunder the trailer, the kingpin will rotate the jaw until

the jaw is in the unlocked position, allowing the king-pin to move out of the mechanism. With the jaw inthe fully open position, the operating rod drops out ofthe lockset position, and the fifth wheel is ready forcoupling. See Fig. 10.5 .

During coupling, the kingpin contacts and rotates thejaw into the locked position. This action automaticallymoves the operating rod into the locked position.This securely locks the jaw around the kingpin. In thelocked position the safety latch swings freely over theoperating rod. See Fig. 10.6 .

Simplex Locking OperationLocking the Simplex Fifth Wheel1. Chock the front and rear of the trailer tires to


2. Inspect the fifth wheel for damaged or missingparts, and for mounting bolts that are loose ormissing.

04/08/96 f310446

1

23 4

A

B C

56

A. Locked PositionB. Jaw movement compresses springC. Fully open1. Operating Rod2. Safety Latch3. Jaw

4. Jaw Eccentric Pin5. Lock6. Spring

Fig. 10.4, Simplex Series Kingpin Locking MechanismOperation

1

1

2

3

04/08/96 f310447

1. Safety Latch2. Operating Rod (retracted)3. Operating Rod (extended)

Fig. 10.5, Simplex Kingpin Locking Mechanism,Locking and Unlocking


10.4


3. Be sure that the top surface of the fifth wheel iscompletely lubricated with chassis or multi-purpose grease. For lubrication instructions, seethe Simplex Series Fifth Wheels Operating andMaintenance Manual.

4. The fifth wheel jaw must be fully open. Makesure that the operating rod is in the extendedposition.

5. Make sure the fifth wheel top plate is tilted so theramps are as low as possible. If equipped withan air suspension, make sure the air bags arecompletely inflated.

6. Position the tractor so that the center of the fifthwheel is in line with the trailer kingpin. The king-pin should be in a position to enter the throat ofthe locking mechanism. Adjust the trailer landinggear so that the lower front trailer edge contactsthe top surface of the tilted fifth wheel plate, ap-proximately 8 inches (20 cm) before the fifthwheel center.

7. With the fifth wheel lock opening aligned with thetrailer kingpin, back the tractor slowly toward thetrailer, making sure that the kingpin enters the

throat of the locking mechanism. Continue back-ward motion until positive lockup occurs.


9. Make a visual check for positive kingpin lockup.See Fig. 10.6 .

9.1 The trailer bed plate must be flush on thefifth wheel plate surface. There should beno gap between the fifth wheel and thetrailer bed plate.

9.2 When positive lockup has occurred, thefifth wheel operating rod will have movedinward to the fully retracted position, andthe safety latch will swing freely over theoperating rod.

NOTE: Only when the operating rod is fully re-tracted in the locked position will the safety latchbe freely rotated down.

10. Release the tractor parking brakes. Test for king-pin lockup by pulling on the trailer against thechocks.


11. After lockup is completed, connect the tractor-to-trailer air system lines and electrical cable to thetrailer. Take care to prevent dirt or foreign mate-rial from entering the air system lines.


WARNINGAdjust the jaw pin if there is more than 1/8-inch(3-mm) clearance between the kingpin and thelock. Incorrect adjustment could cause the trailerto disconnect, possibly resulting in serious per-sonal injury or death.

13. With the trailer wheels chocked and the brakesset, check for clearance between the kingpin and

1

2

11/18/94 f310448

NOTE: The safety latch is shown in the locked position.

1. Safety Latch 2. Operating Rod

Fig. 10.6, Simplex Kingpin Locking Mechanism, SafetyLatch


10.5

the fifth wheel jaws by moving the tractor forwardand backward against the locked kingpin. Aclearance of approximately 1/16 inch (1.6 mm)between the jaw and kingpin is allowable. Whenclearance between the jaw and kingpin exceeds1/8 inch (3 mm), adjust the jaw to restore the1/16-inch (1.6-mm) clearance between the jawand kingpin. For instructions, see the SimplexSeries Fifth Wheels Operating and MaintenanceManual.

14. Retract the trailer landing gear, and secure theratchet handle.

15. Remove the chocks from the trailer tires.



The maximum axle weight ratings are shown onthe Federal Motor Vehicle Safety Standard(FMVSS) label or Canadian Motor Vehicle SafetyStandard (CMVSS) label attached to the left reardoor post of the tractor. The desired load on theaxle is no less than 80 percent of the maximumaxle weight rating, but in no instances should theaxle load exceed the maximum axle weight rat-ings given on the FMVSS or CMVSS label.


Unlocking the Simplex Fifth Wheel1. Apply the tractor parking brakes.


WARNINGDo not use the trailer air supply for parking trail-ers not equipped with spring parking brakes.This applies the trailer service brakes only. As airbleeds from the trailer brake system, brake appli-cation is lost. This could allow the unattended

vehicle to roll away, possibly resulting in seriouspersonal injury or death.


4. Lower the trailer landing gear until the trailerrises about 1/2 inch (13 mm).


6. Release the kingpin lock mechanism.

6.1 Raise the safety latch to the rear.

6.2 Pull the operating rod out and up into thelockset position. The operating rod shouldbottom against the plate casting above thehole.

NOTE: If the operating rod cannot be pulled tothe lockset position, back the tractor slightly torelease the kingpin force against the jaw.


Simplex Fifth Wheel Lubrication


The fifth wheel plate must be kept well lubricatedwith chassis grease to prevent friction and bindingbetween the tractor fifth wheel plate and the trailer.For lubrication instructions, see the Simplex SeriesFifth Wheels Operating and Maintenance Manual.

Holland Fifth WheelsThe Model FW35 fifth wheel (Fig. 10.7 ) is a station-ary fifth wheel with a capacity of 55,000 lb (25 000kg) maximum of vertical load and 155,000 lb (68 000kg) maximum drawbar pull.

Holland Kingpin Lock MechanismThe Type "B" kingpin lock mechanism (Fig. 10.8 )utilizes two spring-loaded lock halves. The final for-ward motion of the kingpin into the open lock halves


10.6

forces the locks to close in a 360-degree grip aroundthe shoulder and neck of the kingpin, positioning slid-ing yokes between the lock halves and tapered ribmembers of the fifth wheel understructure. The king-pin can be released only by manually operating thekingpin lock control handle. The adjustment nut willcompensate for wear on the lock or kingpin.

Holland Lock GuardThe Holland lock guard (Fig. 10.9 ) is a device thatprevents a false lockup, and is used on all models.The lock guard is a spring-tensioned, smooth-surfaced tongue that the kingpin passes over anddepresses when entering the lock mechanism. Thelock guard will prevent the locks from engaging be-fore the kingpin fully enters the locks. If the kingpinenters the fifth wheel incorrectly and does not de-press the tongue, the locks are unable to close.

Holland Locking OperationLocking the Holland Fifth Wheel1. Chock the front and rear of the trailer tires to


WARNINGKeep the fifth wheel plate lubricated to preventbinding between the tractor and trailer. A bindingfifth wheel could cause erratic steering and loss

of vehicle control, possibly resulting in seriouspersonal injury or death.

2. The kingpin lock mechanism must be fully open,and the fifth wheel plate must be completely lu-bricated with chassis grease.

3. Position the tractor so that the fifth wheel lockopening is in line (both vertically and horizontally)with the trailer kingpin. The kingpin should be ina position to enter the throat of the lockingmechanism, to prevent a false lockup. SeeFig. 10.9 . Adjust the trailer landing gear to giveenough alignment height so that the fifth wheelpicks up the trailer on the fifth wheel ramps.

4. With the fifth wheel lock opening aligned with thetrailer kingpin, back the tractor slowly toward thetrailer, making sure that the kingpin correctly en-ters the throat of the locking mechanism. Whenthe trailer is picked up by the fifth wheel, stop thetractor, then continue slow backward motion untilpositive lockup occurs.


WARNINGAdjust the locks correctly to a maximum clear-ance of 1/8 inch (3 mm). Incorrect adjustment ofthe lock could cause the trailer to disconnect,possibly resulting in serious personal injury ordeath.

6. Make a visual check for proper kingpin lockup.Release the tractor parking brakes. Test for king-pin lockup by pulling on the trailer against thechocks. Check for correct maximum clearancebetween the lock halves. If more than 1/8-inch(3.2-mm) clearance exists between the lockhalves, the lock must be adjusted. For adjust-ment instructions, see the Holland fifth wheelmaintenance procedures manual.


12

3

01/19/95 f310046a

1. Kingpin Lock Mechanism2. Kingpin Control Handle3. Mounting Bracket

Fig. 10.7, Holland Fifth Wheel


10.7

7. After lockup is completed, connect the tractor-to-trailer air system lines and electrical cable to thetrailer. Take care to prevent dirt or foreign mate-rial from entering the air lines.


9. Retract the trailer landing gear and secure theratchet handle.

10. Remove the chocks from the trailer tires.

07/11/2000 f310841

2 2

1 1

4

33

5

A B

A. Closed Position, Locked B. Open Position, Unlocked1. Release Handle and Spring2. Adjustment Nut

3. Lock Halves4. Lock Pivot

5. Sliding Yoke

Fig. 10.8, Holland Type "B" Kingpin Lock Mechanism (bottom view)

1

2

3

4A

11/07/94 f310106a

1

2

3

4

B

D C

A. Locks open.B. Locks closed.C. Kingpin correctly entering the lock. Note how the depressed tongue allows lock halves to close completely around the

neck and shoulder of the kingpin.D. Kingpin incorrectly entering the lock. Note how the steel tongue prevents lock halves from closing, preventing false

lockup.1. Fifth Wheel Plate2. Trailer

3. Kingpin4. Lock Guard

Fig. 10.9, Holland Lock Guard Mechanism (rear view)


10.8



The maximum axle weight ratings are shown onthe Federal Motor Vehicle Safety Standard(FMVSS) label or Canadian Motor Vehicle SafetyStandard (CMVSS) label attached to the left reardoor post of the tractor. The desired load on theaxle is no less than 80 percent of the maximumaxle weight rating, but in no instances should theaxle load exceed the maximum axle weight rat-ing given on the FMVSS or CMVSS label.


Unlocking the Holland Fifth Wheel1. Apply the tractor parking brakes.




4. Lower the trailer landing gear until the weight isremoved from the fifth wheel.


6. Release the kingpin locking mechanism by pull-ing the kingpin lock control handle (Fig. 10.7 ) tothe outward position.


Holland Fifth Wheel Lubrication


For lubrication instructions, see the Holland fifthwheel maintenance procedures manual.

Holland Trailer CouplingThe Holland PH–T–60–AL trailer coupling is de-signed for use with trailers having a maximum grossweight of 10,000 lbs. It is a rigid type pintle hook,used only on truck applications, and is fastened tothe rear closing crossmember of the vehicle. SeeFig. 10.10 . It is a non-air adjusted coupling.

OperationTrailer Hookup1. Chock the front and rear tires of the trailer.

2. Remove the cotter pin, then lift the lock and raisethe latch.

3. Back up the vehicle until the drawbar eye is overthe pintle hook.

1 2

3

4

01/20/95 f310314a

1. Lock2. Cotter Pin

3. Latch4. Pintle Hook

Fig. 10.10, Holland PH-T-60-AL Trailer Coupling


10.9

4. Lower the trailer until the drawbar eye rests onthe pintle hook.

5. Close the latch, then insert the cotter pin.


6. Hook up the trailer’s electrical and air lines.

7. Remove the chocks from the trailer’s tires.

Trailer Release1. Apply the truck and trailer parking brakes.


2. Chock the front and rear tires of the trailer.

3. Disconnect the trailer air and electrical lines.Plug the air lines to keep out dirt.

4. Take the weight of the trailer drawbar off thepintle hook.

5. Open the latch by first removing the cotter pin;then lift up the lock and raise the latch.

6. Slowly drive the vehicle away from the trailer.


10.10

11

Pretrip and Post-TripInspections and

MaintenancePretrip and Post-Trip Inspection Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Pretrip and Post-Trip Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3

Pretrip and Post-TripInspection ChecklistsRegulations in both Canada and the United Statesclearly indicate that it is the driver’s responsibility toperform an inspection and ensure the complete road-worthiness of a vehicle before placing it into servicefor the day. Commercial vehicles may be subject toinspection by authorized inspectors, and an unsafevehicle can be put "out of service" until the driver orowner repairs it.

IMPORTANT: The pre- and post-trip checklists,and inspections and maintenance proceduresdetailed in this chapter, are not all-inclusive .Also refer to other component and body manu-facturers’ instructions for specific inspection andmaintenance instructions.

Use the inspection checklists to ensure that vehiclecomponents are in good working condition beforeeach trip. A driver that is familiar with the vehicle,and drives it regularly, can perform the daily inspec-tions, then add the weekly and monthly post-trip in-spections as scheduled. If the driver does not oper-ate the vehicle on a consistant basis, all three of theinspection procedures should be performed beforethe trip.

NOTE: Procedure reference numbers in thechecklists reference the corresponding detailedinstructions found under the pretrip and post-tripmaintenance procedures.

Pre- and post-trip inspections cannot be donequickly. However, careful inspections save time byeliminating stops later to adjust items overlooked orforgotten.

If any system or component does not pass this in-spection, it must be corrected before operating thevehicle. Whenever equipment requires adjustment,replacement, repair, addition of lubricants, or achange of lubricants, see the Business Class® M2Workshop Manualfor procedures and specifications,and see the Business Class® M2 Maintenance Manu-alfor lubricant recommendations, specifications, andmaintenance intervals.

See Table 11.1 for a list of procedures that shouldbe perfomed daily, before the first trip.

See Table 11.2 for a list of procedures that shouldbe performed weekly, post-trip.

See Table 11.3 for a list of procedures that shouldbe performed monthly, post-trip.

IMPORTANT: Before performing any checks,apply the parking brake and chock the tires.

Pretrip and Post-Trip Inspections and Maintenance

11.1

Procedure Performed(check off)

Daily Pretrip Inspections/ChecksProcedureReference

_______ Drain manually drained air reservoirs (that are not equipped with automatic drainvalves) D1

Check _______ windshield washer reservoir fluid D2Inspect _______ wheel seal and hub cap (for leakage) —Check _______ surge tank coolant; and, if equipped, coolant for hybrid cooling system D3Inspect _______ radiator and charge air cooler D4Check _______ engine for fuel, oil, or coolant leaks —Inspect _______ engine and chassis wiring D5Inspect _______ air intake system D6Check _______ intake-air restriction indicator mounted on air intake D6Check _______ engine oil level D7Check _______ power steering fluid level —Inspect _______ fuel tank(s), fuel lines, connections, and fuel level D8Check _______ fuel/water separator D9Inspect _______ natural gas fuel system, if equipped D10Inspect _______ front and rear suspension components D11Inspect _______ headlights, mirrors, and window glass, and windshield wipers D12Check _______ doors (open without difficulty and close securely) —

_______ Adjust driver’s seat, then align rearview and downview mirrors —Check _______ dash-mounted intake-air restriction indicator D6Check _______ oil- and air-pressure warning systems D13Check _______ ICU fault codes D14Check _______ horn, windshield wipers, and windshield washer D15Check _______ heater, defroster, and optional mirror heat controls D16Check _______ backup alarm —Check _______ panel lights and interior lights D17Check _______ exterior lights and reflectors D18Check _______ tire pressure D19Inspect _______ tire condition D20Inspect _______ rims and wheels D21Check _______ automatic transmission fluid level —Inspect _______ air brake chambers and pushrods D22Inspect _______ air brake lines D23Inspect _______ slack adjusters D24Check _______ air brake system operation D25Check _______ Bendix Hydro-Max® Power Booster, if equipped D26Inspect _______ frame rails (missing bolts) and crossmembers (bent or loose) —

Check _______ mud flaps (aren’t damaged, at least 10 inches above the ground, and bracketsare secure) —

Check _______ exhaust system (mounted securely, connected tightly, no signs of leaks such assoot trails) —

_______ Remove chocks and test service brakes D27

Inspector___________________________________________________ Date ________________

Table 11.1, Daily Pretrip Inspection and Maintenance Checklist


11.2


Weekly Post-Trip Inspections/ChecksProcedureReference

_______ Manually drain air reservoirs that are equipped with automatic drain valves —Inspect _______ batteries and battery cables W1Check _______ wheel bearing lubricant level W2Inspect _______ steering components W3Check _______ serpentine drive belt condition W4Check _______ V-belt tension W5Inspect _______ seat belts and tether belts W6

Inspector___________________________________________________ Date ________________

Table 11.2, Weekly Post-Trip Inspection and Maintenance Checklist


Monthly Post-Trip Inspections/ChecksProcedureReference

_______ clean the battery terminals M1Inspect _______ radiator hoses and heater hoses M2

Check _______ fluid level in the hydraulic clutch reservoir (if applicable, and if necessary, fill withDOT 4 brake fluid) —

Check _______ steering wheel play M3Check _______ outer surfaces of the hood and body (for visible surface breaks and damage) —Check _______ hood tilt damper (attached at both ends) —Inspect _______ brake lining wear M4Inspect _______ driveshaft —Inspect _______ natural gas fuel system leak test, if equipped M5

_______ drain the CNG high-pressure fuel filter housing, if equipped M6

Inspector___________________________________________________ Date ________________

Table 11.3, Monthly Post-Trip Inspection and Maintenance Checklist

Pretrip and Post-TripMaintenance ProceduresDaily Pretrip Inspection andMaintenanceWhenever equipment requires adjustment, replace-ment, and/or repair, see the Business Class® M2Workshop Manual for procedures and specifications.Specific references to the manual will be foundwhere appropriate.

1. Drain manually drained air reservoirs.

Water and oil normally enter the air reservoir inthe form of vapor because of the heat generatedduring compression. After the water and oil con-dense, drain the resulting emulsion as follows:

1.1 Open the wet tank valve. The drain cockor pull chain drain is located on the for-ward end of the supply air reservoir, whichis connected directly to the air compres-sor. Block the valve open.

WARNINGWhen draining the air reservoir, do not look intothe air jets or direct them toward anyone. Dirt orsludge particles may be in the airstream andcould cause injury.

1.2 Exhaust the remaining air and moisturefrom the system by opening the draincocks on the bottoms of the remaining airreservoirs. Block the valves open.


11.3

1.3 Water and oil emulsion often form pocketsthat will not drain while compressed air isin the reservoirs. Because of these pock-ets, leave the valves blocked open duringthe first part of the pretrip inspection.

1.4 If the drained water is cloudy or oily, itmay indicate a problem with the compres-sor. If oil is allowed to contaminate the airdryer, it will not remove the water from theair brake system, which could adverselyaffect braking.

2. Check the fluid level in the windshield washerreservoir.

Add washer fluid as needed. Unscrew the cap toadd fluid.

WARNINGWasher fluids may be flammable and poisonous.Do not expose washer fluid to an open flame orany burning material, such as a cigarette. Alwayscomply with the washer fluid manufacturer’s rec-ommended safety precautions.

3. Check the engine coolant levels in the radiatorsurge tank, and, if equipped, the reservoir for thehybrid cooling system.

See Fig. 11.1 . If the coolant is low, add a 50/50mixture of water and the type of antifreeze speci-fied for your vehicle. Fill the surge tank with cool-ant to the MAX line when the tank is cool. If thesurge tank was empty, start the engine after re-filling and check the level again when the engineis at operating temperature.

For natural gas vehicles, use only Fleetguard ESCompleat™ EG Premix 50/50 engine coolant.

For vehicles equipped with a hybrid cooling sys-tem, the coolant should be approximately 1.5inches (4 cm) below the top of the reservoir forthis system. If the coolant is low, add a 50/50mixture of water and the type of antifreeze speci-fied for your vehicle.

CAUTIONCoolant must be filled to the full line of the surgetank. Low coolant could result in engine over-heating, which could cause engine damage.

4. Inspect the radiator and charge air cooler.

4.1 Inspect the radiator and charge air coolerfor clogged fins. Use compressed air orwater directed from the fan side of thecore to backflush any material restrictingairflow.

4.2 Inspect the radiator and charge air coolerfor damage and accumulated debris.Straighten bent or damaged fins to permitairflow across all areas of the cores.

NOTE: When traveling through areas of highinsect concentration, it may be necessary toclean the exterior of the radiator or thecharge air cooler core as often as every 200miles (320 km).

4.3 On vehicles equipped with air condition-ing, also inspect and clean the condenser.If clogged, the condenser can restrict air-flow through the radiator.

4.4 Check the radiator for leaks. If leaks arefound, have the radiator repaired or re-placed. See Group 20 of the BusinessClass® M2 Workshop Manual for instruc-tions, or take the vehicle to an authorizedFreightliner dealer.

5. Inspect the engine and chassis wiring.

Check for loose wiring, chafed insulation, anddamaged or loose hold-down clamps. Tightenloose wires or hold-down clamps; replace dam-aged wiring or clamps.

6. Inspect the air intake system for leaks or dam-age.

11/02/2001 f820382

Add coolant here (arrow).

Fig. 11.1, Coolant Level Checking


11.4

CAUTIONFailure to maintain a sealed air intake systemcould allow the entry of dirt and contaminantsinto the engine. This could adversely affect en-gine performance and result in engine damage.

6.1 Check the intake-air restriction indicator (ifmounted in the air intake system).

6.2 Replace the primary filter element in theair cleaner (see Fig. 11.2 ) if the yellowsignal stays locked at 25 inH2O for Cater-pillar engines or 20 inH2O for Mercedes-Benz engines. See Group 09 of theBusiness Class® M2 Workshop Manual forfilter element replacement instructions.

NOTE: After replacing the filter element,reset the restriction indicator by pressing therubber reset button.

6.3 Inspect the secondary or safety filter ele-ment in the air cleaner when replacing theprimary element, and replace it when

clogged or dirty. This element should bereplaced with every third primary elementreplacement.

6.4 Check the engine air intake piping fromthe air cleaner to the engine intake. In-spect the piping for loose connections,cracks, torn or collapsed hoses, punc-tures, and other damage. Tighten looseconnections, and have damaged compo-nents replaced. Make sure the piping sys-tem is airtight so that all of the intake airpasses through the air cleaner.

7. Check the engine oil level.

If the oil level is at or below the minimum fill (or"add") mark on the dipstick, add enough oil tomaintain the level between the minimum fill (or"add") and the maximum fill (or "full") marks onthe dipstick. See Fig. 11.3 . Engine lube oil musthave a sulfated ash level less than 1.0 wt %;currently referred to as CJ-4 oil. Use the properSAE viscosity rating for the temperature and timeof year.

For natural gas vehicles, use only Exxon Bus-gard® Geo 15W-40 natural gas engine oil. Bus-gard Geo engine oil with an SAE grade of15W-40 has multiple benefits in natural gas ve-hicles, including improved cold-weather startingand pumping, and reduced oil consumption.

CAUTIONOperating the engine with the oil level below theminimum fill (or "add") mark or above the maxi-mum fill (or "full") mark could result in enginedamage.

8. Inspect the fuel tanks, fuel lines, and connectionsfor leaks, and check the fuel level in the fueltank(s).

09/12/2001 f090363

2

1

1. Primary Filter Element2. Secondary or Safety Filter Element

Fig. 11.2, Air Cleaner Filter Elements

01/13/99 f011525

1 2

NOTE: The MBE900 dipstick is shown.1. Maximum Fill Level2. Minimum Fill Level

Fig. 11.3, Checking Engine Oil Level


11.5

8.1 Check that the fuel tanks are secured totheir mounting brackets and that themounting brackets are secured to theframe.

8.2 Replace leaking fuel tanks.

8.3 If lines or connections are leaking, havethem repaired or replaced.

For repair and/or replacement procedures,see Group 47 of the Business Class® M2Workshop Manual, or take the vehicle into an authorized Freightliner dealer.

8.4 If equipped with fuel tank shutoff valves,be sure the valves are fully open.

WARNINGNever operate the engine with the fuel tank shut-off valves partly closed. This could damage thefuel pump, causing loss of engine power and re-duced vehicle control.

8.5 Check the fuel level in the fuel tank(s).

To keep condensation to a minimum, fueltanks should be filled at the end of eachday. Federal regulations prohibit filling afuel tank to more than 95 percent of itsliquid capacity.

WARNINGDo not mix gasoline or alcohol with diesel fuel.This mixture could cause an explosion, possiblyresulting in serious personal injury or death. Donot fill the fuel tanks in the presence of sparks,open flames, or intense heat. These could ignitethe fuel, possibly causing severe burns.

IMPORTANT: Use ultralow-sulfur diesel(ULSD) with 15 ppm sulfur content or less,based on ASTM D2622 test procedure. Fail-ure to use ultralow-sulfur diesel fuels mayvoid the warranty on emission components.

8.6 Fuel should always be strained or filteredbefore being put into the tanks. This willlengthen the life of the engine fuel filterand reduce the chances of dirt getting intothe engine.

8.7 Before installing the fuel cap, clean thearea with a rag, or if necessary, clean thecap with solvent.

8.8 If needed, prime the fuel system. Forpriming procedures, see the applicableengine manufacturer’s manual.

9. If equipped with a fuel/water separator, check forwater. Drain any water found. Check the fuel/water separator for leaks and contaminants.

9.1 Place a suitable container under the fuel/water separator.

9.2 Check the water level in the sight bowl, ifequipped, and loosen the filter vent at thetop of the separator.

9.3 Drain the water by loosening the valve atthe bottom and allowing the water to runout. Close and tighten the valve finger-tight.

9.4 Close and tighten the filter vent at the topof the separator.

IMPORTANT: When draining fluid from a fuel/water separator, drain the fluid into an appropri-ate container and dispose of it properly. Manystates now issue fines for draining fuel/waterseparators onto the ground. On all types ofseparators, stop draining fluid when you seefuel come out of the separator drain valve.

10. Inspect all natural gas fuel system components,if equipped, for damage or leaks. Replace com-ponents as necessary.

10.1 Inspect fuel tanks for dents, scratches,gouges, or other signs of damage. Inspectthe fuel lines and connections for leaks.

10.2 Check that the fuel tanks are securelymounted. Look for signs of abrasion be-tween components.

CNG Fuel System: Ensure that the CNGfuel cylinder storage box is secured to theframe. Inspect for any signs of looseness.

LNG Fuel System: Ensure that the LNGfuel tank is secured to the mountingbrackets and that the mounting bracketsare secured to the frame. Inspect for any


11.6

signs of looseness. Ensure all rubber iso-lator straps are secure around the LNGfuel tank.

10.3 Check for the presence of all required de-cals. Natural gas decals should be presentin the following locations:

• Left front bumper

• End-of-frame crossmember

• LNG fuel tank fill port (maximumpsi), if equipped

10.4 Check for the presence of all necessaryvent caps on pressure relief valves anddevices.

CNG Fuel System: Check for the pres-ence of blue caps on all pressure reliefdevices. Each fuel cylinder is equippedwith two caps (one on each end), whichare visible on the back of the CNG fuelcylinder storage box. One cap is locatedon the pressure relief valve on the inboardside of the CNG fuel box, next to the fueloutlet line. If any blue caps are missing,remove the vehicle from service and havethe fuel system inspected by a qualifiedtechnician.

LNG Fuel System: Check for the presenceof a red cap on the secondary relief valve.If the red vinyl cap is missing from thesecondary relief valve (Fig. 11.4 , Item 4),remove the vehicle from service and havethe fuel system inspected by a qualifiedtechnician.

10.5 Inspect all plumbing components, includ-ing the fuel shutoff valve(s), primary andsecondary relief valves, and the LNGvapor shutoff and excess flow valves, ifequipped, for signs of damage or leaks.See Fig. 11.4 or Fig. 11.5 .

Inspect the fuel fill fitting for signs of dam-age or leaks.

Inspect all lines for signs of leaks or dam-age, and check all threaded connections.

10.6 Inspect all fuel gauge components forsigns of leaks or damage. Inspect theLNG fuel level sender cable and wiring, ifequipped.

10.7 Inspect all coolant hoses for signs of chaf-ing, kinks, or leaks. The LNG fuel systemutilizes coolant hoses between the engineand the vaporizer, while the CNG fuel sys-tem utilizes coolant hoses between theengine and the pressure regulator insidethe fuel panel.

10.8 If equipped with an LNG fuel system,check the LNG fuel tank pressure gaugeto ensure that pressure is within the nor-mal range of 120 to 150 psi (827 to 1034kPa). In the unlikely event that tank pres-sure exceeds 230 psi (1586 kPa) and thepressure relief valve does not open auto-matically, vent the tank immediately.

10.9 Inspect the LNG vaporizer, if equipped, forsigns of damage or leaks. See Fig. 11.6 .

Inspect the vaporizer mounting bracketsfor signs of looseness.

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1. Pressure ControlRegulator

2. Vapor Shutoff Valve3. Fuel Fill Hose4. Secondary Relief

Valve (red cap)5. Fuel Fill Fitting6. Fuel Level Sender

Box

7. Primary Relief Valve8. Tank Pressure Gauge9. Fill Vent Fitting10. Excess Flow Valve11. Fuel Shutoff Valve

(liquid)12. Fill Check Valve

Fig. 11.4, LNG Tank Plumbing Components


11.7

10.10 Inspect the LNG vaporizer overpressureregulator, if equipped, for signs of damageor leaks.

11. Inspect the front and rear suspension compo-nents, including springs, spring hangers, shocks,and suspension brackets.

11.1 Check for broken spring leaves, looseU-bolts, cracks in the suspensionbrackets, and loose fasteners in the springhangers and shackles.

11.2 Inspect the shock absorbers for loose fas-teners and leaks.

11.3 Tighten all loose fasteners and have anycomponent(s) replaced that are worn,cracked, or otherwise damaged.

11.4 On vehicles with air suspensions, checkfor leaks. Check air suspension compo-nents for cuts and bulges.

12. Clean the windshield, side, and rear windowswith a long-handled or telescoping window clean-ing device and standard cleaning solutions.Stand only on the ground, on a stepladder, or anelevated walkway. The cab entry/exit steps andhandholds are not designed for this purpose. Thetires, fenders, engine, and other under-hood

components do not have adequate gripping sur-faces and handholds.

Check the condition of the windshield wiper armsand blades.

Be sure the windshield wiper blades are ten-sioned against the windshield.

Inspect the wiper blades for damage and deterio-rated rubber.

Replace the wiper arms if the wiper blades arenot tensioned against the windshield.

Replace damaged or deteriorated wiper blades.

WARNINGWhen cleaning windshields and windows, alwaysstand on the ground or on a secure ladder orplatform. Use a long-handled window cleaner. Donot use the cab steps, tires, fenders, fuel tanks,engine, or under-hood components to access thewindshield or windows. Doing so could cause afall and result in an injury.

13. After starting the engine, make sure the oil- andair-pressure warning systems are operating andthat the buzzer stops sounding when the presetminimum is reached.

If the warning systems do not come on when theignition is turned on, have the systems repaired.

The air pressure in both the primary and second-ary air reservoir systems must be above 65 psi(448 kPa) on most vehicles. For vehicles with anoptional Bendix dryer reservoir module (DRM),the cut-out pressure is 130 psi (896 kPa).

NOTE: If the air pressure in both systems isabove the preset minimum when the engine isstarted, test the low air pressure warning sys-tem by lowering the pressure to below thisrange, or until the warning system comes on.

14. Check the instrumentation control unit (ICU) forfault codes.

During the ignition sequence, if an active fault isdetected in any device that is connected to theECU, the message display screen will show theactive fault codes, one after the other, until theparking brake is released or the ignition switch isturned off. See Chapter 2 for detailed operatinginstructions for the ICU.

HIGH PRESSURE PRESSURELOW

CYLINDERSINSPECT CYLINDERS

EVERY 36 MONTHSOR 36000 MILES

WHICHEVER OCCURS FIRST

NATURALGAS

VEHICLE110 PSIG

ON

MANUAL

SHUT O

FFVALV

EOPEN VALVE

SLOWLY3600 PSIG MAX.

SERVICE PRESSURE

REGULATOR

FILTER

INSPECT PRESSURERELIEF DEVICE

EVERY 2000 MILES

DRAIN HOUSINGEVERY 1500 MILESREPLACE ELEMENTEVERY 3000 MILES

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1. High Pressure Gauge2. Low Pressure Gauge3. Manual Fuel Shutoff Valve4. Fuel Fill Port

Fig. 11.5, CNG Fuel Panel


11.8

15. Make sure that the horn, windshield wipers, andwindshield washers are operating properly.These devices must be in good working order forsafe vehicle operation.

15.1 Make sure that the horn works. If a horn isnot working, have it repaired before tripdeparture.

15.2 Check the wiper and washer control onthe multifunction turn signal switch. If thewipers and/or washers are not working,have them repaired before trip departure.

16. During cold weather, make sure the heater, de-froster, and optional mirror heat controls are op-erating properly. If so equipped, turn on the mir-ror heat switch and make sure the system isworking.

17. Check the operation of all the panel lights andinterior lights.

Turn on the headlights, dash lights, and four-wayflashers and leave them on. If any of the gaugebulbs, the dome light bulbs, or the right- and left-turn indicator bulbs are not working, replacethem.

18. Make sure all the exterior lights are workingproperly.

Check that all the lights and reflectors are clean.See Fig. 11.7 .

18.1 Check that the brake lights, taillights,headlights, parking lights, turn signals,marker lights, identification lights, roadlights (if so equipped), and front clearancelights are working properly and are clean.

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1. Pressure Relief Device2. Fuel Inlet Line3. Check Valve4. CNG Quick-Connect Port

5. Coolant Inlet Line6. Vaporizer7. Fuel Shutoff Solenoid Valve8. Coolant Outlet Line

9. Pressure Gauge10. Overpressure Regulator11. Pressure Relief Valve12. Fuel Outlet Line

Fig. 11.6, LNG Vaporizer Assembly


11.9

18.2 Test the high and low beams of the head-lights.

18.3 Replace light bulbs or sealed beam unitsthat are not working.

18.4 Be sure all reflectors and lenses are ingood condition and are clean. Replaceany broken reflectors or lenses.

19. Check tire inflation pressures using an accuratetire pressure gauge.

Tires should be checked when cool. For inflationpressures and maximum loads (per tire) see thetire manufacturer’s guidelines.

19.1 Be sure valve stem caps are on every tireand that they are screwed on finger-tight.

19.2 Inflate the tires to the applicable pressuresif needed.

19.3 If a tire has been run flat or underinflated,check the wheel for proper lockring andside-ring seating, and possible wheel, rim,or tire damage before adding air.

Moisture inside a tire can result in bodyply separation or a sidewall rupture. Dur-ing tire inflation, compressed air reservoirsand lines must be kept dry. Use well-maintained inline moisture traps and ser-vice them regularly.

WARNINGDo not operate the vehicle with underinflated oroverinflated tires. Incorrect inflation can stressthe tires and make the tires and rims more sus-ceptible to damage, possibly leading to rim ortire failure and loss of vehicle control, resultingin serious personal injury or death.

IMPORTANT: The load and cold inflation pres-sure must not exceed the rim or wheel manu-facturer’s recommendations, even though thetire may be approved for a higher load inflation.Some rims and wheels are stamped with amaximum load and maximum cold inflation rat-ing. If they are not stamped, consult the rim orwheel manufacturer for the correct tire inflationpressure for the vehicle load. If the load ex-ceeds the maximum rim or wheel capacity, theload must be adjusted or reduced.

CAUTIONA weekly pressure loss of 4 psi (28 kPa) or morein a tire may indicate damage. The tire should beinspected and, if necessary, repaired or replaced.

20. Inspect each tire for wear, bulges, cracks, cuts,penetrations, and oil contamination.

20.1 Check the tire tread depth. If tread is lessthan 4/32 inch (3 mm) on any front tire, orless than 2/32 inch (1.5 mm) on any reartire, replace the tire.

20.2 Inspect each tire for bulges, cracks, cuts,and penetrations.

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NOTE: The parking lights, front clearance lights, andtaillights all function as turn signals.

1. Utility Light2. Identification Light3. Marker Lights4. Front Clearance Light

5. Headlight Low Beam6. Headlight High Beam7. Parking Light8. Road Light

Fig. 11.7, Exterior Lights


11.10

20.3 Inspect each tire for oil contamination.Fuel oil, gasoline, and other petroleumderivatives, if allowed to contact the tires,will soften the rubber and destroy the tire.

21. Check the wheel nuts or rim nuts for indicationsof looseness. Examine each rim and wheel com-ponent.

21.1 Remove all dirt and foreign material fromthe assembly. Dirt or rust streaks from thestud holes, metal buildup around studholes, or out-of-round or worn stud holesmay be caused by loose wheel nuts. SeeFig. 11.8 and Fig. 11.9 .

21.2 Examine the rim and wheel assemblycomponents (including rims, rings, flanges,studs, and nuts) for cracks, or other dam-age.

See Group 33 or Group 35 of theBusiness Class® M2 Workshop Manual forservice procedures on the studs and hubs,and see Group 40 in the same manual forwheel and tire servicing, or take the ve-hicle to an authorized Freightliner dealer.

WARNINGHave any worn or damaged wheel componentsreplaced by a qualified person using the wheelmanufacturer’s instructions and the wheel indus-try’s standard safety precautions and equipment.Otherwise a vehicle or workshop accident could

occur, possibly resulting in serious personal in-jury or death.

21.3 Have broken, cracked, badly worn, bent,rusty, or sprung rings and rims replaced.Be sure that the rim base, lockring, andside ring are matched according to sizeand type.

21.4 Make sure all wheel nuts are tightened450 to 500 lbf·ft (610 to 678 N·m) for Ac-curide wheels with unlubricated threads.Use the tightening pattern in Fig. 11.10 for10-hole wheels and the tightening patternin Fig. 11.11 for 8-hole wheels. SeeGroup 40 of the Business Class® M2Workshop Manual for more information.

NOTICEInsufficient wheel nut torque can cause wheelshimmy, resulting in wheel damage, stud break-age, and extreme tire tread wear. Excessivewheel nut torque can break studs, damagethreads, and crack discs in the stud hole area.Use the recommended torque values and followthe proper tightening sequence.

NOTE: Vehicles operating under severe or ad-verse conditions should be checked more fre-quently.

22. Inspect the air brake chamber and the air brakechamber pushrods.

WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol resulting in property damage or personalinjury.

22.1 Check that the air brake chamber ismounted securely on its mounting bracket,and that there are no loose or missingbolts.

22.2 Look for worn clevis pins on brake cham-ber pushrods and missing or damagedcotter pins on brake chamber pushrod cle-vis pins. Replace worn clevis pins and in-stall new cotter pins if necessary.

02/09/95 f400058

Fig. 11.8, Dirt and Rust Streaks from the Stud Holes


11.11

22.3 See if the chamber piston rod is in linewith the slack adjuster. Misalignment cancause the piston rod to rub on the non-pressure chamber and cause a draggingbrake. See Group 42 of the BusinessClass® M2 Workshop Manual.

CAUTIONIf the external breather tube or breather cap ismissing or incorrectly installed, road dirt and de-bris can adversely affect the operation of thebrake chamber. Once inside of the chamber, dirtand debris can cause the internal parts of thechamber to deteriorate faster.

22.4 Inspect the exterior surfaces of the cham-ber for damage. Make sure that breatherholes in the non-pressure section(s) areopen and free of debris. See Group 42 ofthe Business Class® M2 WorkshopManual to replace any damaged parts.

DANGERDo not loosen or remove the parking brake clampring for any purpose. The parking/emergencybrake section of the brake chamber is not in-tended to be serviced. Serious injury or deathmay result from sudden release of the powerspring.

02/09/95 f400001

Fig. 11.9, Worn Stud Holes

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6

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9

10

f400081a08/23/93

Fig. 11.10, Tightening Pattern, 10-Hole Wheels

f400052a

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08/20/93

Fig. 11.11, Tightening Pattern, 8-Hole Wheels


11.12

Before doing any repairs or adjustments on aservice/parking brake chamber, read the appli-cable warnings and instructions in Group 42 ofthe Business Class ® M2 Workshop Manual .

22.5 On all parking brake installations, makesure the end cover cap or dust plug is se-curely snapped into place. See Fig. 11.12 .

NOTE: On most MGM parking brake cham-bers equipped with an integral release bolt,an end cover cap is installed over the re-lease bolt.

22.6 Check for rusted connections, missingsnap rings, and damaged camshaftgrease seals. Have damaged or missingparts repaired or replaced.

23. Inspect the air brake lines.

23.1 Check the clearance between the hosesand the exhaust manifold or other hotspots. Excessive heat will cause materialin the hoses to deteriorate rapidly or be-come brittle. Provide at least 6 inches(150 mm) of clearance. More clearance isrecommended if the hose is located abovethe heat source.

23.2 Check for kinks, dents, or swelling of thehoses. If damaged, have the hose re-placed with the same size and type.

NOTE: Do not route the hose on top of any-thing likely to be stepped on.

23.3 Check for damage to hoses located nearmoving parts, such as drivelines, kingpins,suspensions, and axles. If moving partsare catching or pinching the lines, correctas needed.

23.4 Check for hose damage caused by abra-sion. If abraded, have the hose replaced.Check for the cause of abrasion, such asloose or damaged hose clamps. Have theclamps repaired or replaced as needed.

23.5 Observe the hose cover condition, espe-cially hoses exposed to water splash andice. If dried out or ragged (the wire or lineris showing through the cover), have thehose(s) replaced.

23.6 Inspect the air tubing, especially tubingmade of nylon. In cold weather, nylon tub-ing is sensitive to damage, such as nicksor cuts. Have nicked or cut tubing re-placed, even if it is not leaking.

23.7 Check for kinked or twisted hoses. Aseven-percent twist in the hose can re-duce its life by up to 90 percent. A twistedhose under pressure tends to untwist,which may loosen the fitting. Reconnecthoses that are twisted.

NOTE: The front brake lines flex continu-ously in vehicle operation, so they requirespecial examination. Give particular attentionto the areas near where they connect to thefront air brake chambers. This inspectionrequires two people, one in the driver seatand another to inspect the brake line con-nections at the wheels.

23.8 Both wheel air lines must be inspectedwith the emergency brake set, engineidling, air pressure at 80 to 90 psi (550 to620 kPa), and the brake pedal held down.

23.9 Turn the wheels to full lock in one direc-tion and inspect both air lines where theyconnect to the air chambers, then turn the

1

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02/22/2000 f421352

A. Do not remove this clamp ring.1. MGM TR–T (TR Series) Brake Chamber shown

Fig. 11.12, Parking Brake Chamber Clamp


11.13

wheels to full lock in the other directionand inspect both lines. If a hose is leak-ing, have it replaced.

IMPORTANT: ABS-equipped vehicles operat-ing in regions where especially corrosiveice-removal chemicals are used may experi-ence higher than normal rotor corrosion.Tone rings should be routinely inspected forcorrosion. Severe corrosion of the integralABS tone ring may cause the ABS warninglamp in the dash to illuminate due to falsewheel speed readings. If the ABS warninglamp illuminates at any time other than atvehicle start-up, have the problem repairedimmediately.

24. Inspect the slack adjusters.

24.1 Meritor Slack Adjusters: Check the bootfor cuts, tears, or other damage. Have itreplaced if necessary.

24.2 Gunite Slack Adjusters: Inspect the slackadjuster for any signs of damage. If dam-aged, have the slack adjuster replaced.

Inspect the slack adjuster boot for cuts ortears. If the boot is damaged, have it re-placed. See Fig. 11.13 .

24.3 Haldex Slack Adjusters: Inspect eachslack adjuster and anchor strap for dam-age. See Fig. 11.14 . Have any damagedcomponents replaced.

25. Check the air brake system for proper operation.

25.1 Check the air governor cut-in and cut-outpressures as follows.

Run the engine at fast idle. The air gover-nor should cut out the air compressor atapproximately 120 psi (827 kPa). With theengine idling, apply the brake pedal sev-eral times. The air governor should cut inthe air compressor at approximately 100psi (689 kPa). If the air governor does notcut in and out as described above, it mustbe adjusted to these specifications. If theair governor cannot be adjusted or re-paired, replace it before operating the ve-hicle.

25.2 Check the air pressure buildup time asfollows.

With the air system fully charged to 120psi (827 kPa), make one full brake appli-cation and note the air pressure readingon the gauge. Continue to reduce the airpressure by moderate brake applicationsto a maximum of 90 psi (620 kPa), thenrun the engine at governed rpm. If thetime required to raise the air pressure to120 psi (827 kPa) (from the pressurenoted after one brake application) is morethan 30 seconds, eliminate any leaks orreplace the air compressor before operat-ing the vehicle.

25.3 Check the air pressure reserve as follows.

With the air system fully charged to 120psi (827 kPa), stop the engine and notethe air pressure. Then make one full brakeapplication and observe the pressuredrop. If it drops more than 25 psi (172kPa), all areas of leakage must be elimi-nated before operating the vehicle.

25.4 Check the air leakage in the system asfollows.

f42139806/17/2003

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1. 7/16-inch AdjustingNut

2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston

Rod

6. Clevis7. 1/2-inch Clevis Pin8. 1/4-inch Clevis Pin9. Grease Relief

Opening10. Slack Adjuster Spline

Fig. 11.13, Gunite Automatic Slack Adjuster


11.14

With the parking brake (spring brake) ap-plied, the transmission out of gear, andthe tires chocked, charge the air systemuntil cut-out pressure of 120 psi (827 kPa)is reached.

With the service brakes released, shutdown the engine, wait 1 minute and notethe air pressure gauge reading. Observethe air pressure drop in psi (kPa) perminute.

Charge the air system until cut-out pres-sure of 120 psi (827 kPa) is reached. Withthe parking brakes released and the ser-vice brake applied, shut down the engine,wait 1 minute and note the air pressuregauge reading. Observe the air pressuredrop in psi (kPa) per minute.

If leakage exceeds the limits shown inTable 11.4 , repair all areas of leakage be-fore driving the vehicle.

Maximum Allowable Service Brake Air Leakage

DescriptionAir Leakage in psi(kPa) Per Minute

Released AppliedTruck or Tractor Only 2 (14) 3 (21)Truck or Tractor w/Single Trailer 3 (21) 4 (28)Truck or Tractor w/Two Trailers 5 (35) 6 (42)

Table 11.4, Maximum Allowable Service Brake AirLeakage

26. Check the operation of the Bendix Hydro-Max®

brake booster, if equipped, as follows.

26.1 With the engine off, depress the brakepedal; the warning light and buzzer shouldcome on, and the electric motor shouldrun.

26.2 Start the engine and allow the gauges tosweep. Depress the brake pedal; no warn-ing lights, buzzer, or electric motor shouldcome on.

27. Test the service brakes.

When starting to move the vehicle and beforepicking up speed, test the brakes with the footpedal and parking brake control valve (yellowknob) to be sure they will bring the vehicle to asafe stop.

Weekly Post-Trip Inspection andMaintenance

WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.

1. Inspect the batteries and battery cables.

1.1 Access the batteries. Be sure the batteryhold-down is secure. If it is loose, tightenthe hold-down bolts; if it is broken, replaceit.

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A. Rotate the control arm toward the brake chamberuntil you can feel it contacting the internal stop.

1. Clevis2. Slack Adjuster3. Clevis Pin4. Manual Adjusting Nut5. Control Arm

6. Control-Arm Washersand Nut

7. Anchor Strap Slot8. Anchor Strap9. Brake Chamber

Fig. 11.14, Haldex Automatic Slack Adjuster


11.15

1.2 If the battery is equipped with a built-inhydrometer, examine the hydrometer. If agreen dot shows in the sight glass, thebattery is sufficiently charged.

If the sight glass is dark, the charge is lowand the battery must be recharged.

If the sight glass is clear, the battery has alow level of electrolyte and must be re-placed.

2. Check the level of the wheel bearing lubricant inthe hub cap at each end of the front axle.

If needed, fill the hubs to the level indicated onthe hub cap. See Group 35 of the BusinessClass® M2 Maintenance Manual, for recom-mended lubricants.

IMPORTANT: Before removing the fill plug, al-ways clean the hub cap and plug.

3. Examine the steering components.

See Fig. 11.15 . If repairs are needed, seeGroup 46 of the Business Class® M2 WorkshopManual for instructions, or take the vehicle to anauthorized Freightliner dealer.

3.1 Check the mounting bolts and pitman armnut for tightness.

3.2 Check the drag link nuts for missing cotterpins.

3.3 Inspect the steering drive shaft and steer-ing linkage for excessive looseness, orother damage.

3.4 Tighten loose nuts and have damagedparts replaced as needed.

4. Check the condition of the serpentine drive belt.

Look for signs of glazing, wear (frayed edges),damage (breaks or cracks), or oil contamination.If a belt is glazed, worn, damaged, or oil soaked,have the belt replaced, following the instructionsin Group 01 of the Business Class® M2 Work-shop Manual.

NOTICEDo not drive with a serpentine belt that is visiblyworn or damaged. If it fails, the lack of coolantflow could rapidly cause damage to engine com-ponents.

5. Check the drive belt for proper tension.

Use your index finger to apply force at the centerof the belt free-span. See Fig. 11.16 . There is noadjustment for belt tension on engines with auto-matic belt tensioners. If there is not proper ten-sion, have the belt tensioner replaced. SeeGroup 01 of the Business Class® M2 WorkshopManual for instructions, or take the vehicle to anauthorized Freightliner dealer.

6. Inspect the seat belts and tether belts.

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1. Steering Gear Mounting Bolt2. Pitman Arm Pinch Bolt Nut3. Drag Link Nut

Fig. 11.15, Steering Gear Fasteners

10/31/94 f200036a

A

B

A. Deflection B. Belt Free-Span

Fig. 11.16, Checking Belt Tension


11.16

WARNINGInspect and maintain seat belts as instructedbelow. Worn or damaged seat belts could failduring a sudden stop or crash, possibly resultingin serious injury or death.

IMPORTANT: Seat belts have a finite lifewhich may be much shorter than the life ofthe vehicle. Regular inspections and re-placement as needed are the only assur-ance of adequate seat belt security over thelife of the vehicle.

NOTE: When any part of a seat belt needsreplacement, the entire seat belt must bereplaced, both retractor and buckle side.

6.1 Check the web for fraying, cuts, or ex-treme wear, especially near the bucklelatch plate and in the D-loop guide area.

6.2 Check the web for extreme dirt or dustand for severe fading from exposure tosunlight.

6.3 Check the buckle and latch for operationand for wear or damage.

6.4 Check the Komfort Latch or Sliding Kom-fort Latch (if equipped) for function andcracks or other damage.

6.5 Check the web retractor for function anddamage.

6.6 Check the mounting bolts for tightnessand tighten any that are loose.

Monthly Post-Trip Inspection andMaintenance

WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.

1. Clean the batteries.

1.1 Remove any corrosion from the hold-downand the top of the battery.

NOTICETake care to keep the vent plugs tight so that theneutralizing solution does not enter any of thebattery cells and damage the battery.

1.2 Use a soda solution to neutralize the acidpresent, then rinse off the soda solutionwith clean water.

1.3 If the battery posts or cable terminals arecorroded, disconnect the terminals fromthe posts. Clean them with a soda solutionand a wire brush. After cleaning, connectthe terminals to the battery posts, thenapply a thin coat of petroleum jelly to theposts and terminals to help retard corro-sion.

2. Inspect the radiator and heater hoses, includingthe clamps and support brackets.

2.1 Make sure the radiator inlet and outlethoses are pliable and are not cracking orballooning. Replace hoses that show signsof cracking, weakening, or ballooning.

2.2 Make sure the heater hoses are pliableand are not cracking or ballooning. Re-place hoses that show signs of cracking,weakening, or ballooning.

2.3 Tighten hose clamps as necessary, but donot overtighten, as hose life can be ad-versely affected.

2.4 Be sure the hose support brackets aresecurely fastened. Make sure the hosesare not located near sources of wear,abrasion, or high heat.

IMPORTANT: Replace all hoses, includingheater hoses, at the same time. Service-typeknitted or braided yarn-reinforced neoprenehose is acceptable. Silicone hoses having anextended service life can be substituted for thereinforced neoprene type. See the FreightlinerService Parts Catalog or contact your Freight-liner Dealer.

3. Check the steering wheel for excessive play.


11.17

3.1 Start the engine. With the front tiresstraight ahead, turn the steering wheeluntil motion is observed at the frontwheels.

3.2 Align a reference mark on a ruler, thenslowly turn the steering wheel in the oppo-site direction until motion is again detectedat the wheels.

3.3 Check the lash (free play) at the rim of thesteering wheel. See local/federal regula-tions for acceptable ranges of lash.

If there is excessive lash, check the steer-ing system for wear or incorrect adjust-ment of the linkage and steering gear be-fore operating the vehicle.

4. Check the brake lining wear on all vehicles, in-cluding those with automatic slack adjusters.Proper brake operation is dependent on periodicmaintenance and inspection of the brake linings.

4.1 Check that brake linings are free of oil andgrease.

4.2 Inspect the thickness of the brake linings.If the axle assembly is equipped with adust shield or backing plate, remove theinspection plugs. If any brake linings areworn to less than approximately 1/4 inch(6.4 mm) at the thinnest point, have thelinings replaced on all brake assemblieson that axle. See Group 42 of theBusiness Class® M2 Workshop Manual forlining replacement instructions and cam-shaft end-play inspection.

4.3 Check the brake drums for wear andcracks.

4.4 Check that the inspection plugs in the dustshields or backing plates, if so equipped,are installed.

5. Leak test the natural gas fuel system, ifequipped.

Use a methane detector to test all fuel systemcomponents, joints, and fittings for leaks. Abubble solution can be used to pinpoint the exactlocation of leaks.

Replace any leaking or damaged fuel tanks andfuel lines; repair or replace leaking or damagedfittings.

6. Drain the CNG high-pressure fuel filter housing,if equipped.

6.1 Purge the CNG fuel lines by closing theCNG fuel cylinder shutoff valves. Start theengine and let it idle until the fuel lines areempty and the engine stops.

Gauges on the fuel panel should now readat or near 0 psi (0 kPa).

6.2 Close the manual fuel shutoff valve on thefuel panel.

6.3 Remove the two capscrews that securethe access cover to the fuel panel, thenremove the access cover. See Fig. 11.17 .Save the capscrews for installation.

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56

7

8

1

1. Fuel Panel AccessCover

2. Capscrews (qty 2)3. Wiring Harness4. Pressure Relief Valve

and Cap

5. Coolant Outlet Line6. Coolant Inlet Line7. Fuel Inlet Line (to fuel

cylinders)8. Fuel Outlet Line (to

engine)

Fig. 11.17, CNG Fuel Panel Assembly


11.18

6.4 Slowly open the bleed valve on the mani-fold to relieve remaining fuel pressurewithin the system. See Fig. 11.18 .

IMPORTANT: Some pressure may remain inthe fuel system between the solenoid valveand the engine. Use caution when looseningfittings, as a small amount of gas may leakout.

6.5 Put a clean receptacle under the filter as-sembly.

6.6 Using an 11/16-inch wrench, remove thedrain plug from the filter bowl.

When all liquid has drained, install andtighten the drain plug on the filter bowl.

6.7 Close the bleed valve on the manifold andopen the manual fuel shutoff valve on thefuel panel.

Open the fuel cylinder shutoff valves.

6.8 Use a methane detector to leak test allfuel system components between the fuelcylinders and the solenoid valve. A bubblesolution can be used to pinpoint the exactlocation of leaks.

Repair or replace any leaking compo-nents.

6.9 Using the two capscrews removed in sub-step 6.3, install the access cover on thefuel panel.

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910111213141

2

3

4

5

1. Coolant Inlet Port2. Coolant Outlet Port3. Pressure Relief Valve4. Pressure Regulator5. Wiring Harness6. Manifold Bleed Valve7. Manifold8. Manual Fuel Shutoff

Valve

9. Fuel Fill Port10. Filter Housing11. Filter Bowl12. Filter Drain Plug13. Solenoid Valve14. Fuel Line To Cylinders

Fig. 11.18, CNG Fuel Panel Components


11.19

12

Cab AppearanceCab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2

Cab Washing and Polishing

CAUTIONWhen pressure washing the vehicle or leavingthe hood open when parked outdoors and sub-ject to rain, cover the air cleaner inlet with a plas-tic bag to prevent water from entering the air in-take system and possibly damaging the engine.

To protect the finish of your new vehicle, follow theseguidelines carefully:

• During the first 30 days, rinse your vehicle fre-quently with water. If the vehicle is dirty, use amild liquid soap. Do not use detergent.

• During the first 30 days, do not use anythingabrasive on your vehicle. Brushes, chemicals,and cleaners may scratch the finish.

• During the first 120 days, do not wax yourvehicle.

To extend the life of your vehicle’s finish, follow theseguidelines:

• Avoid washing your vehicle in the hot sun. Al-ways use water. After the cab is completelywashed, dry it with a towel or chamois.

• Do not dust painted surfaces with a dry cloth,as this will scratch the paint.

• Do not remove ice or snow from a painted sur-face with a scraper of any sort.

• To prevent damage to the finish, wax it regu-larly. If the finish has become dull, before wax-ing, remove oxidized paint using a cleaner spe-cifically designed for this purpose. Remove allroad tar and tree sap before waxing. Freight-liner recommends that a quality brand ofcleaner or cleaner-polish and polishing wax beused.

• Do not let diesel fuel or antifreeze stand on apainted surface. If either should occur, rinsethe surface off with water.

• To prevent corrosion, have any nicks or otherdamage on the finish touched up as soon aspossible.

• Park your vehicle in a sheltered area wheneverpossible.

Care of Fiberglass PartsWash unpainted fiberglass air fairings and shieldsmonthly with a mild detergent, such as dishwashingliquid. Avoid strong alkaline cleansers.

Apply a wax specifically designed for fiberglass.

Care of Chrome PartsTo prevent rust, keep chrome parts clean and pro-tected at all times. This is especially important duringwinter driving and in coastal areas where there isexposure to salt air.

When cleaning chrome parts, use clean water and asoft cloth or sponge. A mild detergent may also beused.

Sponge gently, then rinse. If necessary, use a non-abrasive chrome cleaner to remove stubborn rust orother material. Do not use steel wool.

To help protect the chrome after cleaning, apply acoat of polishing wax to the surface. Never use waxon parts that are exposed to high heat, such as ex-haust pipes.

Care of Exterior LightsClean the headlight lenses by hand only, using aflannel cloth with mild, non-caustic soap or detergent,and water.

CAUTIONDo not use a power buffer, paper towels, chemi-cal solvents, or abrasive cleaners on the head-light lens, all of which can remove the UV coatingfrom the surface, and result in yellowing of thelens.

Dashboard CarePeriodically wipe the dashboard with a water-dampened cloth. A mild detergent can be used, butavoid using strong detergents.

CAUTIONDo not use Armor-All Protectant ®, STP Son-of-a-Gun®, or other equivalent treatments. Thesecleaners contain vinyl plasticizers that can cause

Cab Appearance

12.1

stress crazing in the interior plastic panels,which can result in cracking of the panels.

Vinyl Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Harshcleaning agents can cause permanent damage tovinyl upholstery. To preserve the upholstery and pre-vent damage, carefully review the following sectionsfor recommended cleaning procedures. Waxing orrefinishing improves soil resistance and cleanabilityfor all vinyls. Any hard wax, such as that used onautomobiles, may be used.

Ordinary DirtWash the upholstery with warm water and mild soap,such as saddle or oil soap. Apply soapy water to alarge area and allow to soak for a few minutes, thenrub briskly with a cloth to remove the dirt. This canbe repeated several times as necessary.

If dirt is deeply imbedded, use a soft bristle brushafter applying the soap.

If dirt is extremely difficult to remove, wall-washingpreparations normally found around the home can beused. Powdered cleaners, such as those used forsinks and tiles, are abrasive and must be used withcaution as they can scratch the vinyl or give it a per-manent dull appearance.

Chewing GumHarden the gum with an ice cube wrapped in a plas-tic bag, then scrape it off with a dull knife. Any re-maining traces of gum can be removed with an all-purpose light oil (peanut butter will also work) andwiped off.

Tars, Asphalts, and CreosoteTars, asphalts, and creosote stain vinyl after pro-longed contact. They should be wiped off immedi-ately and the area carefully cleaned, using a clothdampened with naphtha.

Paint, Shoe Heel MarksPaint should be removed immediately. Do not usepaint remover or liquid-type brush cleaner on vinyl.An unprinted cloth, dampened with naphtha or tur-

pentine may be used. Use care to prevent contactwith parts of the upholstery that are not vinyl.

Sulfide StainsSulfide compounds, such as those found in eggs andsome canned goods, can stain after prolonged con-tact with vinyl. These stains can be removed by plac-ing a clean, unprinted piece of cloth over the spottedarea and pouring a liberal amount of 6 percent hy-drogen peroxide onto the cloth. Allow the saturatedcloth to remain on the spot for 30 to 60 minutes. Forstubborn spots, allow the hydrogen-peroxide satu-rated cloth to remain on the area overnight. Use cau-tion to prevent the solution from seeping into theseams or it will weaken the cotton thread.

Nail Polish and Nail Polish RemoverProlonged contact with these substances causes per-manent damage to vinyl. Careful blotting immediatelyafter contact minimizes damage. Do not spread theliquid during removal.

Shoe PolishMost shoe polishes contain dyes which penetratevinyl and stain it permanently. Shoe polish should bewiped off as quickly as possible using naphtha orlighter fluid. If staining occurs, try the procedure usedfor sulfide stains.

Ball Point InkBall point ink can sometimes be removed if rubbedimmediately with a damp cloth, using water or rub-bing alcohol. If this does not work, try the procedureused for sulfide stains.

MiscellaneousIf stains do not respond to any of the treatments de-scribed above, it is sometimes helpful to expose thevinyl to direct sunlight for up to 30 hours. Mustard,ball point ink, certain shoe polishes, and dyes oftenbleach out in direct sunlight leaving the vinyl undam-aged.

Velour Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Spotclean with a mild solvent or an upholstery shampoo,

Cab Appearance

12.2

or the foam from a mild detergent. When using a sol-vent or a dry-cleaning product, follow the instructionscarefully and clean only in a well-ventilated area.Avoid any product that contains carbon tetrachlorideor other toxic materials. With either method, pretest asmall area before proceeding. Use a professionalupholstery cleaning service when extensive cleaningis needed.

Grease and Oil-Based StainsDampen a small absorbent cloth with dry-cleaningsolvent or spot remover. Apply the cloth carefully tothe spot from the outer edge to the center. Pat andblot the spot with a clean, dry cloth. Repeat severaltimes, as necessary, turning the cloths so that thestain does not redeposit on the fabric.

Sugar and Water-Based StainsApply water-based detergent or cleaner, working incircular motions. Pat and blot as dry as possible. Re-peat if necessary before drying thoroughly.

Chewing Gum or WaxHarden the gum or wax with an ice cube wrapped ina plastic bag, then scrape it off with a dull knife. Ex-cess wax can be absorbed by placing a thick whiteblotter over the wax and heating with a warm (nothot) iron. Remove the remainder by using the proce-dure for grease and oil-based stains.

MildewBrush the dry fabric with a soft brush. Sponge withdetergent, and blot. If the fabric is colorfast, dilute ateaspoon of bleach in one quart (one liter) of coolwater. Apply with a swab, directly on the mildewstain. Dab repeatedly with clear, cool water, and blotdry.

Cab Appearance

12.3

13

In an EmergencyHazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Emergency Filter Replacement, Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6

Hazard Warning LightsThe hazard warning light flasher (Fig. 13.1 ) is part ofthe multifunction turn signal switch. It is a red rockerswitch located on the top of the multifunction switchmodule.

To flash the hazard warning lights, press down onthe upper part of the rocker (towards the dash). Tostop the hazard warning lights, press down on thelower part of the rocker (towards the steering wheel).

Fire ExtinguisherA fire extinguisher is located in the cab by the driv-er’s door.

Emergency Kit, OptionalAn optional emergency kit is located in the cab. Thekit includes one or more of the following: a first aidkit, a reflective vest, a triangular reflector, a flare kit,and (on vehicles with a Davco fuel/water separator) aspin-on fuel filter element.

If there is an emergency while driving, cautiously pulloff the road. Turn on the hazard warning lights. Placethe flares and reflector along the side of the road toalert other drivers that an emergency situation exists.

WARNINGUse extreme care when placing flares in emer-gency situations that involve exposure to flam-mable substances such as fuel. An explosion orfire could occur causing serious personal injury.

Emergency FilterReplacement, DavcoIf the filter cover on the Davco fuel/water separator isbroken, it will not be possible to operate the vehicle.A standard spin-on filter will correct this problem.

Refer to the Davco web site for additional informa-tion, www.davcotec.com .

To replace the filter on all Davco fuel/water separa-tors, follow these procedures:

1. Drain the fuel until it is below the level of the fil-ter collar. See Fig. 13.2 for the model 232/233fuel/water separator and Fig. 13.3 for the model382 fuel/water separator.

2. Remove the filter vent and vent seal.

NOTE: The filter vent and vent seal are notneeded in the emergency replacement. Theyshould be retained for later installation at thetime when the filter cover is replaced.

3. Remove the filter collar using channel-lock pliers.

4. Remove the filter cover, filter cover seal andspring. Retain them for later assembly.

5. Remove the filter element and dispose of it prop-erly.

6. Install the standard engine spin-on filter (includedin the emergency kit) on the threaded stud.

NOTE: Remove the rubber grommet from thestud.

7. Install the filter cover, filter cover seal, andspring, as removed.

8. Install the filter collar over the filter cover. Tightenthe filter collar finger-tight.

9. Start the engine and run it at increased rpm forone minute to purge air from the fuel lines.

f820386

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11/16/2001

Press down on the upper part of the rocker to activatethe flashers.1. Washer Button2. Wiper Control Dial3. Turn Signal Lever4. Hazard Flasher (red)5. Multifunction Switch Module

Fig. 13.1, Hazard Warning Flashers

In an Emergency

13.1

www.davcotec.com

Emergency Starting WithJumper CablesWhen using jumper cables, follow the instructionsbelow.

WARNINGBatteries release explosive gas. Do not smokewhen working around batteries. Put out all flamesand remove all sources of sparks or intense heat

in the vicinity of the battery. Do not allow the ve-hicles to touch each other. Do not lean over thebatteries when making connections, and keep allother persons away from the batteries. Failure tofollow these precautions could lead to severepersonal injury as a result of an explosion oracid burns.

f47041611/14/2001

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3

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5

6

7

8

10

9

1. Filter Vent2. Filter Vent Seal3. Filter Collar4. Filter Cover

5. Filter Cover Seal6. Spring7. Filter Element

8. Threaded Stud9. Fuel Port10. Drain

Fig. 13.2, Davco Model 232 and 233 Fuel/Water Separator

In an Emergency

13.2

CAUTIONMake sure both starting systems have the samevoltage outputs, and avoid making sparks. Other-wise the vehicle charging systems could be se-verely damaged. Also, do not attempt to chargeisolated, deep-cycle batteries with jumper cables.Follow the battery manufacturer’s instructionswhen charging deep-cycle batteries.

NOTE: On vehicles equipped with an optionaljump-start post, attach the positive cable clampto that post instead of to the battery.

1. Apply the parking brakes and turn off the lightsand all other electrical devices.

2. To gain access to the batteries, open the batterycompartment. See Fig. 13.4 . For detailed instruc-tions, see Chapter 2 .

CAUTIONAlways connect the battery, jumper cables, andcharger correctly (positive-to-positive andnegative-to-negative). Connecting a charging de-vice backwards (positive-to-negative) will blowfuses that power the bulkhead module (BHM) and

f470417

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11/14/2001

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11

10

1. Filter Collar2. Filter Vent3. Filter Vent Seal4. Filter Cover

5. Filter Cover Seal6. Spring7. Filter Element8. Threaded Stud

9. Fuel Port10. Drain11. Bottom Plate Collar

Fig. 13.3, Davco Model 382 Fuel/Water Separator

In an Emergency

13.3

chassis module (CHM), and the devices they con-trol will not work.

3. Connect an end of one jumper cable to the posi-tive terminal of the booster battery (or jump-startpost if equipped), and connect the other end ofthe cable to the positive terminal of the dis-charged battery (or jump-start post if equipped).See Fig. 13.5 .

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting insevere personal injury from explosion and acidburns.

4. Connect one end of the second jumper cable tothe negative terminal of the booster battery, andconnect the other end of the cable to a ground atleast 12 inches (300 mm) away from the batter-ies of the vehicle needing the start. The vehicleframe is usually a good ground. Do not connectthe cable to or near the discharged batteries.

WARNINGOn vehicles with Mercedes-Benz AGS transmis-sions, make sure the current gear indicator dis-plays "N" before starting the vehicle. If the trans-mision starts in gear, it could cause an accidentresulting in death, serious personal injury, orproperty damage.

5. Start the engine of the vehicle with the boosterbatteries, and let the engine run a few minutes tocharge the batteries of the other vehicle.

6. Attempt to start the engine of the vehicle with thebatteries receiving the charge. Do not operatethe starter longer than 30 seconds, and wait atleast two minutes between starting attempts toallow the starter to cool.

7. When the engine starts, let it idle a few minutes.

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting insevere personal injury from explosion and acidburns.

8. Disconnect the grounded cable from the frame orother non-battery location, then disconnect theother end of the cable.

9. Disconnect the remaining cable from the newlycharged battery (or jump-start post if equipped)first, then disconnect the other end.

10/24/2001 f543933

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1. Top Step2. Battery

3. Cab4. Battery Access Door

Fig. 13.4, Battery Compartment, Open

+ −

+

−

+

−

+−

f540303a10/18/94

A

B

C

D

E

F

G

21A

E

A. To GroundB. 3rdC. To Frame (ground)D. 4th

E. To StarterF. 2ndG. 1st

1. Booster Battery2. Discharged Battery

Fig. 13.5, Jumper Connections

In an Emergency

13.4

10. Close the battery compartment. For detailed in-structions, see Chapter 2 .

TowingWhen it is necessary to tow the vehicle, make surethe instructions below are closely followed to preventdamage to the vehicle.

WARNINGDo not tow an unbraked vehicle if the combinedweight of both vehicles is more than the sum ofthe gross axle weight ratings (GAWR) of the tow-ing vehicle. Otherwise brake capacity will be in-adequate, which could result in personal injury ordeath.

Front Towing Hookup1. Disconnect the battery ground cables.

CAUTIONFailure to remove the axle shafts when towingthe vehicle with the rear wheels on the groundcould result in damage to the transmission andother parts.

2. Remove both drive axle shafts. On dual driveaxles, if the vehicle is to be lifted and towed, re-move only the rearmost drive axle shafts.

On vehicles equipped with an air fairing, removeboth the forward and rearmost drive axle shafts ifthere is insufficient towing clearance.

3. Cover the ends of the hubs with metal plates orplywood cut to fit the axle opening, and drilled tofit the axle shaft studs. This prevents lubricantfrom leaking out and will keep contaminants fromgetting into and damaging the wheel bearingsand axle lubricant.

CAUTIONFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.

4. On dual drive axles, if the vehicle is to be liftedand towed, chain the forward rear-axle assembly

to the vehicle frame. Use protection to keep thechains from damaging the frame.

5. Remove the bumper end caps and chromebumper (if equipped).

CAUTIONDo not pass a sling (for example, a rope or chain)from one tow hook to another to fasten for tow-ing (see Fig. 13.6). Known as reeving, this prac-tice is not permissible in most industrial applica-tions of towing and hoisting. Reeving canoverload the hooks and result in damage to thevehicle.

6. Attach the towing device. Due to the many vari-ables that exist in towing, positioning the liftingand towing device is the sole responsibility of thetowing-vehicle operator.

7. Lift the vehicle and secure the safety chains. Ifextra towing clearance is needed, remove thefront wheels.

8. Connect the clearance lights, taillights, and sig-nal lights. Connect any special towing lights re-quired by local regulations.

WARNINGFailure to chock the tires or connect the towtruck’s air brake system before releasing thespring parking brakes could allow the disabledvehicle to suddenly roll. This could cause prop-erty damage or personal injury.

9. Chock the tires on the disabled vehicle and con-nect the towing vehicle’s air brake system to thevehicle being towed. Then, release the springparking brakes and remove the chocks.

Rear Towing Hookup

CAUTIONUsing a rear towing hookup on a vehicleequipped with a roof fairing could cause damageto the cab structure.

1. Place the front tires straight forward and securethe steering wheel in this position.

2. Disconnect the battery ground cables.

In an Emergency

13.5

CAUTIONFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.

3. On dual drive axles, using protection to keep thechains from damaging the vehicle frame, chainthe forward-rear drive axle to the frame.

4. Attach the towing device. Due to the many vari-ables that exist in towing, positioning the liftingand towing device is the sole responsibility of thetowing-vehicle operator.

5. Lift the vehicle and secure the safety chains. Ifextra clearance is needed, remove the bumperextension if equipped.

6. Connect the clearance lights, taillights, and sig-nal lights. Also connect any special towing lightsrequired by local regulations.

Fire in the CabThe incidence of fire in medium-duty trucks is rare,according to data from the National Highway Traffic

Safety Administration. Federal Motor Vehicle SafetyStandard #302 limits the flammability of specifiedmaterials used inside the cab, but despite this, mostmaterials will burn. The cab of this vehicle containsurethane foam, which is of concern in this respect.

WARNINGUrethane foam is flammable! Do not allow anyflames, sparks, or other heat sources such ascigarettes or light bulbs to contact urethanefoam. Urethane foam in contact with such heatsources could cause a serious, rapid fire, whichcould result in death, severe burns, or gas poi-soning, as well as damage to the vehicle.

In Case of a Cab FireAs quickly as possible, bring the vehicle to a safestop, apply the parking brake, turn off the ignition,and get out of the vehicle.

f88069401/11/2006

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OK

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12

IMPORTANT: Do not reeve when towing.

1. Tow Hook 2. Chain

Fig. 13.6, Reeving

In an Emergency

13.6

14

Headlight AimingPreliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2

Preliminary ChecksBefore checking or adjusting the headlight aim, dothe following:

• Remove large amounts of mud or ice from theunderside of the fenders.

• Check the springs for sagging or brokenleaves.

• Check the suspension for proper functioning ofthe leveling mechanism. On cabs with air sus-pensions, make sure that the height is properlyadjusted.

• Check for damage to the hood and hinge as-sembly. Repair as necessary.

• With the vehicle unloaded, check that the tiresare inflated to the recommended air pressure.

• Clean the headlight lenses. Clean by handonly, using a flannel cloth with mild, non-caustic soap or detergent, and water.

CAUTIONDo not use a power buffer, paper towels, chemi-cal solvents, or abrasive cleaners on the head-light lens, all of which can remove the UV coatingfrom the surface, and result in yellowing of thelens.

Checking Headlight Aim1. Park the vehicle on a level surface 25 ft (7.6 m)

from a screen or wall that can be used for aimingthe headlights. Shut down the engine, apply theparking brake, and chock the front tires. SeeFig. 14.1 .

NOTE: The low-beam headlight is the top bulbin the dual-beam assembly.

2. On each headlight, find the bulb center. SeeFig. 14.2 .

3. Measure the distance from the ground to thecenter of each low-beam bulb. Note those dis-tances.

f544233

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6

25 ft (7.6 m)

01/20/2003

1. Vertical Centerline of Right Headlight2. Distance Between Headlights3. Vertical Centerline of Left Headlight

4. Projected Vehicle Centerline5. Screen or Wall6. Height of Lamp Centers

Fig. 14.1, Headlight Aiming Screen or Wall

Headlight Aiming

14.1

4. On the screen or wall 25 ft (7.6 m) away, makethe appropriate markings directly across fromeach headlight and at the same height as mea-sured for the headlight.

5. Turn on the headlights to the low-beam setting.See Fig. 14.3 for the ideal and acceptable pat-terns for both headlights.

• If either or both headlights do not aim intothe inner edges of the centerline, follow theadjusting procedure below.

• If both headlights come close to the insideof each headlight centerline (as shown), nofurther work is needed. Turn off the head-lights and remove the chocks from thefront tires.

Adjusting Headlight Aim1. Lift the flap over the rear end of the headlight

bucket to expose the two plastic adjusting knobson each headlight. See Fig. 14.4 .

NOTE: Horizontal aim should not be adjusted inthe field.

2. With the vehicle parked 25 ft (7.6 m) from thescreen or wall, put the headlights on low beams,and turn both adjusting knobs the same amount,as needed to adjust the lights until the beam pat-tern meets the acceptable standard. Turn theknobs clockwise to raise the beam and counter-clockwise to lower it.

NOTE: Blocking off each light is not necessary,but it can help to present a clearer beam pat-tern.

3. Remove the chocks from the front tires.

11/06/2002 f544236

Measure beam height from the ground to the small dotroughly in the center of the headlight lens.

Fig. 14.2, Headlight Beam Height Adjusting Dot

11/11/2002

1

1f544153

A

A

B

B

NOTE: The top view shows the ideal beam pattern; thebottom view shows an acceptable standard.

A. Vertical Centerline B. Horizontal Centerline1. Bright Area

Fig. 14.3, Headlight Beam Pattern

11/05/2002 f544235

1

2

NOTE: The right-hand side headlight bucket is shown.The left-hand side is opposite.1. Inboard Adjusting Knob2. Outboard Adjusting Knob

Fig. 14.4, Headlight Adjusting Knobs

Headlight Aiming

14.2

15

Hybrid Electric VehicleHybrid Electric Vehicle (HEV) Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Safety Precautions (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2Starting, and Engine Shutdown (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2Hybrid System Fault Lamps (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2Emergencies (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Jumpstarting (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Towing (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3

Hybrid Electric Vehicle (HEV)OverviewA hybrid electric vehicle (HEV) has both a diesel en-gine and an electric motor. Engine torque is aug-mented with electrical torque. The electric motor ispowered by batteries, which are charged by regen-erative braking and, on vehicles equipped with theePTO option, the diesel engine.

The batteries cannot move the vehicle for long dis-tances at highway speeds. In the event of a dieselengine failure, drive the vehicle to a safe location asquickly as possible.

Eaton Corporation developed and supplies the hybridelectric system for Freightliner Trucks. The primarysystem components are the hybrid drive unit (or"HDU", which includes the electric generator/motorand automated transmission), power electronics car-rier (PEC), and the motor inverter/controller. Electricpower take-off (ePTO) and auxiliary power generator(APG) components are optional on the HEV system.

Freightliner Trucks designed the stand-alone liquidcooling system required to support the operation ofEaton’s HEV system. Its primary system componentsare the electric water pump, reservoir/expansiontank, radiator, electric radiator fan, and coolantplumbing.

Body builders will develop the components for thePTO, the PTO plumbing, and a safety switch to pre-vent the diesel engine from starting when the hood isopen.

Regenerative BrakingRegenerative braking reduces vehicle speed by con-verting some of the vehicle’s kinetic energy into elec-tric energy to charge the hybrid system’s batteries.When the accelerator pedal is at idle while coasting,or the service brake is depressed to slow the vehicle,the hybrid system charges the batteries.

The regeneration will feel as if the brake is beinglightly applied when you remove your foot from theaccelerator pedal. The full power of the service brakeis always available to the driver, and regenerativebraking is automatically shut off during an ABS (an-tilock brake) event.

The Eaton Hybrid Control Unit will automatically shutoff regenerative braking when the batteries are fullycharged.

High-Voltage Safety FeaturesThe HEV has high-voltage cables and a serviceswitch on the PEC.

High-voltage cables are covered in orange insulationand conduit. Each high-voltage component is taggedwith a warning or danger label.

IMPORTANT: The service switch on the PECshould only be used for an emergency shut-down, or when the service manual or trouble-shooting guide calls for work on the high-voltagesystem. The service manual and troubleshootingguide for the hybrid electric system are availablefrom www.roadranger.com .

The red service switch is located next to the high-voltage cable connections at one end of the PEC.Pushing in the red service switch will shut down theengine. The hybrid system will be disabled, and thehigh-voltage batteries in the PEC, though still live,are isolated in the PEC.

NOTE: The PEC may be mounted in an areawith limited access.

For information on emergency shutdowns, see"Emergencies" in this chapter.

Cooling SystemThe HEV requires a liquid cooling system for theHDU, inverter, DC/DC Converter (if ePTO equipped),and APG (if equipped). The HEV’s cooling system isseparate from the engine cooling system.

For coolant, use a mixture of 50 percent ethyleneglycol and 50 percent water.

Electric Power Take-Off (ePTO)The Electric Power Take-Off (ePTO) option providesstandard hydraulic functions without continuous die-sel engine operation. The PTO drive power is pro-vided by the hybrid motor and hybrid batteries. Whenthe hybrid batteries deplete, the diesel engine auto-matically starts to recharge them and provide PTOdrive power. Once the batteries are fully charged, theengine shuts down automatically. Vehicles with theePTO option are designed with a safety switch toensure the diesel engine does not start when thehood is open.

A DC/DC converter is required for ePTO applicationsto convert high-voltage DC to 12-volt DC.

Hybrid Electric Vehicle

15.1

http://www.roadranger.com

NOTE: To maintain a power supply from the ve-hicle’s low-voltage batteries, the alternatorcharges them when the vehicle is being driven.

Safety Precautions (HEV)The HEV has high-voltage components, including340-volt DC batteries and a 500-volt AC motor.Never cut high-voltage cables or connectors. Do notpaint high-voltage cables.

Avoid direct pressure wash on high-voltage connec-tions (PEC, DC/DC Converter) and the air intake andexhaust on the PEC.

Starting, and Engine Shutdown(HEV)The Cranking SystemThe primary engine starter is the electric motor in theHDU, which cranks the engine very quickly. Theback-up cranking system is the standard 12-voltstarter on the engine. If the hybrid system is offlineor the hybrid batteries are insufficiently charged, thevehicle will automatically use the 12-volt crankingsystem to start the engine.

Starting1. Set the parking brake.

2. Place the key in the ignition, and turn it clock-wise to the ON position to initiate power to thehybrid system.

Wait for the gauges on the instrument panel tocomplete two sweeps (one from left to right, andone from right to left) and return to their normalranges.

3. Ensure the transmission is in neutral. The geardisplay should display a solid "N".

WARNINGNever start the engine unless the transmission isin neutral and the brake is applied. Accidentalmovement of the vehicle could result in propertydamage, personal injury, or death.

4. Turn the key clockwise to the START position.The engine will crank after a brief delay. As soonas the engine starts, release the key, allowing it

to return to the ON position. The engine will con-tinue to run with the key in the ON position.

5. Apply the service brake, then release the parkingbrake.

6. With the service brake applied, press the desiredmode on the shift control to put the vehicle intogear.

7. Slowly release the service brake.

NOTE: The vehicle may be powered by theelectric motor or the diesel engine, dependingon battery charge and the demand for drivelinetorque. If the electric motor alone is poweringthe driveline, the diesel engine will stay at idle.

Engine Shutdown1. Place the transmission in neutral by selecting N

on the shift control.

IMPORTANT: The transmission must be in neu-tral for proper shutdown.


3. Turn the key counterclockwise to the OFF posi-tion.

NOTE: Intermittent noises such as clicking andtransmission shifting may be audible from thetransmission while it completes a self-test andshutdown.

Hybrid System Fault Lamps(HEV)There are two lamps on the dashboard that indicatea hybrid system fault is active — the red STOP HY-BRID lamp and the amber CHECK HYBRID lamp.See Fig. 15.1 . When the red STOP HYBRID lamp isilluminated, do not drive the vehicle; have it towed toa Freightliner dealer or an authorized service centerfor repairs. When the amber CHECK HYBRID lampis illuminated, the vehicle can still be driven, though itmay operate without the assistance of the hybridelectrical system.


15.2

Emergencies (HEV)Emergency Shutdown

WARNINGAfter disabling the vehicle, power is maintainedin the high-voltage electrical system for up to fiveminutes. Unprotected contact with any "live" highvoltage components can cause serious injury oreven death.

There are two options for performing an emergencyshutdown. The preferred method is to turn off theignition key. The other option is to disconnect thelow-voltage (12-volt) vehicle batteries. In either case,the engine will shut down, dash lights will shut down,the hybrid electrical system will shut down, and thehigh-voltage batteries in the Power Electronics Car-rier (PEC) will remain "live" but isolated in the PEC.

NOTE: If the service switch on the PEC is ac-cessible, it may be pushed in to shut down thehybrid electrical system and isolate the "live"HEV batteries in the PEC.

In Case of an Accident or FireIf the HEV becomes involved in an accident or fire,be aware of the following:

• Use CO2 or dry chemical extinguishers. Thebatteries in the PEC are lithium ion.

• Do not cut into high-voltage cables. The high-voltage wiring is covered in orange insulationor convoluted tubing.

• Do not cut into or open the PEC.

• Do not cut into or open the DC/DC converter.

• Do not cut into or open the inverter.

If it is necessary to remove occupants using cuttingequipment, avoid high-voltage cables and the PEC.

Jumpstarting (HEV)Jumpstarting vehicles equipped with the Eaton® Hy-brid System is identical to Non-Hybrid vehicles,which use the vehicle 12-volt battery system.

Towing (HEV)When towing the vehicle, the output shaft of thetransmission must not be allowed to spin or turn. Ifthe vehicle is towed with the drive wheels still in con-tact with the road surface, the vehicle axle shafts ordriveline must be removed or disconnected. See"Towing" in Chapter 13 .

STOPHYBRID

CHECKHYBRID

07/09/2008 f611013

Fig. 15.1, Hybrid System Fault Lamps


15.3

16

Natural Gas VehicleGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Fuel Tank Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2Gas Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9Major Repair and Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10

General InformationThe Business Class® M2 can be equipped with acompressed natural gas (CNG) fuel system, or a liq-uefied natural gas (LNG) fuel system. CNG is madeby compressing natural gas to less than 1% of itsvolume at standard atmospheric pressure. LNG iscreated by condensing natural gas into a liquid bycooling it to approximately -259°F (-162°C).

When vaporized at ambient temperatures, naturalgas is less dense than air, and it rises and disperses.However, LNG is intially heavier than air due to itscryogenic temperature. When released in largeamounts, it may drop or pool on the ground beforeit’s temperature rises and the LNG vaporizes. Coldatmospheric conditions may prevent natural gas fromdispersing quickly when released in large amounts.

Natural gas is nontoxic, but it can cause asphyxiationif present in very large concentrations.

CNG often contains an odor-producing chemical,while LNG does not have any odor. Users of natural-gas-fueled vehicles should never expect to detectnatural gas leaks by scent.

For natural gas to burn, it must first vaporize, thenmix with air in the proper proportions (flammablerange is 5 to 15% by volume in air), and then be ig-nited.

A typical natural gas fuel system consists of:

• Fuel supply cylinders that store compressedgas at high pressure (CNG), or a tank thatstores liquefied gas at an extremely low tem-perature (LNG).

• A vaporizor or heat exchanging device thatchanges LNG to gaseous form (LNG fuel sys-tems only).

• Pressure relief and manual fuel shutoff valves.

• A filling connection with a check valve that pre-vents the gas from flowing back out of the fuelfilling line.

• High-pressure and low-pressure fuel filters.

• A pressure control regulator that reduces thehigh fuel tank or cylinder pressure to the lowerpressure needed for the engine.

• A fuel contents gauge that indicates the fuelsupply in the tank or cylinders.

Safety Precautions

DANGERNatural gas is highly flammable. Failure to ob-serve the following safety precautions could leadto the ignition of the natural gas, which couldcause serious bodily injury or death.

Follow these safety precautions when operating orrepairing a natural gas vehicle.

• Do not start the engine if a natural gas leak isdetected.

• Do not transfer CNG from one vehicle to an-other, as a buildup of static electricity couldcause a spark and ignite the fuel.

• Avoid open flames or sparks near a naturalgas vehicle.

• Cover eyes and exposed skin when working ona natural gas fuel system or fueling a naturalgas vehicle.

• Permit no smoking or other ignition sourceswithin thirty feet of a natural gas vehicle.

• Have CO2 fire extinguishers (ABC minimum)located in a highly visible and easily accessiblelocation.

• Always purge the fuel lines before performingmaintenance or repairs on a natural gas fuelsystem. To purge the lines, close the manualfuel shutoff valve, and start the engine. Let thevehicle idle until the fuel lines are empty andthe engine stops.

• Always use a natural gas detector to test thesystem for leaks, whether an odor is present ornot. Routinely inspect the fuel filtering andregulating mechanisms, and the fuel lines. Abubble solution can be used to pinpoint theexact location of leaks.

• Always tighten fasteners and fuel connectionsto the required torque specification. Overtight-ening or undertightening could cause leaks.

• Close the fuel shutoff valve(s) before perform-ing maintenance and repairs.

• Do not store a natural gas vehicle indoors forany extended period of time. Do not bring anatural gas vehicle inside indoors unless the

Natural Gas Vehicle

16.1

workshop is equipped with a methane detec-tion and ventilation system.

Fuel Tank Filling ProceduresCNG Vehicle FuelingCNG is moved from the fuel station storage tanks tothe vehicle cylinders through a metered dispenser.During fueling, as pressure inside of the vehicle cyl-inders increases, so does the temperature. The dis-penser shuts off when it determines the CNG cylin-ders are full.

CNG fuel cylinders cannot be filled to their full capac-ity of 3600 psi (24 800 kPa) in cooler weather. Sincetemperature change causes gas to expand and con-tract, less pressure in the cylinders on a cold day isequal to the same amount of gas at a higher pres-sure on a warm day. The fuel station dispenser has atemperature-pressure compensating device, whichaccounts for ambient temperature during fueling. SeeTable 16.1 for approximate full cylinder pressures atvarious temperatures.

CNG Temperature/Pressure Compensation Values

Temperature:°F (°C)

Fill Station Pressure Set Point3000 psi (20 684kPa) Set Point

3600 psi (24 821kPa) Set Point

100 (37.8) 3415 (23 546) 4086 (28 172)90 (32.2) 3276 (22 587) 3909 (26 952)80 (26.7) 3138 (21 636) 3754 (25 883)70 (21.1) 3000 (20 684) 3600 (24 821)60 (15.6) 2861 (19 726) 3445 (23 752)50 (10) 2723 (18 774) 3288 (22 670)40 (4.4) 2584 (17 816) 3131 (21 587)30 (-1.1) 2446 (16 865) 2973 (20 498)20 (-6.7) 2307 (15 906) 2814 (19 402)

10 (-12.2) 2169 (14 955) 2655 (18 306)0 (-17.8) 2031 (14 003) 2495 (17 202)

-10 (-23.3) 1893 (13 052) 2336 (16 106)-20 (-28.9) 1755 (12 100) 2180 (15 031)-30 (34.4) 1616 (11 142) 2024 (13 955)-40 (-40) 1477 (10 184) 1868 (12 879)

Table 16.1, CNG Temperature/Pressure CompensationValues

Use the following steps to fuel a CNG vehicle.

1. Shut down the engine and apply the parkingbrake.

IMPORTANT: Close all windows and doors dur-ing the fueling process. Keeping windows anddoors closed allows for easier leak detectioninside the cab after fueling.

WARNINGNatural gas fuel tanks, lines, and valves are al-ways pressurized. Always observe safety precau-tions. Failure to do so could lead to loss of con-trol over a filling hose or to ignition of the naturalgas, which could cause serious bodily injury,death, or severe property damage.

2. Ensure all fuel cylinder shutoff valves are open.See Fig. 16.1 .

04/22/2010 f470554

1 2

3 4

578 6

1. Fuel Cylinder StorageBox

2. Fuel Cylinder ShutoffValves (qty 5)

3. High-Pressure Gauge4. Low-Pressure Gauge

5. Fuel Fill Port6. Dust Cap7. Manual Shutoff Valve8. Fuel Panel Access

Door

Fig. 16.1, CNG Fuel Cylinder Storage Box (5-cylindersystem shown)

Natural Gas Vehicle

16.2

3. Ensure the vehicle fuel system main shutoffvalve is open.

4. Open the CNG fuel panel access door and re-move the dust cap from the vehicle fuel fill port.

5. Ensure the O-ring is present inside the fuel fillport. If the O-ring has been dislodged or is miss-ing, the station dispensing nozzle will not con-nect securely to the fill port.

6. Turn the selector knob on the service pump tothe VENT position, if equipped.

7. Connect the quick coupling on the dispensingnozzle securely to the vehicle fuel fill port.

8. Turn the selector knob on the service pump tothe FILL position, if equipped.

IMPORTANT: If at any time the service pump orvehicle begins to vent CNG uncontrollably, notifya station attendant or activate the service sta-tion emergency shut-off switch to cease the flowof CNG.

9. Switch on the service pump. A slight hissingnoise may be heard as the fuel cylinders fill.

10. Watch the pressure gauge on the service pump.When the gauge reads approximately 3600 psi(24 800 kPa), or when the fill pressure stopsclimbing, the CNG cylinders are full. The servicepump will shut itself down automatically. SeeTable 16.1 for pressure compensation valuesbased on ambient temperatures.

11. Move the selector knob on the service pump tothe VENT position, if equipped. A short hiss willbe heard as a small amount of natural gas isvented into the hose.

WARNINGDo not attempt to remove the fill station nozzlefrom the tank fill fitting until venting of pressureis noted. If no venting occurs, ask for assistancefrom the station attendant. Removing an un-vented coupling could result in an uncontrolledhose, which could lead to property damage orpersonal injury.

12. Remove the station dispensing nozzle from thevehicle fill port.

13. Install the dust cap on the vehicle fuel fill portand close the fuel panel access door.

LNG Vehicle FuelingThe LNG fuel tank is designed to be filled from anyLNG fuel source that has a 100 micron or finer fuelfilter and a fuel delivery pressure between 120 and225 psi (827 and 1551 kPa).

The LNG fuel tank is designed to be top-filledthrough a single hose with no vent return. As coldLNG is sprayed into the vapor space of the tank, thecold liquid condenses the vapor and creates spacefor itself inside the tank, eliminating any need to ventduring the filling process.

The LNG tank is equipped with a small internal ul-lage tank for vapor space, which allows for fuel ex-pansion and increases vehicle standby time. Whenan LNG tank is full, fuel can continue to flow into theullage tank. However, if the ullage tank is completelyfilled during fueling, standby time will be reduced tozero and the primary relief valve will open almostimmediately after fueling, allowing excess LNG vaporto escape. If fueling is stopped when the ullage tankis empty (i.e., the fuel tank has sufficient vapor spaceto accommodate fuel expansion due to temperatureincrease), the vehicle will have approximately oneweek of standby time before venting will occur.

Use the following steps to fuel an LNG vehicle.

1. Shut down the engine and apply the parkingbrake.

IMPORTANT: Close all windows and doors dur-ing the fueling process. Keeping windows anddoors closed allows for easier leak detectioninside the cab after fueling.

WARNINGLiquefied natural gas is a cryogenic liquid storedat approximately -259°F (-162°C). Cryogenicburns can be caused by coming into contact withthe pressurized liquid stream, or by coming intocontact with fuel system components that havebeen cooled to cryogenic temperatures. Alwayswear gloves and a face shield, and cover ex-posed skin when fueling.

2. Remove the fuel fill fitting dust cap. SeeFig. 16.2 .

Natural Gas Vehicle

16.3

3. Using compressed air, remove any dirt, debris, orwater that may have collected in the fuel fill fit-ting and the station dispensing nozzle. Contami-nants in the fuel system can cause drivabilityproblems.

WARNINGNatural gas fuel tanks, lines, and valves are al-ways pressurized. Always observe safety precau-tions. Failure to do so could lead to loss of con-trol over a filling hose or to ignition of the naturalgas, which could cause serious bodily injury,death, or severe property damage.

4. Connect the station fueling nozzle to the tankfuel fill fitting.

5. Connect an electrical ground clamp and cable tothe fuel tank.

IMPORTANT: An LNG tank which is first in-stalled, or is on a vehicle that has not been op-erated in approximately ten days, is consideredto be a hot tank. When fueling a hot tank, LNGentering the tank will immediately vaporize,

causing tank pressure to spike above 250 psi(1724 kPa) and automatically shutting down thestation fuel pump. To prevent the pump fromshutting down, connect a vent line to the fill ventfitting on the LNG tank to capture escapingvapor, then open the shroud cover and open thevapor shutoff valve (Fig. 16.3 , Item 2).

6. Open the station’s fill valve, if equipped, andstart fueling. Monitor the flow or line pressure asfilling progresses. When filling begins, line pres-sure will spike quickly until the vehicle tank coolsdown. The flow and pressure will then remainstable during the remainder of the fillingprocedure.

IMPORTANT: When fueling a hot tank, initiallyput 5 to 10 gallons (19 to 37 liters) of LNG inthe tank and manually stop the fueling process.Drive the vehicle for 15 to 20 minutes to cool

05/29/2009 f470534

1

2 3

4

6

5

6

1. Fuel Fill Fitting2. Fuel Outlet Line3. Primary Relief Vent

Line

4. Fill Vent Fitting5. Shroud Cover6. Shroud Cover Latches

Fig. 16.2, LNG Fuel Tank

05/05/2010 f470533

1

2

3

4

5

67 8

10

11

12

9

1. Pressure ControlRegulator

2. Vapor Shutoff Valve3. Fuel Fill Hose4. Secondary Relief

Valve (red cap)5. Fuel Fill Fitting6. Fuel Level Sender

Box

7. Primary Relief Valve8. Tank Pressure Gauge9. Fill Vent Fitting10. Excess Flow Valve11. Fuel Shutoff Valve

(liquid)12. Fill Check Valve

Fig. 16.3, LNG Fuel Tank Plumbing Components

Natural Gas Vehicle

16.4

the tank and reduce tank pressure, then con-tinue fueling the tank to full.

7. When the tank is full, the line pressure will rap-idly spike and the flow rate will fall. When a pres-sure rise or flow rate drop is observed, close thestation’s fill valve, if equipped.

NOTE: Do not over-fill an LNG tank. If the ul-lage tank is completely filled during fueling, tankstandby time will be reduced to zero and theprimary relief valve will open almost immediatelyafter fueling.

8. Disconnect the station hose from the tank fuel fillfitting.

9. Disconnect the electrical ground clamp and cablefrom the fuel tank.

10. Install the dust cap on the tank fuel fill fitting.

Gas Detection SystemA gas detection system is used in all Daimler Trucksnatural-gas-fueled vehicles. This system has a sen-sor in the engine compartment and one in the cab,both situated in high areas to detect natural gasbuildup as a result of leaks.

The AMGaDS III Plus is a natural gas detection sys-tem. This device is meant to serve as a supplemen-tal warning only. It is not intended to replace stan-dard safety practices that should be conductedaround flammable gases.

IMPORTANT: To function properly, the gas de-tection system must be powered at all times.The gas detection system is directly powered bythe batteries, and can only be powered off bydisconnecting the batteries.When servicing anatural-gas-fueled vehicle, disconnect the bat-teries only when necessary, and do not leavethe batteries disconnected for extended periodsof time.

The lower flammability limit (LFL) is the smallestamount of the gas that supports a flame when mixedwith oxygen and ignited. Zero percent (0%) LFL indi-cates a gas-free atmosphere. One hundred percent(100%) LFL indicates that gas concentration hasreached its lower flammability limit (5% gas in air byvolume). The red warning light and audible alarmlocated in the overhead console activate when a sen-

sor detects gas fumes in concentrations above 50%LFL, and should allow ample time to utilize safetyprocedures. However, individuals with special needsshould review the system with a professional safetyengineer.

Alarm ProcedureBefore operating the vehicle, the driver must be fa-miliar with the procedures as shown on the interiorsticker on the overhead panel (Fig. 16.4 ) and theexterior sticker on the door (Fig. 16.5 ).

IMPORTANT: If an audible alarm activates, donot operate any electrical switch, includinglights. Avoid causing sparks and stay away fromarcing switches and equipment. Do not use atelephone, including cellular phones or anytypes of portable communication or electronicdevices that have a battery.

If the vehicle is in motion when the audible alarmactivates, bring it to a safe stop, shut down the en-gine, and exit the vehicle. Do not open the hood.

If outside the vehicle when the audible alarm acti-vates, do not open the cab door or hood.

In the event of an audible alarm, immediately followthese procedures, as allowed by conditions:

1. Immediately shut off all engines. Extinguish anycigarettes, pilot lights, flames, or other sources ofignition in the area and adjacent areas.

04/28/2009 f080157

Fig. 16.4, Interior Warning Sticker

Natural Gas Vehicle

16.5

2. Manually close all fuel shutoff valves, includingthose on the LNG tank or CNG cylinders.

3. If the vehicle is indoors (as in a service shop),immediately open windows and doors to provideextra ventilation to the area. Do not start the en-gine or any other type of equipment until the gasleak is corrected and the area cleared of naturalgas.

4. Evacuate the area.

5. Check the fuel lines, LNG tank/CNG cylinders,and fittings to locate the leak. After the area iscleared of natural gas and the alarm is no longeractive, have the vehicle inspected by a qualifiedtechnician.

IMPORTANT: Do not consider the area clearuntil all alarm indicators are off, and the alarmpanel light returns to green.

SensorsGas detection sensors are located on the cab over-head console and in the engine compartment on the

frontwall. The sensors are located in high areas,where rising gas vapors will pass by or accumulate.

If the system detects that one of the sensors hasbeen disconnected or has malfunctioned, the sensorfault light for that zone will illuminate. A failed sensormay trigger and lock on an alarm. If a fault conditionor locked alarm continues after the sensor’s connec-tion and wiring integrity has been verified, replacethe sensor.

The sensors are sensitive to all hydrocarbon vapors.An alarm may be triggered by the use of chemicalssuch as cleaners, paint, polish, lacquer, gasoline,silicone, silicone spray, or other harsh chemicals.The sensors will also detect hydrogen fumes from anovercharged battery. If a sensor sends an alarm, butno gas fumes are present, check for recent use ofchemicals or a battery charger.

NOTICESilicone-based chemicals and cleaners will per-manently disable the sensors. When cleaning thevehicle, cover the sensors with a plastic cover-ing. Keep the sensors covered until the area hasbeen cleared of any cleaning fumes.

Harsh chemicals and extremely high tempera-tures may damage the sensor.

Puncture of or damage to the seal located insidethe sensor housing will significantly shorten thesensor life.

Frequent exposure to high concentrations of gaswill accelerate sensor deterioration.

Overhead ConsoleThe overhead console consists of an alarm panel onthe right side and the control module on the left side.

The alarm panel has a green light, a red light, abuzzer, and a sensor. See Fig. 16.6 . It is locatedwithin view from outside of the vehicle. The largegreen light is continuously illuminated during normaloperating conditions.

Before entering the vehicle, always verify that thegreen light is illuminated. If the green light is not illu-minated, do not enter the vehicle. Complete thealarm procedure previously outlined.

The alarm panel meets the California Highway PatrolTitle 13-2008 and NFPA 52 2010 requirements. All

04/28/2009 f080158

Fig. 16.5, Exterior Warning Sticker

Natural Gas Vehicle

16.6

drivers and technicians using it should be trained re-garding the red and green lights, and the audiblewarning.

The control module, located on the left side of theoverhead console, contains the status lights and con-trol buttons for the system. The areas that the sen-sors monitor are defined as Zone 1 (cab) and Zone 2(engine compartment). The control module has lightsassigned to each zone that will illuminate if a sensordetects a trace level leak (between 20% and 30%LFL), a significant level leak (above 50% LFL), or if asensor is disconnected or malfunctioning.

• Trace Level: If either sensor detects gas fumesat a concentration greater than 20% to 30%LFL (1% gas in air by volume), the amber lightnext to the Trace indicator for that zone willflash. There is no buzzer alarm for a tracelevel detection, and the large green light on thealarm panel will remain illuminated.

• Significant Level: If either sensor detects gasfumes at a concentration greater than 50% to60% LFL (2.5% gas in air by volume), thesmall red light next to the SIGNIFICANT indi-cator for that zone will flash. After approxi-mately 15 seconds, the large green light on thealarm panel will switch off, the red light will illu-minate, and the buzzer will sound. All alarmindicators will remain on as long as fumes aredetected.

• Sensor Fault: If the system detects that eitherof the sensors has been disconnected or hasmalfunctioned, an amber light next to the Sen-sor Fault indicator for that zone will illuminate.

The control module also has buttons used to test orreset the the control module after an alarm. Redlights next to each button indicate when they are en-gaged.

04/28/2009 f611034

10 11 12 13

PushTo

Silence

ShutdownReset

Power

SIGNIFICANT

Trace

SilenceEngaged

RelayEngaged

Sensor Fault

Zone 2

Gas Concentration:

Push To Test

AMGaDS III Plus Gas Detection System

Zone 1

2

3

4

5 67

8

91

1. Test Button2. Sensor Fault Indicator Lights3. Zone 1 Leak Indicator Lights4. Power Indicator Light5. Zone 2 Leak Indicator Lights

6. Silence Button7. Silenced Engaged Light8. Relay Engaged Light9. Shutdown Reset Button

10. Buzzer Alarm11 Red Light12. Green Light13. Sensor

Fig. 16.6, AMGaDS III Plus Overhead Console

Natural Gas Vehicle

16.7

• Shutdown Reset: If an alarm has been acti-vated and the Relay Engaged light is illumi-nated, the Shutdown Reset button will resetthe internal relay. Press the Shutdown Resetbutton only after the gas has cleared, thebuzzer has turned off, and the alarm panellight has returned to green.

• Push To Silence: If an alarm has been acti-vated, the Push To Silence button will silencethe buzzer.

See Table 16.2 for the functions of all lights and but-tons on the overhead console.

TestingDaimler Trucks North America strongly recommendsthat all operators follow California Code of Regula-tions (CCR) inspection requirements, regardless ofwhere the vehicle is operated. Per Title 13 CCR §

935 (2), gas detection systems should be tested

three times per calendar year at equal intervals. Thetesting procedure should simulate the same operat-ing environment in which the vehicle is used, with thesame gaseous fuel.

Test results validating the performance of the gasdetection system within the parameters establishedby the component manufacturer and NFPA 52 2010should be maintained as a permanent part of the ve-hicle service records. Use of alcohol, propane, andother harsh liquids or gases are not acceptablemethods for testing.

Always test the system and sensors after any com-ponent has been replaced, or if the vehicle has beeninvolved in an accident or fire. Ensure that the gasdetection system is wired directly to the battery.

It is recommended that the highest level of safetyvalidation be utilized if there are multiple validationrequirements in the state or locality where the vehicleis operated or domiciled.

Control Module FunctionsItem Display Function Action Required

Green Power Light

Illuminated System is on. None required.

Unlit Detection system is notfunctioning.

Ensure the batteries areconnected and replace any blownfuses. If the gas detection systemis still not functioning, replace thesystem immediately.

SIGNIFICANT GasConcentration Lights Red (illuminated) Dangerous gas concentration

detected.

Suspend vehicle operationimmediately and follow alarmprocedures.

Trace Gas ConcentrationLights Amber (flashing) Minor gas concentration detected. Use caution and monitor the

system.

Sensor Fault LightsOff Sensor is functioning properly. None required.On Sensor has malfunctioned. Replace the sensor immediately.

Shutdown Reset Button — Resets the system after an alarmactivation.

Press to reset the system onlyafter the gas has cleared, thebuzzer has turned off, and thealarm panel light has returned togreen.

Relay Engaged LightOn Relay is engaged and test or

alarm is being cleared. Press the Shutdown Reset button.

Off Normal condition. None required.

Test Button — Tests the overhead consoleoperation and circuitry.

Press and hold for one minute toto activate a test of all overheadconsole components.

Silence Button — Silences the alarm buzzer. Press to silence the alarm buzzer.

Natural Gas Vehicle

16.8

Control Module FunctionsItem Display Function Action Required

Silence Engaged LightOn Indicates the buzzer is active but

silenced.

Suspend vehicle operationimmediately and follow alarmprocedures.

Off Normal condition. None required.

Table 16.2, Control Module Functions

Overhead Console TestPress and hold the Push To Test button for oneminute. The system will proceed with a self-diagnostic test that will include illumination of theTrace and SIGNIFICANT gas concentration lights,and the sensor fault lights. Verify the large red lightand buzzer activate, and that all lights illuminate orflash to ensure that all bulbs are operational.

Sensor TestThe gas detection system sensors must be testedusing certified test gas, which can be purchased aspart of a test kit. Testing with alcohol or heavy gasessuch as butane or propane does not satisfy CCR §

935 (2) or NFPA 52 regulations.

Expose each sensor to certified test gas for at leastthirty seconds. The system will proceed through thealarm procedure consistent with a significant leakand the buzzer will sound after approximately fifteenseconds. If a sensor fails to respond after exposureto the test gas, replace the sensor.

Engine StartingNOTE: Before starting the engine, read Chap-ter 3 for detailed information on how to read theinstruments and Chapter 4 for detailed informa-tion on how to operate the controls. Read theoperating instructions in the engine manufactur-er’s operation manual before starting the en-gine.

1. Before engine start-up, complete the engine pre-trip and post-trip inspections and maintenanceprocedures in Chapter 11 .

2. Ensure the fuel shutoff valve is open.


4. Ensure that the transmission shift control is inNeutral (N), Park (P), or the Park Brake (PB) po-sition.

5. Without starting the engine, turn the ignitionswitch to the ON position (Fig. 16.7 ). The elec-tronic gauges on the instrumentation control unit(ICU) will complete a full sweep of their dials, thewarning and indicator lights will illuminate, andthe buzzer will sound for three seconds.

6. Turn the ignition switch to the START position.

Press down on the clutch pedal, if equipped, butdo not press down on the accelerator pedal.

Release the key the moment the engine starts.

7. Bring the engine up to operating speed graduallyas it warms up and develops stable oil pressure.If the vehicle has not been operated previously ina 24-hour period, allow the vehicle to idle for fiveminutes.

NOTICEDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the engine

09/12/2001 f610509


Natural Gas Vehicle

16.9

within approximately ten seconds to avoid enginedamage.

8. Check the oil pressure gauge for any drop in lu-bricating oil pressure or mechanical malfunctionin the lubricating oil system.

Major Repair and Replacementof PartsIf a natural-gas-fueled vehicle is involved in an acci-dent, remove the fuel tank or cylinders from serviceand have them inspected by a qualified technician.Replace any leaking or damaged fuel tanks/cylindersand fuel lines; repair or replace leaking or damagedfittings. Install parts and components in accordancewith the manufacturer’s instructions.

Natural Gas Vehicle

16.10

Subject Page

AAdjustable Steering Column . . . . . . . . . . . . . . . . . 4.14Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 14.2Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . 7.1

EPA07 AftertreatmentSystem (ATS) . . . . . . . . . . . . . . . . . . . . . . . . 7.1

EPA10 AftertreatmentSystem (ATS) . . . . . . . . . . . . . . . . . . . . . . . . 7.3

Air Bag, Optional . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Air Bag Safety Guidelines . . . . . . . . . . . . . . . . 5.10

Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Air Brake Operation . . . . . . . . . . . . . . . . . . . . . 9.3Automatic Slack Adjusters . . . . . . . . . . . . . . . . . 9.3Emergency Braking System . . . . . . . . . . . . . . . . 9.2Meritor™ WABCO® Antilock

Braking System (ABS) forAir Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

Parking Brakes, Tractor andTrailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Primary Air Brake System . . . . . . . . . . . . . . . . . 9.1Secondary Air Brake System . . . . . . . . . . . . . . . 9.1

Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . 10.1Allison MD Series . . . . . . . . . . . . . . . . . . . . . . . . 8.5

Operating Instructions, MDSeries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 8.5Allison On-Highway

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3Operating Instructions, On-

Highway Transmissions . . . . . . . . . . . . . . . . . 8.4Range Inhibit Indicator, 2000

and 2400 Series . . . . . . . . . . . . . . . . . . . . . . 8.3Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 8.3

All-Wheel-Drive Controls,Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12AWD Operation Switch . . . . . . . . . . . . . . . . . . 4.12AWD Range Switch . . . . . . . . . . . . . . . . . . . . 4.12

BBack-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . 2.5

Climbing Down from Back-of-Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

Entering Back-of-Cab . . . . . . . . . . . . . . . . . . . . 2.6Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

Battery Compartment . . . . . . . . . . . . . . . . . . . . 2.6Cab (Battery) Isolation

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

Meritor™ WABCO® AntilockBraking System (ABS) . . . . . . . . . . . . . . . . . 4.13

Parking Brake Control Valve . . . . . . . . . . . . . . . 4.13Trailer Air Supply Valve . . . . . . . . . . . . . . . . . . 4.13

Subject Page

Trailer Brake Lever . . . . . . . . . . . . . . . . . . . . . 4.13

CCab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

Cab Storage . . . . . . . . . . . . . . . . . . . . . . . . . 5.10Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

Cab Door Locks and Handles . . . . . . . . . . . . . . . . 2.1Cab Entry and Exit, Vehicles

With One Step . . . . . . . . . . . . . . . . . . . . . . . . . 2.4Entering from the Driver’s

Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4Entering from the

Passenger’s Side . . . . . . . . . . . . . . . . . . . . . 2.5Exiting from the Driver’s Side . . . . . . . . . . . . . . . 2.4Exiting from the Passenger’s

Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5Cab Entry and Exit, Vehicles

With Two Steps . . . . . . . . . . . . . . . . . . . . . . . . . 2.2Entering from the Driver’s

Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2Entering from the

Passenger’s Side . . . . . . . . . . . . . . . . . . . . . 2.3Exiting from the Driver’s Side . . . . . . . . . . . . . . . 2.3Exiting from the Passenger’s

Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Cab Washing and Polishing . . . . . . . . . . . . . . . . . 12.1Canadian Motor Vehicle Safety

Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . 1.2Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 12.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 12.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 12.1Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 14.1Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . 6.1

Air Conditioning, Optional . . . . . . . . . . . . . . . . . 6.4Air Selection Switch . . . . . . . . . . . . . . . . . . . . . 6.1Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Fresh Air Mode . . . . . . . . . . . . . . . . . . . . . . . . 6.3Recirculation Mode . . . . . . . . . . . . . . . . . . . . . 6.3Temperature Control Switch . . . . . . . . . . . . . . . . 6.3

Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Clutch Adjustments . . . . . . . . . . . . . . . . . . . . . 8.2Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . 8.2Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . 8.1Clutch Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Sachs Hydraulic Clutch . . . . . . . . . . . . . . . . . . . 8.2

Cold-Weather Operation . . . . . . . . . . . . . . . . . . . 7.14Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . 7.10Collision Warning System,

Eaton VORAD EVT–300 . . . . . . . . . . . . . . . . . . 3.17Driver Display Unit (DDU) . . . . . . . . . . . . . . . . 3.18In Case of Accident . . . . . . . . . . . . . . . . . . . . 3.21

Index

I-1

Subject Page

Maintenance andDiagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

Side Sensor Display . . . . . . . . . . . . . . . . . . . . 3.20Special Road Situations . . . . . . . . . . . . . . . . . 3.20

ConMet Simplex® Series FifthWheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3Simplex Fifth Wheel

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 10.6Simplex Lock Mechanism . . . . . . . . . . . . . . . . 10.3Simplex Locking Operation . . . . . . . . . . . . . . . 10.4

Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12Dash-Mounted Switches . . . . . . . . . . . . . . . . . 7.12Shift Knob Controls, Optional . . . . . . . . . . . . . . 7.13

DDashboard Care . . . . . . . . . . . . . . . . . . . . . . . . 12.1

EEaton Fuller AutoShift™ . . . . . . . . . . . . . . . . . . . . 8.12

Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . 8.13Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . 8.13Push-Button Shift Selector . . . . . . . . . . . . . . . . 8.12Selecting Gears . . . . . . . . . . . . . . . . . . . . . . . 8.14

Eaton Fuller Range-ShiftTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9General Information, Range-

Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9Operation, Deep-Reduction

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11Operation, Range-Shift . . . . . . . . . . . . . . . . . . 8.10

Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . 8.15General Information,

UltraShift ASW . . . . . . . . . . . . . . . . . . . . . . 8.15General Information,

UltraShift DM . . . . . . . . . . . . . . . . . . . . . . . 8.15Operation, UltraShift . . . . . . . . . . . . . . . . . . . . 8.16UltraShift Diagnostics . . . . . . . . . . . . . . . . . . . 8.20

Eaton® Fuller® Straight-ShiftTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8General Information,

Straight-Shift . . . . . . . . . . . . . . . . . . . . . . . . 8.8Operation, Straight-Shift . . . . . . . . . . . . . . . . . . 8.8

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Emergencies (HEV) . . . . . . . . . . . . . . . . . . . . . . 15.3

Emergency Shutdown . . . . . . . . . . . . . . . . . . . 15.3In Case of an Accident or

Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Emergency Filter Replacement,

Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . 13.1Emergency Starting With

Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 13.2

Subject PageEngine Braking . . . . . . . . . . . . . . . . . . . . . . . . . 7.15Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . 7.11Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 7.11Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 7.14Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . 16.9

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10Starting Precautions, All

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10EPA Emission Control . . . . . . . . . . . . . . . . . . . . . . 1.2

EPA07 and EPA10 EmissionControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Vehicle Noise EmissionControl Label . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Exhaust Braking Systems . . . . . . . . . . . . . . . . . . 7.16Exhaust Brake Switch . . . . . . . . . . . . . . . . . . . 7.16Mercedes-Benz Exhaust

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16Pacbrake® Exhaust Brake . . . . . . . . . . . . . . . . 7.17

FFederal Motor Vehicle Safety

Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . 1.1Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 13.1Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 13.6

In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 13.6Fontaine Fifth Wheels . . . . . . . . . . . . . . . . . . . . . 10.1

Fontaine Fifth WheelLubrication . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Fontaine Lock Mechanism . . . . . . . . . . . . . . . . 10.1Fontaine Locking Operation . . . . . . . . . . . . . . . 10.1

Freightliner SmartShift ShiftControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15General Information,

SmartShift . . . . . . . . . . . . . . . . . . . . . . . . . 8.15Fuel Tank Filling Procedures . . . . . . . . . . . . . . . . 16.2

CNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . 16.2LNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . . 16.3

Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . 2.8Main Fuse Box/PDM . . . . . . . . . . . . . . . . . . . . 2.8Trailer and Taillight Fuse

Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

GGas Detection System . . . . . . . . . . . . . . . . . . . . 16.5

Alarm Procedure . . . . . . . . . . . . . . . . . . . . . . 16.5Overhead Console . . . . . . . . . . . . . . . . . . . . . 16.6Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8

General Information . . . . . . . . . . . . . . . . . . . . . . 16.1Grab Handles and Access

Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Index

I-2

Subject Page

HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . 13.1Heater/Air Conditioner Control

Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15High-Altitude Operation . . . . . . . . . . . . . . . . . . . . 7.14Holland Fifth Wheels . . . . . . . . . . . . . . . . . . . . . 10.6

Holland Fifth WheelLubrication . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

Holland Kingpin LockMechanism . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

Holland Lock Guard . . . . . . . . . . . . . . . . . . . . 10.7Holland Locking Operation . . . . . . . . . . . . . . . . 10.7

Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . 10.9Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.7To Close the Hood . . . . . . . . . . . . . . . . . . . . . . 2.7To Open the Hood . . . . . . . . . . . . . . . . . . . . . . 2.7

Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Air Horn, Optional . . . . . . . . . . . . . . . . . . . . . . 4.7Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

Hybrid Electric Vehicle (HEV)Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Cooling System . . . . . . . . . . . . . . . . . . . . . . . 15.1Electric Power Take-Off

(ePTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1High-Voltage Safety

Features . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Regenerative Braking . . . . . . . . . . . . . . . . . . . 15.1

Hybrid System Fault Lamps(HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2

Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . 9.6General Information . . . . . . . . . . . . . . . . . . . . . 9.6Meritor™ WABCO® Antilock

Braking System (ABS) forHydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . 9.7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

IIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . 4.1Instrumentation Control Unit . . . . . . . . . . . . . . . . . . 3.1

Dash Message Center . . . . . . . . . . . . . . . . . . . 3.1Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 3.2Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . . 3.5Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

JJumpstarting (HEV) . . . . . . . . . . . . . . . . . . . . . . 15.3

Subject Page

LLighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Control Panels . . . . . . . . . . . . . . . . . . . . . . . . 4.1Exterior Light Controls . . . . . . . . . . . . . . . . . . . 4.2Interior Lights and Light

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

MMajor Repair and Replacement

of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10Mercedes-Benz Automated

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.22AGS Diagnostics . . . . . . . . . . . . . . . . . . . . . . 8.27General Information, AGS . . . . . . . . . . . . . . . . 8.22Operation, AGS . . . . . . . . . . . . . . . . . . . . . . . 8.23

Mercedes-Benz ManualTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.22

Meritor™ Drive Axles . . . . . . . . . . . . . . . . . . . . . . 8.28Axle Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30Drive Axles With Differential

Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28Tandem Drive Axles With

Interaxle Lock . . . . . . . . . . . . . . . . . . . . . . . 8.29Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Down View Mirror, Optional . . . . . . . . . . . . . . . . 5.1Mirror Heat Switch, Optional . . . . . . . . . . . . . . . 5.1Power Mirrors, Optional . . . . . . . . . . . . . . . . . . 5.1

Multifunction Turn Signal Switch . . . . . . . . . . . . . . . 4.5Hazard Warning Flasher . . . . . . . . . . . . . . . . . . 4.7Headlight High Beams . . . . . . . . . . . . . . . . . . . 4.6Turn-Signal Controls . . . . . . . . . . . . . . . . . . . . . 4.5Windshield Wiper/Washer

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

OOptional Instruments . . . . . . . . . . . . . . . . . . . . . . 3.14

Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14Axle Oil Temperature

Gauges, Forward and Rear . . . . . . . . . . . . . . 3.14Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . 3.14Engine Oil Temperature

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15Intake-Air Restriction

Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16Pyrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16Turbocharger Boost

Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 3.17Other Dash-Mounted Controls . . . . . . . . . . . . . . . 4.14

CB Radio Connections . . . . . . . . . . . . . . . . . . 4.14Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . 4.14

Index

I-3

Subject Page

Suspension Autofill OverrideValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

Suspension Dump Switch . . . . . . . . . . . . . . . . 4.15Windshield-Fan Switches,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14Overhead Instrument Panel,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

PPower Takeoff (PTO) Governor . . . . . . . . . . . . . . . 7.13Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 4.8

After-Treatment System(ATS) Request/InhibitRegen Switch . . . . . . . . . . . . . . . . . . . . . . . . 4.8

Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . 4.10Cruise Control Switches . . . . . . . . . . . . . . . . . . 4.8Engine Brake Switch,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8Engine Fan Switch, Optional . . . . . . . . . . . . . . . 4.9Exhaust Brake Switch,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9Transmission Controls . . . . . . . . . . . . . . . . . . . 4.10

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 14.1Pretrip and Post-Trip Inspection

Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Pretrip and Post-Trip

Maintenance Procedures . . . . . . . . . . . . . . . . . . 11.3Daily Pretrip Inspection and

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 11.3Monthly Post-Trip Inspection

and Maintenance . . . . . . . . . . . . . . . . . . . . 11.17Weekly Post-Trip Inspection

and Maintenance . . . . . . . . . . . . . . . . . . . . 11.15

SSafety Precautions (HEV) . . . . . . . . . . . . . . . . . . 15.2Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 16.1Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 5.7

General Information . . . . . . . . . . . . . . . . . . . . . 5.7Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 5.7Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 5.7

Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Bench Seat Adjustment

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Suspension Seat Adjustment

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

Bench Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . 5.4General Information . . . . . . . . . . . . . . . . . . . . . 5.2National 2000 Series Seat . . . . . . . . . . . . . . . . . 5.5Sears Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

Subject PageSpeedometer and Tachometer . . . . . . . . . . . . . . . 3.10

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 3.10Tachometer, Optional . . . . . . . . . . . . . . . . . . . 3.11

Standard Instruments . . . . . . . . . . . . . . . . . . . . . 3.11Coolant Temperature Gauge . . . . . . . . . . . . . . . 3.11Engine Oil Pressure Gauge . . . . . . . . . . . . . . . 3.11Fuel Level Gauge, Pre-

EPA10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12Fuel/Diesel Exhaust Fluid

(DEF) Gauge, EPA10 . . . . . . . . . . . . . . . . . . 3.12Primary and Secondary Air

Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 3.13Transmission Fluid

Temperature Gauge . . . . . . . . . . . . . . . . . . . 3.12Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

Starting After ExtendedShutdown or Oil Change . . . . . . . . . . . . . . . . . . 7.10

Starting, and Engine Shutdown(HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . 15.2Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2The Cranking System . . . . . . . . . . . . . . . . . . . 15.2

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Power Steering System . . . . . . . . . . . . . . . . . . 9.1Steering Wheel Adjustment . . . . . . . . . . . . . . . . 9.1

TTire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . 1.2Towing (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5

Front Towing Hookup . . . . . . . . . . . . . . . . . . . 13.5Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 13.5

VVehicle Specification Decal . . . . . . . . . . . . . . . . . . 1.1Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 12.2

Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 12.3Grease and Oil-Based Stains . . . . . . . . . . . . . . 12.3Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3Sugar and Water-Based

Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 12.2

Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 12.2Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 12.2Nail Polish and Nail Polish

Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 12.2Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 12.2

Index

I-4

Subject Page

Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 12.2

WWarning and Indicator Lights . . . . . . . . . . . . . . . . . 3.6

Check Engine Indicator . . . . . . . . . . . . . . . . . . . 3.6Emergency Buzzer . . . . . . . . . . . . . . . . . . . . . . 3.8Engine Protection Warning . . . . . . . . . . . . . . . . 3.6

Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Windshield Washer Reservoir . . . . . . . . . . . . . . . . 5.11

Index

I-5

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