manual de conduccion camion freightliner business class m2

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.).

Emissions and Fuel EfficiencyComplianceThis vehicle must be regularly inspected and main-tained as indicated in the Business Class M2 Mainte-nance Manual, and in the Pretrip and Post-Trip In-spections and Maintenance chapter in this manual, inorder to continue satisfactory performance and en-sure coverage of the vehicle under the manufactur-er’s warranty. Many maintenance procedures ensurethat the vehicle and engine continue to comply withapplicable emissions standards. Maintenance proce-dures, using components engineered to comply withgreenhouse gas emissions and fuel efficiency regula-tions, may be performed by an authorized DaimlerTrucks North America dealer, an independent outlet,or the vehicle owner or operator.

The vehicle owner is responsible for determining thesuitability of replacement components to maintaincompliance with federal and local jurisdictional regu-lations. Components including, but not limited to,tires, cab/sleeper side extenders, chassis fairings,bumper, hood, vehicle speed limiters, and idle reduc-tion timers are specifically designed and manufac-tured to exacting standards for regulatory fuel effi-ciency and greenhouse gas emissions compliance. Itis important that these components are always re-placed with components that meet or exceed the per-formance of the originally installed components.

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, fordealer 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 safety

Foreword

STI-455-6 (6/12)A24-01238-000

Printed in U.S.A.

defect 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 .

© 2001–2012 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

www.safercar.gov

www.safercar.gov

www.tc.gc.ca/roadsafety

www.tc.gc.ca/roadsafety

http://www.daimler-trucksnorthamerica.com

www.freightlinertrucks.com

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Emissions and Fuel Efficiency Compliance,Customer Assistance Center, Reporting Safety 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 IdentificationComponent Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Federal Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Canadian Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Component GWR Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Emission Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

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

The component information label lists the vehiclemodel, identification number, and major componentmodels. It also lists the major assemblies and instal-lations shown on the chassis specification sheet.One copy of the component information label is in-stalled on the right-side dash; another copy is insidethe rear cover of the Owner’s Warranty Informationfor North America booklet. An illustration of the labelis shown in Fig. 1.1 .

Federal Motor Vehicle SafetyStandard LabelsNOTE: Due to the variety of Federal Motor Ve-hicle Safety Standard (FMVSS) certification re-quirements, not all of the labels shown will applyto your vehicle.

Tractors with or without fifth wheels purchased in theU.S. are marked as certified by means of an FMVSScertification label. See Fig. 1.2 . This label is attachedto the driver-side B-pillar, as shown in Fig. 1.3 .

The tire and rim portion of the FMVSS certificationlabel certifies suitable tire and rim combinations thatcan be installed on the vehicle, for the given grossaxle weight rating. Tires and rims installed on thevehicle at the time of manufacture may have a higherload capacity than that certified by the tire and rimlabel. If the tires and rims currently on the vehiclehave a lower load capacity than that shown on thetire and rim label, then the tires and rims determinethe load limitations on each of the axles.

Trucks built without a cargo body that are intendedfor service in the U.S. have an incomplete vehiclecertification label attached by the final-stage manu-facturer. See Fig. 1.4 . This label will be attached tothe incomplete vehicle document included with thevehicle, and certifies that the vehicle conforms to allapplicable FMVSS regulations in effect on the date ofcompletion.

Canadian Motor Vehicle SafetyStandard LabelsIn Canada, tractors with fifth wheels are marked ascertified by means of a statement of compliance labelwith the Canadian National Safety Mark attached tothe driver-side door frame B-pillar. See Fig. 1.5 .

If purchased for service in Canada, trucks built with-out a cargo body and tractors built without a fifthwheel are marked as certified by a "Statement ofCompliance" label, similar to Fig. 1.4 . This label mustbe attached by the final-stage manufacturer to certifythat the vehicle conforms to all applicable CanadaMotor Vehicle Safety Standard (CMVSS) regulationsin effect on the date of completion.

Component GWR LabelThe component GWR label is located on thepassenger-side B-pillar. The label provides maximumGWR ratings for each component.

02/20/2012 f080176

Fig. 1.1, Component Information Label

02/20/2012 f080177

Fig. 1.2, Vehicle Certification Label

Vehicle Identification

1.1

See Fig. 1.6 for a typical component GWR label.

Emission LabelsAftertreatment System IndicatorsLabelEngines and vehicles manufactured after December31, 2006 and domiciled in the U.S. or Canada arerequired to meet all EPA regulations effective as ofthe vehicle build date, and are equipped with anemission aftertreatment system (ATS). Vehicles do-miciled outside of the U.S. and Canada may nothave aftertreatment equipment, depending upon localstatutory emissions guidelines. See Table 1.1 .

A warning label on the driver-side visor contains im-portant warning indicators in the instrument clusterthat pertain to the ATS. See Fig. 1.7 or Fig. 1.8 .

It is a violation of U.S. federal law to alter exhaustplumbing, ATS, or other components in any way thatwould bring the engine/vehicle out of compliance withcertification requirements [Ref: 42 U.S.C. S7522(a)(3)]. It is the owner’s responsibility to maintain thevehicle so that it conforms to EPA regulations.

EPA Noise Emission Control LabelA vehicle noise emission control label (Fig. 1.9 ) islocated on the driver-side B-pillar as shown inFig. 1.3 . It is the owner’s responsibility to maintainthe vehicle so that it conforms to EPA regulations.

IMPORTANT: Certain Freightliner incompletevehicles may be produced with incomplete noisecontrol hardware and will not have a noiseemission control information label. For such ve-hicles, it is the final-stage manufacturer’s re-sponsibility to complete the vehicle in conformityto EPA regulations (40 CFR Part 205) and labelit for compliance.

1

2

f08011711/13/2001

1. Tire and Rim Information2. FMVSS Certification Label

Fig. 1.3, Label Locations

f08018002/28/2012

Fig. 1.4, Incomplete Vehicle Certification Label

f08002410/10/2006

Fig. 1.5, Canadian National Safety Mark


1.2

Applicable Emissions System Based on Build Date and EPA RegulationsBuild Date Regulation: Emissions Components

January 1, 2007–December 31,2009

EPA07 (reduce nitrogen oxides (NOx) emissions to 1.1 g/bhp-hr, and reduceparticulate matter emissions to 0.01 g/bhp-hr): Aftertreatment device (ATD) containinga diesel particulate filter that traps soot and ash.*

January 1, 2010–December 31,2012

EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): EPA07-type ATD, with additionalselective catalyst reduction (SCR) technology that utilizes diesel exhaust fluid (DEF)to convert NOx to nitrogen and water vapor.

From March 5, 2012

GHG14: Aerodynamic and fuel efficiency components including, but not limited to,tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speedlimiters, and idle reduction timers specifically designed to meet regulatory fuelefficiency and greenhouse gas emissions standards.

* Cummins, Detroit, and Mercedes-Benz ATD’s are also equipped with a diesel oxidation catalyst to break down pollutants.

Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations

Vehicle Emission Control InformationLabelModel year 2013 and later vehicles meet additionalrequirements as specified by federal greenhouse gasand fuel efficiency regulations (GHG14). These ve-hicles are equipped with components that increasefuel efficiency and reduce GHG emissions. Compo-nents may include, but are not limited to, low-rollingresistance tires; aerodynamic devices such as hood,cab side extenders, and fuel tank fairings; vehiclespeed limiters; and idle shutdown timers.

A Vehicle Emission Control Information Label is lo-cated on the driver-side door. See Fig. 1.10 . It is theowner’s responsibility to maintain the vehicle so thatit conforms to EPA and NHTSA regulations.

Certified Clean Idle LabelThe California Air Resources Board (CARB) requiresmodel year 2008 and newer heavy-duty diesel en-gines to be equipped with a non-programmable en-gine shutdown system that automatically shuts down

the engine after five minutes of idling in order to limitemissions of particulate matter and NOx.

Certified vehicles are equipped with a label placednear the bottom edge of the driver-side door. SeeFig. 1.11 .

02/20/2012 f080178

Fig. 1.6, Component GWR Label


1.3

f080156

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended.

Filter is reaching

Bring vehicle tohighway speeds to

Filter Regeneration

Filter is nowreaching maximumcapacity.

To avoid enginederate, bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked, and a Parked

Service Regeneration Required.Engine Derate To Idle Only.

Filter has exceeded maximumcapacity.

Vehicle must be parked, and aService Regeneration must be

(Solid) (Flashing) (Flashing)

CHECKINDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity.

STOP

allow for an AutomaticRegeneration orperform a Parked

to highway speedsto allow for anAutomaticRegeneration, orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed.Engine will beginderate.

performed. Check engineoperator’s manual for details.Engine will shut down.

For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.

02/20/2009

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust componentsand exhaust gas are athigh temperature. Whenstationary, keep awayfrom people andflammable materials orvapors.

A regeneration is inprogress.

Flashing

Solid

Regeneration.

Necessary

Fig. 1.7, ATS Indicators, EPA07


1.4

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.

24−01656−000

IMPORTANT

DEF

11/30/2010 f080162

See operator’s manual for complete instructions.

Fig. 1.8, ATS Indicators, EPA10 and Newer

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. 1.9, Vehicle Noise Emission Control Label

f08018102/29/2012

MANUFACTURED BY:VIN:VEH FAMILY CD:GVWR−KGGVWR−LBS

REGULATORY CLASS:

EMISSION CONTROL IDENTIFIERS:

DATE OF MANUFACTURE:VEHICLE EMISSION CONTROL INFORMATION

THIS VEHICLE COMPLIES WITH U. S. EPA REGULATIONS FOR XXXX HEAVY DUTY VEHICLES.SEE OWNER’S MANUAL FOR PROPER MAINTENANCE OF THIS VEHICLE. U PART NO. 24−01177−060 REV A

Fig. 1.10, Vehicle Emission Control Information Label

CERTIFIEDCLEAN IDLE

02/20/2012 f080179

Fig. 1.11, CARB Clean Idle Label


1.5

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.

10/24/2001 f880555

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.

09/25/2001 f543935

1

2

1. Bulkhead Module 2. Main Fuse Box

Fig. 2.11, Location of the Main Fuse Box

10/25/2001 f543936

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12Overhead Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

Instrumentation Control UnitThe ICU3 instrument cluster is a single unit that pro-vides the driver with engine and vehicle information.It is comprised of gauges, warning and indicatorlamps, an audible warning, and a liquid crystal dis-play (LCD) screen.

IMPORTANT: Vehicles that are domiciled out-side of the U.S. and Canada may not haveEPA07- or EPA10-compliant engines with anemission aftertreatment system (ATS), depend-ing upon local jurisdictional emissions guide-lines.

Figure 3.1 shows a typical ICU3 instrument clusterinstalled in EPA07- and EPA10-compliant vehicles.

Vehicles that are not EPA10-compliant do not have afuel/diesel exhaust fluid (DEF) gauge.

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

The ICU3 also has the capability to drive up to sixindependent stand-alone gauges such as those in-stalled on the auxiliary dash panel. Figure 3.2 showsa typical dash panel layout.

Dash Message CenterThe dash message center houses all of the standardand optional warning and indicator lamps, as well asthe driver display screen. The display screen has a

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. Driver Display Screen4. Headlight High-Beam Indicator

5. Fuel/DEF Level Gauge6. Primary Air Pressure Gauge7. Mode/Reset Button8. Secondary Air Pressure Gauge

9. Speedometer (U.S. version)10. Tachometer11. Transmission Temperature Gauge12. Coolant Temperature Gauge

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

Instruments

3.1

7-character LCD that normally shows odometer read-ings and, below that, a smaller 3-character LCD thatshows voltmeter readings. Warning messages anddiagnostic fault codes will also appear in the displayscreen.

Information provided by the driver display screen in-cludes:

• odometer readings (in miles or kilometers)

• trip and total engine distance

• trip and total engine hours

• service screens

• fault code displays

• warning messages

Ignition SequenceWhen the ignition is turned on, the ICU3 runsthrough the ignition sequence. See Fig. 3.3 . First,the ICU3 performs a self-test, looking for active faultcodes and displays them, if any, one after the otheruntil the engine is started or the ignition switch isturned off. If there are no active fault codes, thedriver display screen displays the odometer.

When the ignition is first turned on, all the electronicgauges complete a full sweep of their dials, thewarning and indicator lamps illuminate, and the au-dible warning sounds for three seconds. On EPA10-compliant vehicles, the DEF level indicator illumi-nates all segments green, then turns them off one ata time before turning the left most segment amberthen red.

5

4

f610578

1

23

10/11/2001

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

1. Left-Hand Control Panel2. ICU33. Right-Hand Control Panel

4. Auxiliary Dash Panel5. Climate Control Panel

Fig. 3.2, Dash Panel Layout (typical)

Instruments

3.2

NOTE: The air gauges do not sweep.

NOTE: If active fault codes are present, take thevehicle to an authorized Freightliner service fa-cility as soon as possible.

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.

If service miles or service hours has been exceeded,either Fig. 3.4 or Fig. 3.5 will come up before thefault screen (if fault codes are present). If no faultcodes are present and service hours or miles areexceeded, either Fig. 3.4 or Fig. 3.5 will stay dis-played until the parking brake is released with theengine running, or the mode/reset button is pressed.

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 fault codes.

Fig. 3.3, Ignition Sequence

10/26/2009

SERVICEHOURS

f040805

Fig. 3.4, Service Hours Exceeded

10/26/2009

SERVICE

MI

f040806

Fig. 3.5, Service Miles Exceeded

Instruments

3.3

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 are on.

The odometer is a 7-digit display with a decimal pointuntil the vehicle has traveled 999,999.9 miles or kilo-meters (km). At one million miles (km), the odometerrolls over to "1000000" without the decimal point, andcan continue up to 9,999,999. The odometer onlydisplays significant figures (no leading zeros).

Mode/Reset ButtonThe mode/reset button (Fig. 3.6 ) is located on theright side of the instrument cluster. The mode/resetbutton is used to scroll through the displays on thedriver display screen, and to reset the trip distanceand trip hours values to zero.

FunctionsWhen the parking brake is off, pressing the mode/reset button will scroll through the following screens:

i. Trip distance

ii. Trip hours

iii. Outside temperature

iv. Back to odometer

When the parking brake is set, pressing the mode/reset button will scroll through the following screens:

i. Trip distance

ii. Trip hours

iii. Outside temperature

iv. Select screen

v. Temperature alert screen

vi. Diagnostic screen

vii. Clear screen (with less than 254 miles)

viii. Engine miles

ix. Engine hours

x. Setup screen

xi. Back to odometer

Trip MilesTo reset trip miles and/or trip hours to zero, press themode/reset button for one second or longer.

Miles or KilometersTo toggle between MI (miles) or KM (kilometers),press the mode/reset button while in the Selectscreen.

Audible WarningsAn audible warning sounds during the ignition se-quence and whenever one of the following conditionsexist:

• Engine oil pressure falls below the minimumlevel shown in Table 3.1 .

• Coolant temperature rises above the maximumtemperature shown in Table 3.2 .

• Air pressure falls below approximately 70 psi(483 kPa).

• Parking brake is set with the vehicle moving ata speed greater than two miles per hour.

• System voltage falls below 12.0 volts.

• Door is open and the parking brake is off.

• Occupied seat belts are not fastened and theparking brake is off.

• Outside temperature falls below 35°F (1.7°C).

Minimum Oil Pressure *

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)Caterpillar 10–20 (69–138) 30–45 (207–310)Cummins 15 (103) 35 (241)

09/25/99

PUSH− MODE HOLD− RESET

f610340

Fig. 3.6, Mode/Reset Button

Instruments

3.4

Minimum Oil Pressure *

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)Detroit Diesel 14 (97) 55 (350)Mercedes-Benz 7 (50) 36 (250)* 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, Minimum Oil Pressure

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

Caterpillar 230 (110)Cummins 225 (107)Detroit Diesel 215 (101)Mercedes-Benz 222 (105)

Table 3.2, Maximum Coolant Temperature

Warning and Indicator LightsThere can be up to 28 warning and indicator lampsinstalled in the dash message center. See Fig. 3.7for pre-EPA07 engines, Fig. 3.8 for EPA07 engines,or Fig. 3.9 for EPA10 engines.

The lamps, or telltales, in the top row are optional.The lamps on the other three rows are installed atfixed positions that do not vary. If an optional lamp isnot requested, the position is blank.

See Table 3.3 for a list of standard and commonlyused warning and indicator lamps.

Engine Protection SystemIf a critical engine condition exists (for example, lowengine oil pressure, low coolant level, high coolanttemperature, high diesel particulate filter soot level,or uncontrolled regeneration), the CHECK enginelamp will illuminate to alert the driver to correct thecondition as soon as possible. If the condition wors-ens, the STOP engine lamp will illuminate.

NOTE: If the CHECK engine lamp illuminatesduring vehicle operation, take the vehicle di-rectly to an authorized Freightliner service facil-ity.

WARNINGWhen the red STOP engine lamp illuminates,most engines are programmed to shut down au-tomatically within 30 seconds. The driver mustimmediately move the vehicle to a safe locationat the side of the road to prevent causing a haz-ardous situation that could cause bodily injury,property damage, or severe damage to the en-gine.

The STOP engine lamp illuminates when the engineprotection system is activated. The engine protectionsystem typically works as follows, depending on theengine type. Some vehicles may have a shutdown-override switch, which may be used to momentarilyoverride the shutdown sequence. See Chapter 7 formore information.

• On some engines, the engine protection sys-tem will derate the engine, allowing it to run atlower rpm and slower vehicle speed—drive thevehicle to a safe location or to a service facility.

• On other engines, the engine protection sys-tem will shut down the engine. It will first der-ate the engine, then shut it down completely30 to 60 seconds after the indicator illuminates(depending on the critical fault type) if the con-dition does not improve.

Bring the vehicle to a stop on the side of theroad before the engine shuts down. Do not at-tempt to restart the engine while the vehicle ismoving. To restart the engine, turn the ignitionswitch to OFF, leave it there a few seconds,then turn the switch to START. The engine willrun for a short period and shut down again ifthe condition does not improve.

Instruments

3.5

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 Warning2. Low Washer Fluid Indicator3. Intake Heater On Indicator4. Water In Fuel Indicator5. Wheel Spin Indicator6. Low Coolant Warning7. Check Transmission Indicator8. Engine Fan On Indicator9. Low Fuel Warning10. Check Engine Indicator

11. Engine Protection Warning12. No Charge Indicator13. Tractor ABS Indicator14. Transmission Temperature

Indicator15. Trailer ABS Indicator (as applies)16. Low Oil Pressure Warning17. High Coolant Temperature

Warning18. Fasten Seat Belts Warning

19. Parking Brake On Indicator20. Not Used21. Air Restriction Indicator22. Left-Turn Signal23. Low Battery Voltage Warning24. Driver Display Screen25. High-Beam Headlights Indicator26. Low Air Pressure Warning27. Right-Turn Signal

Fig. 3.7, Pre-EPA07 Dash Message Center

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 (as applies)

8. Low Oil Pressure Warning9. High Coolant Temperature

Warning10. Fasten Seat Belt Warning11. Parking Brake On Warning12. DPF Status Lamp13. High Exhaust System

Temperature (HEST) Warning

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

Fig. 3.8, EPA07 Dash Message Center

Instruments

3.6

Common Warning and Indicator Lamps

CHECK CHECK Engine

Indicates a critical engine condition (low oil pressure, lowcoolant level, high coolant temperature, high DPF soot level,or uncontrolled DPF regeneration). Correct the condition assoon as possible. If the condition worsens, the STOP enginelamp will illuminate.

STOP STOP Engine

Indicates a serious fault which requires engine shutdownimmediately. The engine protection system will reduce themaximum engine torque and speed, and, if the conditiondoes not improve, will shut down the engine within 30 to 60seconds.

The driver must safely bring the vehicle to a stop on the sideof the road and shut down the engine as soon as the redlight is seen. If the engine shuts down while the vehicle is ina hazardous location, restart the engine after turning the keyto the OFF position for a few seconds. Move the vehicle to asafer location.

High Exhaust System Temperature(HEST)

Slow (10-second) flashing indicates a regeneration (regen) isin progress.

Solid illumination indicates high exhaust temperatures at theoutlet of the tail pipe, when speed is below 5 mph (8 km/h).It does not signify the need for service; it only alerts thevehicle operator to high exhaust temperatures when a regenis in progress.

DPF Status

Solid illumination indicates a regen is required. Change to amore challenging duty cycle (such as highway driving ) toraise exhaust temperatures for at least twenty minutes, orperform a parked regen.

Blinking indicates that a parked regen is requiredimmediately. An engine derate and shutdown will occur.

Malfunction Indicator Lamp (MIL) Indicates an emissions-related fault. See the engineoperation manual for details.

Vehicle ABS

Indicates the vehicle ABS is engaged.

When ABS is not engaged. illumination indicates a problemwith the vehicle ABS. Repair the ABS immediately to ensurefull braking capability.

Trailer ABS

Indicates the trailer ABS is engaged.

When ABS is not engaged. illumination indicates a problemwith the vehicle ABS. Repair the ABS immediately to ensurefull braking capability.

WHEELSPIN Wheel Spin

Indicates the Automatic Traction Control (ATC) is engaged.

Solid illumination indicates a problem with the ATC system.Repair the ATC system immediately to ensure full brakingcapability.

High Coolant Temperature Indicates the coolant temperature is above the maximumallowable temperature listed in Table 3.2 .

Instruments

3.7


Low Air Pressure Indicates air pressure in the primary or secondary reservoiris below 70 psi (483 kPa).

WAIT

TO START Wait To StartIlluminates when starting the engine during cold conditions.Wait until the lamp goes out before turning the ignition key toSTART.

Low Engine Oil Pressure Indicates the engine oil pressure is below the minimumallowable pressure listed in Table 3.1 .

Water In Fuel Indicates the fuel may contain water. Drain any watercollected in the fuel/water separator.

Fuel Filter Restriction Indicates the fuel filter is clogged and requires service.

Low Battery Voltage Indicates that battery voltage is 11.9 volts or less.

Check Transmission Indicates an undesirable transmission condition.

Transmission Overheat Indicates high transmission temperature.

NOCHARGE No Charge Indicates an alternator charge output failure.

Engine Brake Indicates the engine brake is engaged.

IDLE

MGMT Optimized Idle Indicates optimized idle is enabled.

Left-Turn Signal Flashing indicates the outside left-turn signal lights areactivated.

Right-Turn Signal Flashing indicates the outside right-turn signal lights areactivated.

High-Beam Headlights Indicates the high-beam headlights are on.

Instruments

3.8


Parking/Emergency Brake Indicates the parking brake is engaged.

Cruise Control Indicates the cruise control is enabled.

Unfastened Seat Belt

Activates with an audible alert when the system detects thatthe parking brake is off and the driver seat belt is notfastened on some vehicles. On other vehicles, this lampilluminates for 15 seconds when the ignition is first turnedon.

Table 3.3, Common Warning and Indicator Lamps

Standard InstrumentsStandard instruments are present on every vehicle.They are listed here in alphabetical order, to makethe information easier to find.

Air Pressure Gauges

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. Moving

a vehicle without adequate braking power couldcause an accident resulting in personal injury ordeath.

Air pressure gauges, as shown in Fig. 3.10 , registerthe pressure in the primary and secondary air sys-tems. The gauges are labeled for the A or B reser-voir. Normal pressure with the engine running is 100to 120 psi (689 to 827 kPa) in both systems.

A low-air-pressure warning light and audible warning,connected to both the primary and secondary sys-tems, activate when air pressure in either systemdrops below 64 to 76 psi (441 to 524 kPa).

ABS ABS

BRAKE

CHECK STOP

OPT 9

11/09/2011 f611107a

*WAIT*

TO START

CHECK

TRANS

BRAKEAIR

LOW

WATER

WHEEL

SPIN

AIR

FILTER

WASH

FLUID OPT 8

Fig. 3.9, EPA10 Dash Message Center

Instruments

3.9

When the engine is started, the warning light andaudible warning remain on until air pressure in bothsystems exceeds minimum pressure.

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, as shown in Fig. 3.11 , should read175 to 195°F (79 to 91°C). If the temperature re-mains below 160°F (71°C), inspect the cooling sys-tem to determine the cause.

If coolant temperature rises above the maximumtemperature listed in Table 3.2 , the CHECK enginelamp will illuminate. If the condition does not im-prove, the STOP engine lamp will also illuminate andan audible warning will sound. The engine will thenderate or shut down, depending on the type of en-gine protection system installed.

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, as shown inFig. 3.12 , displays the current engine oil pressure. Ifengine oil pressure falls below the minimum levelsshown in Table 3.1 , the CHECK engine lamp will illu-minate. If the condition does not improve, the STOPengine lamp will also illuminate and an audible warn-ing will sound. The engine will then derate or shutdown, depending on the type of engine protectionsystem installed.

Fuel Gauge, Pre-EPA10Pre-EPA10-compliant vehicles have a fuel levelgauge indicating the level of diesel in the fuel tank(s).See Fig. 3.13 . A single fuel gauge is standard. Ifequipped with an optional second fuel gauge, eachfuel tank level is indicated on a separate gauge.

05/14/2001 f610556

Fig. 3.10, Air Pressure Gauge (reservoir A shown)

10/09/2001 f610565

WATER

100

150 200

250

F°

Fig. 3.11, Coolant Temperature Gauge

10/09/2001

0 100

50

PSI

OIL

f610528

Fig. 3.12, Engine Oil Pressure Gauge

Instruments

3.10

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. 3.14 .

The diesel fuel level is indicated at the top of thegauge, with a low-fuel warning lamp that illuminateswhen the diesel fuel level registers 1/8th of capacity.

The DEF level is indicated in the lightbar on thelower portion of the gauge. There is a low DEF level

warning lamp that illuminates when the DEF levelreaches 10% of capacity. See Chapter 7 for details ofthe DEF gauge functions.

SpeedometerThree speedometer options (see Fig. 3.15 ) are avail-able. The U.S. version of the speedometer registersspeed in both miles per hour (mph) and kilometersper hour (km/h), with mph in larger numbers. Themetric version of the speedometer face reverses thisarrangement, with km/h in larger numbers. Themetric-only version shows km/h exclusively.

VoltmeterThe voltmeter is a digital readout located on the bot-tom line of the dash message center whenever theignition switch is turned on.

The voltmeter indicates the vehicle charging systemvoltage when the engine is running and the batteryvoltage when the engine is off. By monitoring thevoltmeter, the driver can stay aware of potential bat-tery charging problems and have them fixed beforethe batteries discharge enough to create starting diffi-culties.

The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltageof a fully charged battery is 12.7 to 12.8 volts whenthe engine is off. Battery voltage under 12.0 volts isconsidered a low battery, and a completely dis-charged 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.

10/09/2001 f610566

E F

1/2

FUEL

Fig. 3.13, Fuel Level Gauge, Pre-EPA10

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. 3.14, Fuel/DEF Gauge, EPA10

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. 3.15, Speedometer and Tachometer (U.S. version)

Instruments

3.11

If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at an autho-rized Freightliner service facility.

On a vehicle equipped with a battery isolator system,the voltmeter measures the average voltage of all thebatteries when the engine is running. When the en-gine is off, the voltmeter shows only the isolated bat-tery voltage and does not indicate the voltage of theengine-starting batteries.

Optional InstrumentsOptional instruments, typically located on the auxil-iary dash panel or right-hand control panel, are notfound on every vehicle. They are listed here in alpha-betical order, to make the information easier to find.

Air Restriction GaugeThe air intake restriction gauge measures thevacuum on the engine side of the air cleaner. Onstandard installations, it is mounted on the air intakeduct in the engine compartment.

As an option for easier viewing, the air intake restric-tion indicator (see Fig. 3.16 ) can be mounted on thedash, usually on the right-hand control panel.

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

Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with agraduated indicator or a restriction gauge on thedash, check the gauge with the engine off. If the yel-low signal stays locked in the red zone once the en-gine is shut down, or is at or above the valuesshown in Table 3.4 , the air cleaner element needs tobe replaced.

Vehicles may be equipped with a go/no-go restrictionindicator without graduations (see Fig. 3.17 ) insteadof a graduated indicator.

Air Intake Maximum Restriction Values

Engine Make * Pre-EPA07Engines (inH 2O)

EPA07/EPA10Engines (inH 2O)

Caterpillar 25 —Cummins 25 25Detroit Diesel 20 22Mercedes-Benz 22 22* Turbocharged engines must be checked at full load and governed en-

gine speed.

Table 3.4, Air Intake Maximum Restriction Values

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Fig. 3.16, Air Intake Restriction Indicator

04/08/2005 f090431

Fig. 3.17, Manual-Reset Air Restriction Indicator, Go/No-Go

Instruments

3.12

Ambient Temperature GaugeThe ambient temperature gauge, shown in Fig. 3.18 ,displays the in-cab or outside temperature, depend-ing on the settings selected.

When the alarm is enabled, the ambient temperaturegauge will sound an audible alert and the amberlamp will illuminate when the outside or inside tem-perature (depending on the setting selected) reachesthe set temperature. Turn the alarm on and off usingthe steps below.

1. Press the IN button for in-cab temperature, orthe OUT button for outside temperature.

2. Press the SET button.

3. Press the ADJ button until the desired tempera-ture is displayed.

4. Press the ALARM button and "AL" will appear onthe display.

5. Press the SET button to return to the currenttemperature display.

NOTE: To turn the alarm off, press the ALARMbutton again and "AL" will disappear from thedisplay.

AmmeterAn ammeter, shown in Fig. 3.19 , measures currentflowing to and from the battery. When the batteriesare charging, the meter needle moves to the plusside of the gauge. When the batteries are being dis-

charged, the needle moves to the minus side. A con-sistent negative reading when the engine is runningindicates a possible problem with the chargingsystem.

Digital ClockThe digital clock, shown in Fig. 3.20 , displays thecurrent time, and has a 24-hour alarm with a3-minute snooze feature.

Set the clock by pressing the SET button, then se-lecting the desired time by pressing the HRS andMIN buttons. When the clock is set to PM hours, aPM indicator will appear on the display. When thePM indicator is not displayed, the clock is set to anAM hour.

SET ADJ ALARM

IN OUT

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Fig. 3.18, Ambient Temperature Gauge

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Fig. 3.19, Ammeter

SET SNOOZE ALARM

HRS MIN

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Fig. 3.20, Digital Clock

Instruments

3.13

To set the alarm, press the SET button, then pressthe ALARM button. Select the desired alarm time bypressing the HRS and MIN buttons, then press theSET button once again.

To turn the alarm on and off, press the ALARM but-ton when the current time is displayed. When thealarm sounds, pressing the SNOOZE button willdelay the sounding of the alarm for three minutes.

Drive Axle Oil Temperature Gauges

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 vehicle until the cause hasbeen determined and corrected.

During normal operation, forward-rear and rear-rearaxle oil temperature gauges (see Fig. 3.21 ) shouldread between 160 and 220°F (71 and 104°C).

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.

Engine Oil Temperature Gauge

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

• 160 to 195°F (71 to 91°C) for Caterpillar en-gines

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

• 177 to 203°F (81 to 95°C) for Mercedes-Benzengines


TachometerThe tachometer, shown in Fig. 3.9 , indicates enginespeed in revolutions per minute (rpm) and serves asa guide for shifting the transmission and keeping theengine in the appropriate rpm range. For low idle andrated rpm, see the engine identification plate.

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Fig. 3.21, Axle Oil Temperature Gauge

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Fig. 3.22, Engine Oil Temperature Gauge

Instruments

3.14

Transmission Fluid TemperatureGaugeThe transmission fluid temperature gauge, shown inFig. 3.23 , measures the transmission lubricant oper-ating temperature. Temperatures vary by application,but the transmission fluid temperature gauge readingshould not exceed 250°F (121°C).

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.


Turbocharger Boost Pressure GaugeA turbocharger boost pressure gauge, shown inFig. 3.24 , measures the pressure in the intake mani-fold, in excess of atmospheric pressure, being cre-ated by the turbocharger.

Overhead Instrument PanelThe optional overhead instrument panel, shown inFig. 3.25 , may hold a citizen’s band (C/B) radio, amicrophone clip, and any switches that can not be

accommodated on the driver’s or auxiliary dashpanels.

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 .

10/30/2001 f610600

TRANS

125 350

F

275200

Fig. 3.23, Transmission Fluid Temperature Gauge

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Fig. 3.24, Turbo Boost Pressure Gauge

Instruments

3.15

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. 3.25, Overhead Instrument Panel

Instruments

3.16

4

ControlsIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Multifunction Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7All-Wheel-Drive Controls, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Adjustable Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13Other Dash-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14Heater/Air Conditioner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

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,

09/12/2001 f610509

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

10/15/2001 f610579a

1

2

3

4

5

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

Fig. 4.2, Switch and Gauge Panels

10/15/2001 f610580

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;

f61059810/29/2001

Fig. 4.4, Panel Light Increase/Decrease Switch

05/09/2002 f610581

Raise the paddle to flash the marker lights.

Fig. 4.5, Marker Light Interrupt Switch

10/15/2001 f610582

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 is located on the pivoting handleof the spotlight. There may be a single spotlight as-sembly mounted on the driver’s door, or one on eachdoor.

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. 4.8 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. 4.9for the optional dome/reading lights on the overheadconsole.

Light ReplacementRear Dome LightTo replace the rear dome light (Fig. 4.8 ), do the fol-lowing steps:

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. 4.9 ), do the following steps:

10/15/2001 f610583

Fig. 4.7, Utility Light Switch

10/16/2001 f543926

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

Fig. 4.8, Rear Dome Light

10/17/2001 f610587

1

2

3

1. Overhead Console2. Trimplate

3. Light Assembly

Fig. 4.9, Overhead Console Dome Lights

Controls

4.4

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. 4.9 ). 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. 4.10 for the multifunction switch and itscomponent parts.

Turn-Signal ControlsThe turn signal lever (Fig. 4.11 ) is mounted on thesteering column. Moving the lever down turns on theleft 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.

f820386

12

3

4

5

11/16/2001

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. 4.10, Multifunction Turn Signal Switch

10/17/2001 f820384

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

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

Fig. 4.11, Turn Signal Controls

Controls

4.5

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. 4.12 . 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. 4.13 .

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).

f820383

1 3

2

4

5

10/29/2001

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. 4.12, Wiper/Washer Controls

10/17/2001 f820385

1

2

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. 4.13, Headlight High Beams

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. 4.10 ) 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. 4.14 .

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. 4.15 .Pull downward on the lanyard to sound the air horn.

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. 4.16.

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

10/17/2001 f461918

1

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

Fig. 4.14, Electric Horn Control

10/17/2001 f610592

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

Fig. 4.15, Air Horn Control

f61084803/09/2012

RGEN

Fig. 4.16, Request/Inhibit Regen Switch

Controls

4.7

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. 4.17 . 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/ACCabove 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. 4.18 .

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

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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. 4.17, Cruise Control Switches, Dash-Mounted

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1 2

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

Fig. 4.18, Engine Brake Switches

Controls

4.8

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. 4.19or Fig. 4.20 .

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. 4.21 .

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.

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. 4.22 .

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. 4.23 . 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 stay

f61058911/28/2001

Fig. 4.19, Exhaust Brake Switch

f610589a03/31/2009


f61059001/04/2011

Fig. 4.21, Engine Fan Switch

Controls

4.9

illuminated 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. 4.24 . 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.

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.

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1

2

3

f270119

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

brake)

Fig. 4.22, Steering Column-Mounted Shift Controls

f61063801/22/2003

Fig. 4.23, Overdrive Lockout Switch

10/26/2001 f610596

Fig. 4.24, Differential Lock Switch

Controls

4.10

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. 4.25 . 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. 4.26 .

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 theLED 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.

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Fig. 4.25, Interaxle Lock Switch

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Fig. 4.26, Axle Shift Switch

Controls

4.11

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. 4.27 . 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 RANGE

at 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. 4.28 . 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.

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. Press

08/10/2006 f610807

LOCKED

AWD

Fig. 4.27, AWD Operation Switch

1

f610808

LO

RANGEHIGH

RANGELO

RANGEHIGH

N−TRL

07/21/2006

2

1. Two-Position Switch2. Three-Position Switch

Fig. 4.28, AWD Range Switches

Controls

4.12

the 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. 4.29 ) 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. 4.29 ) 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. 4.30 . 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. 4.31 .

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. 4.32 .

To telescope the steering column, press down on thefoot pedal located below the steering column. Pullthe steering wheel closer to you or push the steering

f610291

1 2

03/10/99

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

Fig. 4.29, Brake Valve Control Knobs

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Fig. 4.30, Trailer Brake Lever

Controls

4.13

wheel 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.

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. 4.33 ). 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). To

21 3

10/12/2000 f610454

1. Tractor ABS Indicator2. Wheel Spin Indicator

(optional)

3. Trailer ABS Indicator

Fig. 4.31, 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. 4.32, Adjustable Steering Column

Controls

4.14

raise 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 suspension

will 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. 4.34 .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. 4.35 ) 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.

Seat ControlsBench Seat Adjustment ControlsThe standard bench seat has one control: the seatslide lever. See Fig. 4.36 . The two-person bench

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Fig. 4.33, Suspension Dump Switch

PUSH TO

09/11/2007 f321102

Fig. 4.34, Suspension Autofill Override Valve

Controls

4.15

seat 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 slideadjustment so that the seat back contacts the back-wall. It is the responsibility of the driver to adjust the

seat 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.

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231

40

1 2 3

f831452

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

Fig. 4.35, HVAC Climate Control Panel, Standard

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1

2

1. Three-Person Seat2. Seat Slide Lever

Fig. 4.36, 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.

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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.

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f910445

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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

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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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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)

10/08/2001 f9104881 2

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. When any part ofa seat belt system needs replacement, the entireseat belt must be replaced, both retractor andbuckle side. Any time a vehicle is involved in anaccident, and the seat belt system was in use,the entire vehicle seat belt system must be re-placed before operating the vehicle. Do not at-tempt to modify the seat belt system; doing socould change the effectiveness of the system.Failure to replace worn or damaged seat belts, ormaking any modifications to the system, may re-sult in personal injury or death.

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

1. Check the web for fraying, cuts, extreme dirt anddust, or for severe fading from exposure to sun-light, especially near the buckle latch plate and inthe D-loop guide area.

2. Check operation of the buckle, latch, KomfortLatch or Sliding Komfort Latch (if equipped), webretractor, and upper seat belt mount on the doorpillar. Check all visible components for wear ordamage.

3. Check the seat belt and tether belt connectionpoints and tighten 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.

When engaged and used properly, the Komfort Latch(Fig. 5.16 ) and the Sliding Komfort Latch (Fig. 5.17 )

Cab Features

5.7

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 your

lap (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 5inches (13 cm) will disengage the Sliding Kom-fort Latch, requiring it to be reset.

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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

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 shoulder

belt 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.

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 the

A

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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

steering 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.

There is a dash storage bin located under the cupholders on the center panel. The bin has a hinged

Cab Features

5.10

www.dtsc.ca.gov/hazardouswaste/perchlorate

www.dtsc.ca.gov/hazardouswaste/perchlorate

cover 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 overheadconsole.

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

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3

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

Fig. 5.21, Overhead Storage

Cab Features

5.11

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3

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

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

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1. Printer Top2. Printer/Paper Area

3. Storage Console Base

Fig. 5.23, Center Storage Console (printer option)

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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

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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

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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

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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

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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

EnginesEmissions and Fuel Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Starting After Extended Shutdown or Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10High-Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13Exhaust Braking Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

Emissions and Fuel EfficiencyIMPORTANT: Depending on local jurisdictionalguidelines, vehicles that are domiciled outside ofthe U.S. and Canada may not have emissionsaftertreatment systems (ATS) that are compliantwith EPA regulations.

NOTICEFollow these guidelines for engines that complywith EPA07 or newer regulations, or damage mayoccur to the aftertreatment device (ATD) and thewarranty may be compromised.

• Use ultralow-sulfur diesel with 15 ppm sul-fur content or less.

• Do not use fuel blended with used enginelube oil or kerosene.

• Engine lube oil must have a sulfated ashlevel less than 1.0 wt %; currently referredto as CJ-4 oil.

IMPORTANT: Using non-specification fuels oroils can lead to shortened diesel particulate filter(DPF) cleaning or replacement intervals. Forexample, using CJ-4+ oil with 1.3% sulfated ash(30% more ash content) may result in the needfor DPF cleaning or replacement 20 to 30%sooner than would normally be required.

IMPORTANT: See the engine manufacturer’soperation manual for complete details and op-eration of the ATS.

Greenhouse Gas Emissions and FuelConsumption StandardsVehicles and/or engines manufactured after Decem-ber 31, 2006 and domiciled in the U.S. or Canadaare required to meet all EPA and NHTSA regulationseffective as of the vehicle build date. Engines manu-factured between January 1, 2007 and December 31,2009 meet EPA07 requirements. Engines manufac-tured between January 1, 2010 and December 31,2012 meet EPA10 requirements.

Model year 2013 and later vehicles meet additionalrequirements as specified by GHG14 requirements.These vehicles are equipped with components thatincrease fuel efficiency and reduce GHG emissions.

Components may include, but are not limited to, low-rolling resistance tires; aerodynamic devices such ashood, cab/sleeper extenders, and fuel tank fairings;vehicle speed limiter; and idle shutdown timer. If re-placement of any drag-reducing component is re-quired, the replacement component must meet orexceed the drag reduction performance of the origi-nally installed component in order to maintain compli-ance with GHG14 requirements.

EPA07 EnginesEngines built between January 1, 2007 and Decem-ber 31, 2009 are required to meet EPA07 guidelinesfor reduced exhaust emissions of particulate matterand nitrogen oxides (NOx). NOx is limited to justover 1 gram per brake horsepower hour (g/bhp-hr),and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufac-turer and vehicle configuration, but the exhaust muf-fler is replaced by an aftertreatment device (ATD).Inside the ATD, the exhaust first passes over the die-sel oxidation catalyst (DOC), then passes throughthe diesel particulate filter (DPF), which traps sootparticles. The soot is burned to ash during a processcalled regeneration (regen).

EPA10 and Newer EnginesThe 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, engines that are compliantwith EPA10 and newer regulations use an ATS thathas, in addition to a DOC/DPF device like that usedin an EPA07 ATD, a Selective Catalytic Reduction(SCR) device to reduce NOx downstream of the en-gine. After exhaust gases leave the DPF, a controlledquantity of diesel exhaust fluid (DEF) is injected intothe exhaust stream. In the presence of heat, DEF isconverted to ammonia gas, which reacts with NOx inthe selective catalyst chamber to yield nitrogen andwater vapor, which exit through the tailpipe.

RegenerationThe harder an engine works, the better it disposes ofsoot. If the exhaust temperature is high enough, aprocess called passive regeneration (regen) occurs

Engines

7.1

as the vehicle is driven normally. However, if the en-gine isn’t running hot enough, the electronic controlsmay initiate an active regen , whereby extra fuel isinjected into the exhaust stream to superheat andreduce the soot trapped in the DPF to ash. Activeregen happens only when the vehicle is movingabove a certain speed, determined by the enginemanufacturer. See your engine operation manual forcomplete details. Both active and passive regen hap-pen automatically, without driver input.

WARNINGActive regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (800°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet. The exhaust temperature canremain high even after the vehicle has stopped.When stopping the vehicle shortly after an auto-matic regen, ensure the exhaust outlets are di-rected away from structures, trees, vegetation,flammable materials, and anything else that maybe damaged or injured by exposure to high heat.

See Regen Switches , below, for instructions onpreventing automatic regen if necessary.

When operating conditions do not allow for ATD filtercleaning by active or passive regen, the vehicle mayrequire a driver-activated parked regen . When thisoccurs, the DPF lamp illuminates, indicating that aregen is required. The driver must either bring thevehicle up to highway speed to increase the load(thus starting an active regen), or park the vehicleand initiate a parked regen. See Regen Switches,below, for instructions on initiating a parked regen.

Regen SwitchesThe regen request switch, located on the dash, isused to initiate a parked regen. See Fig. 7.1 . Thefunction of the switch varies by the engine make andmodel in the vehicle. See the engine operationmanual for switch operation details.

Some vehicles may be equipped with a regenrequest/inhibit switch. See Fig. 7.2 . To stop a regenin progress or prevent the start of a regen, press thelower half of the switch. Regen is then delayed untilthe switch is no longer active.

NOTE: The regen switch can initiate a parkedregen only when the DPF lamp is illuminated.

WARNINGDuring parked regen, exhaust temperatures arevery high and could cause a fire, heat damage toobjects or materials, or personal injury to per-sons 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.

To initiate a parked regen, perform the followingsteps.

1. Park the vehicle away from all flammable materi-als,set the parking brake, and put the transmis-sion in neutral.

f61084803/09/2012

RGEN

Fig. 7.1, Regen Request Switch

f61094407/30/2009

Fig. 7.2, Regen Request/Inhibit Switch

Engines

7.2

2. Start and warm the engine until the coolant tem-perature is at least 150°F (66°C).

3. Lift the regen request switch guard and pressand hold the yellow button for five seconds. Asthe regen process is initiated, engine rpm in-creases and the HEST lamp illuminates to indi-cate extremely high exhaust temperatures.

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

4. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed drops to normaland the vehicle can be driven normally. TheHEST lamp is extinguished when vehicle speedexceeds 5 mph (8 km/h) or the system hascooled to normal operating temperature.

5. To stop a parked regen at any time during theprocess:

• depress the clutch pedal, brake pedal, oraccelerator pedal;

• press and hold the regen inhibit switch untilidle returns to normal;

• shut down the engine.

ATS Warning LampsThere are three warning lamps that alert the driver ofhigh exhaust temperature, the need to perform aparked regen or service the DPF, or of an enginefault that affects emissions. A decal attached to thedriver’s sun visor explains the ATS warning lamps.Fig. 7.3 .

See Fig. 7.4 for an explanation of the ATS warnings,and actions required to avoid engine protection se-quences.

Malfunction Indicator Lamp (MIL)A steadily illuminated yellow malfunction indicatorlamp (MIL) indicates an engine fault that affectsemissions. See Fig. 7.5 .

DPF Status LampWhen soot accumulates in the DPF and the DPF sta-tus lamp illuminates, see Fig. 7.6 , perform a parkedregen or bring the vehicle up to highway speed toincrease the load (thus starting an active regen).

If the DPF status lamp blinks while the CHECK en-gine lamp is illuminated, initiate a parked regen im-mediately in order to prevent an engine derate.

If the red STOP engine lamp illuminates with theblinking DPF lamp and the CHECK engine lamp,begin a parked regen in order to prevent an engineshutdown. Park the vehicle and perform a parkedregen.

High Exhaust System Temperature(HEST) LampSlow (10-second) flashing of the high exhaust sys-tem temperature (HEST) lamp indicates that aparked regen is in progress, and the engine’s highidle speed is being controlled by the engine software,not the vehicle driver.

Steady illumination of the HEST lamp alerts thedriver of high exhaust temperature during the regenprocess if the vehicle speed is below 5 mph (8 km/h), or during a parked regen. See Fig. 7.7 .

MaintenanceAuthorized service facilities must perform any DPFservice. For warranty purposes, maintain a recordthat includes:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

Diesel Exhaust Fluid and Tank,EPA10 and Newer EnginesDiesel Exhaust FluidDiesel exhaust fluid (DEF) is used in the ATS tolower NOx in the exhaust stream. DEF is colorlessand close to odorless (it may have a slightly pungentodor similar to ammonia). It is nontoxic, nonflam-mable, and biodegradable. It is mildly corrosive toaluminum, but does not affect the strength or struc-ture of the aluminum.

White crystals may be noticeable around compo-nents that come into contact with DEF. The crystalsare easily removed with water.

DEF consumption varies depending on ambient con-ditions and vehicle application.

Engines

7.3

Freezing ConditionsDEF freezes to slush at around 12°F (-11°C). It is notdamaged or destroyed if frozen, and is fully usablewhen thawed. The DEF in the tank is allowed tofreeze while a vehicle is non-operational. At start-up,normal operation of the vehicle is not inhibited if theDEF is frozen; an immersion heater with engine cool-ant flowing through it warms the DEF once the en-gine is running, allowing the SCR system to operate.

DEF supply lines are electrically-heated and arepurged when the engine is shut down; completepurging of the DEF lines requires approximately fiveminutes after the engine is shut down.

DEF TankEngines that are compliant with EPA10 and newerregulations are equipped with a DEF tank located onthe driver’s side of the vehicle behind the battery boxor forward of the fuel tank. See Fig. 7.8 and Fig. 7.9 .

The DEF tank has a 19 mm filler neck inlet that pre-vents the hose from a diesel outlet from being in-serted, and has a blue cap for easy identification.

Fuel/DEF GaugeThe diesel fuel and DEF levels are measured in adual-purpose gauge. See Fig. 7.10 .

Fuel level is indicated at the top of the gauge. Belowthe fuel level, a low fuel warning lamp illuminatesamber when the fuel level drops below 1/8th of thecapacity.

The lower portion of the gauge has a DEF warninglamp that illuminates amber when the DEF tank isnear empty, and a lightbar that indicates the level ofDEF in the tank. The DEF light bar illuminates as fol-lows:

• Four bars illuminated green—Between 75%and 100% full

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 for complete instructions.24−01656−000

IMPORTANT

DEF

11/30/2010 f080161

1

2

3

Fig. 7.3, Warning Lamp Decal, Sun Visor

Engines

7.4

• Three bars illuminated green—Between 50%and 75% full

• Two bars illuminated green—Between 25%and 50% full

• One bar illuminated green—Between approxi-mately 10% and 25% full

• One bar illuminated amber—DEF very low, re-fill DEF

• One bar flashing red—DEF empty, refill DEF

DEF Warnings and Engine LimitsIMPORTANT: Ignoring the DEF warning lightsresults in limited engine power, with the applica-tion of a 5 mph (8 km/h) speed limit after theengine is shut down and started again.

DEF Level Low—Initial WarningWhen the DEF level is low, the following lamps notifythe driver. See Fig. 7.11 . Refill the DEF tank in orderto cancel the warning sequence.

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. 7.4, ATS Warning Lamps

09/25/2006 f610814a

Fig. 7.5, Malfunction Indicator Lamp (MIL)

09/25/2006 f610815a

Fig. 7.6, DPF Status Lamp

Engines

7.5

• One bar of the DEF level indicator illuminatesamber—DEF very low, refill DEF

• The DEF warning lamp illuminates solid amber

DEF EmptyWhen the DEF level reads empty, the followinglamps notify the drive. See Fig. 7.12 .

• One bar of the DEF level indicator flashesred—DEF empty, refill DEF

• The DEF warning lamp flashes amber

• The MIL lamp illuminates

Detroit engines: Power is limited, with a 55 mph (90km/h) speed limit.

Cummins engines: Power is limited with progres-sively harsher engine power limits applied.

DEF Tank Empty and IgnoredIf the empty warning is ignored and the DEF tank isnot refilled, the red STOP engine lamp illuminates inaddition to the MIL lamp and CHECK engine lamp(on vehicles with a Cummins ISB or ISC/L engine.)See Fig. 7.13 .

If the DEF is not refilled, a 5 mph (8 km/h) speedlimit is applied after the next engine shutdown or if afuel refill is detected.

DEF Contamination or SCR Tampering

NOTICEOnce contaminated DEF or tampering has beendetected, the vehicle must be taken to an autho-rized service facility to check the SCR system fordamage and to deactivate the warning lights andengine limits.

If contaminated DEF or tampering with the ATS isdetected, the DEF warning light flashes and the MILlamp illuminates to warn the driver. The CHECK en-gine lamp also illuminates on vehicles with a Cum-mins ISB or ISC/L engine. See Fig. 7.13 .

• Detroit engines: Engine power is limited withprogressively harsher limits applied. If the fault

09/25/2006 f610816a

Fig. 7.7, HEST Lamp

07/24/2009 f470542

1

2

1. Batteries 2. DEF Tank

Fig. 7.8, DEF Tank Located Behind the Battery Box

07/24/2009 f470541

12

1. DEF Tank 2. Fuel Tank

Fig. 7.9, DEF Tank Located Forward of the Fuel Tank

Engines

7.6

is not corrected, the STOP engine light illumi-nates and a 5 mph (8 km/h) speed limit is ap-plied after the next engine shutdown or if a fuelrefill is detected.

• Cummins engines: Engine power is limited withprogressively harsher limits applied. If the faultis not corrected, the STOP engine light illumi-nates and a 5 mph (8 km/h) speed limit is ap-plied after the next engine shutdown, or whileparked and idling.

Engine StartingFor cold-weather starting, refer to "Cold WeatherStarting" later in this chapter.

This engine chapter is to serve as a guide for bestpractices only. Each make and model engine mayhave operating characteristics that are unique to thatparticular engine, and will be documented in the en-gine manufacturer’s literature. Always refer to specificinstructions and recommendations from the enginemanufacturer.

NOTE: Before starting the engine, read Chap-ter 3 for detailed information on how to read theinstruments and see Chapter 4 for detailed in-formation on how to operate the controls. Readthe operating instructions in the manufacturer’s

11/08/2010 f611037

B


E F

DEF

FE


E F

DEF

FE


E F

DEF

FE

A C

1 2

A. Green bars—DEF level indicatorsB. One bar illuminated amber—DEF very low, refill DEF

C. One bar flashing red—DEF empty, refill DEF

1. Low Fuel Warning Lamp 2. DEF Warning Lamp

Fig. 7.10, Fuel/DEF Gauge

A

B

07/09/2009 f470537

A. DEF Warning Lamp (illuminated)B. DEF Lightbar (one bar amber)

Fig. 7.11, DEF Level Low Initial Warning

A

B

11/08/2010 f470539a

NOTE: MIL illuminates. CHECK engine lamp illuminatesif Cummins ISB or ISC/L engine. Engine power is lim-ited.A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 7.12, DEF Empty Warning

Engines

7.7

engine operation manual before starting theengine.

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 propertydamage.

1. Before engine start-up, complete the pretrip in-spections and maintenance procedures in Chap-ter 11 .

2. Set the parking brake.

3. For manual transmissions, place the transmis-sion in neutral and fully depress the clutch pedal.Do not depress the accelerator pedal.

For automatic transmissions, put the transmis-sion in neutral. Do depress the accelerator pedal.

NOTE: Depending on local jurisdictional emis-sions regulations, vehicles and/or engines thatare domiciled outside of the U.S. and Canadamay not be equipped with the WAIT TO STARTor START BLOCKED lamp.

4. Turn the ignition switch to ON. See Fig. 7.14 .The following actions should occur:

• electronic gauges complete a full sweep oftheir dials

• warning and indicator lamps illuminate,then are extinguished

• DEF level indicator illuminates all seg-ments green, then turns them off one at atime before turning the leftmost segmentamber and then red

• During cold conditions, the WAIT TOSTART lamp may illuminate.

NOTE: The length of time the WAIT TO STARTlamp remains illuminated depends on the ambi-ent temperature. The lower the ambient tem-perature, the longer the lamp will be illuminated.

NOTE: If the ignition switch is turned to STARTbefore the gauge sweep has completed or if thestarter has overheated, the START BLOCKEDlamp may illuminate. Turn the ignition switchback to ON, wait for the lamp to go out, thenturn the ignition switch to START again.

5. Once the gauge sweep has completed, turn theignition key to the START position. Release thekey the moment the engine starts.

NOTICEDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the engineif oil pressure does not build within approxi-mately ten seconds. Check to determine thecause of the problem. Operating the engine withno oil pressure will damage the engine.

6. It is not necessary to idle the engine before en-gaging or starting the operation, but load shouldbe applied gradually during the warm-up perioduntil the oil temperature reaches 140°F (60°C).

A

B

11/08/2010 f470540a

NOTE: STOP engine light and MIL illuminate, enginepower is limited, speed limit of 5 mph (8 km/h)A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 7.13, DEF Empty and Ignored Warning

07/19/2006 f610805

Fig. 7.14, Ignition Switch

Engines

7.8

7. Apply load gradually during the warm-up period.

NOTICEIf the oil pressure gauge indicates no oil pres-sure, shut down the engine within approximatelyten seconds to avoid engine damage.

8. Check the oil pressure gauge for any drop in lu-bricating oil pressure or mechanical malfunctionin the lubricating oil system. Minimum oil pres-sure at idle is 7 psi (50 kPa).

Cold-Weather StartingElectronic engines do not normally require specialstarting aids.

See the engine manufacturer’s operation manual forstarting aids that are approved for specific engines.

Starting After ExtendedShutdown or Oil ChangeBefore engine start-up, complete the engine pretripand post-trip inspections and maintenance proce-dures in Chapter 11 .

NOTICEFailure to eliminate water-diluted lubricating oilmay lead to serious engine damage at startup.

An engine in storage for an extended period of time(over winter, for example) may accumulate water inthe 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.

Engine Break-InEach engine must pass a full-load operating test ona dynamometer before shipment, thereby eliminatingthe need for a break-in. Before running the enginefor the first time, follow the instructions in the enginemanufacturer’s operation manual specific to your en-gine.

Engine OperationSafety and EnvironmentalConsiderationsAll 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 local jurisdictional regulations is with theowner/operator.

IMPORTANT: EPA emissions regulations applyto vehicles domiciled in Canada and the U.S. atthe time of printing this manual. Vehicles thatare domiciled outside of the U.S. and Canadamay not have engines with an emission after-treatment system that is compliant with EPAregulations, depending upon local statutoryemissions guidelines.

NOTICEIt is extremely important that the following guide-lines be followed for vehicles with EPA07 ornewer engines, or damage may occur to the af-tertreatment device, and the warranty may becompromised.

• Use ultralow-sulfur diesel with 15 ppm sul-fur content or less.

• Do not use fuel blended with used enginelube oil or kerosene.

• Use only engine lube oil with a sulfated ashlevel less than 1.0 wt %; currently referredto as CJ-4 oil.

Adequate maintenance of the engine and the dieselparticulate filter (DPF) are the responsibility of theowner/operator, and are essential to keep the emis-sion levels low. Good operating practices, regularmaintenance, and correct adjustments are factorsthat will help keep emissions within the regulations.

Normal Operation

WARNINGDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut off the engine when in an areawhere flammable liquids or gases are being

Engines

7.9

handled. Failure to observe these precautionscould result in serious injury or death.

Every engine has an operating range in which it per-forms most efficiently. The operating range extendsfrom maximum torque rpm at the low end, to enginerated speed at the high end. Most engines deliverbest fuel economy when operated in the low- andmid-speed segments of the efficiency range and pro-duce maximum horsepower at rated speed, which isalso the recommended maximum speed of the en-gine. For further engine-specific information, refer tothe engine manufacturer’s operation manual.

Prolonged idling of engines is not recommended, andis illegal in some states. Idling produces sulfuric acid,that is absorbed by the lubricating oil, and eats intobearings, rings, valve stems, and engine surfaces. Ifyou must idle the engine for cab heat or cooling, usethe high idle function of the cruise control switches.An idle speed of 900 rpm should be enough to pro-vide cab heat in above freezing ambient tempera-tures.

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 secondsthe idle shutdown timer will be disabled until reset.

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 equipped, turn off the load disconnect switchafter the engine is shut down, to prevent bat-tery 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 sectioned,vertical strips. This assures even cooling across eachtube, and reduces header to tube stress, and pos-sible failure. Winterfronts should only be used whenthe ambient temperature remains below 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 Business Class M2 engines 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

brake, and place the transmission in neutral.

Engines

7.10

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.

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

NOTICEWhen the cruise control is engaged, do not at-tempt to shift gears without using the clutchpedal. Failure to follow this precaution will result

in a temporarily uncontrolled increase in enginespeed. Transmission damage and gear strippingcould result.

Cruise control is activated by two dash-mountedswitches (Fig. 7.15 ).

• On/Off Switch—this two-position rocker is la-beled SPD CNTL on the lower half of theswitch. When cruise control is on, an amberlight illuminates the top part of the switch.

• Set/Resume Switch—this three-position paddleswitch is labeled RES/ACC above the paddleand SET/CST below the paddle.

1. To cruise at a particular speed:

1.1 Press the upper half of the On/Off switch.

09/13/2001

1

2

f610510

To turn cruise control on, press the upper half of the On/Off switch. To turn cruise control off, press the lower halfof the On/Off switch.

To increase cruise speed, raise and hold the paddle ofthe Set/Resume switch to RES/ACC until the vehicleaccelerates to the desired speed. To decrease cruisespeed, lower and the paddle of the Set/Resume switch toSET/CST until the vehicle decelerates to the desiredspeed.1. Cruise Control On/Off Switch2. Cruise Control Set/Resume Switch

Fig. 7.15, Cruise Control Switches

Engines

7.11

1.2 Depress the accelerator pedal until thespeedometer reaches the desired speed.

1.3 Momentarily lower the paddle of the Set/Resume switch to set the desired speed.

NOTE: The speed memory is lost whenever theignition switch is turned to OFF, or cruise controlis turned off.

2. To disengage the cruise control, do one of thefollowing:

• Press the lower half of the on/off switchbutton.

• Depress the brake pedal.

• Depress the clutch pedal (on a manualtransmission only).

3. To resume a preselected cruise speed:

3.1 Ensure the cruise control is on.

3.2 Momentarily raise the paddle of the Set/Resume switch. Cruise will return to thelast speed selected.

NOTE: If vehicle speed drops below theminimum cruise control speed, cruise controlwill disengage. To resume to the preselectedcruise speed, increase vehicle speed toabove minimum cruise control speed andpress the ACC/RES button.

NOTE: The speed memory is lost whenever theignition is turned off or the cruise control switchis toggled to Off.

4. To increase cruise speed, raise and hold thepaddle of the Set/Resume switch until the vehicleaccelerates to the desired speed.

5. To decrease cruise speed, lower and the paddleof the Set/Resume switch until the vehicle decel-erates to the desired speed.

Shift Knob Controls, OptionalCruise control can also be activated by the optionalPAUSE, RESUME, and SET buttons on the transmis-sion shift knob (Fig. 7.16 ).

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 thedesired speed.

5. To adjust cruise speed down, push the RESUMEbutton and hold it in until the vehicle deceleratesto the desired speed.

Power Takeoff (PTO) GovernorEngine power takeoffs (PTO) are devices used to tapinto engine power to run auxiliary devices, such ashydraulic pumps that power additional equipment.The following instructions are general guidelines foroperating a PTO.

05/23/95 f260316

Fig. 7.16, Cruise Control Buttons on the TransmissionShift Knob

Engines

7.12

1. Set the parking brake and put the transmission inneutral.

2. Press the dash-mounted PTO switch. Releasethe switch when the amber light behind theswitch begins to blink.

When the light is steadily illuminated, 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 reverse,neutral, 1st, or 2nd gears only.

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 down powerto the 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.

Engine BrakingEach engine manufacturer uses a specific enginebrake for their engine. Regardless of the manufac-turer, the engine brake is operated with the principlesoutlined in this chapter. Refer to the engine manufac-turer’s operation manual for details of their particularengine brake product.

WARNINGTo avoid injury from loss of vehicle control, donot activate the engine brake system under thefollowing conditions:

• on wet or slippery pavement, unless thevehicle is equipped with antilock brakingsystem (ABS) and you have had prior expe-rience driving under these conditions;

• when driving without a trailer or pulling anempty trailer;

• if the tractor drive wheels begin to lock, orthere is fishtail motion after the enginebrake is activated.

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 control of,and is not a substitute for, service brakes.

WARNINGUsage of the engine brake as the primary brakingsystem can cause unpredictable stopping dis-tances, that could result in personal injury orproperty damage. Service brakes are the primaryvehicle braking system.

Two dash-mounted switches control the enginebrake:

• The On/Off switch (ENG BRK), is used to turnthe engine brake on and off. See Fig. 7.17 .When the engine brake is on, an amber lightwill illuminate behind the switch.

• The engine brake intensity switch (HI/MED/LOor, in some cases, HI/LO) controls the amountof engine braking. When the panel lights areon, the ENG BRK legend is backlit in green.

Since the engine brake is most effective at rated en-gine speed, gear selection is very important. Gearing

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1 2

1. Engine Brake On/Off2. Engine Brake Intensity Switch

Fig. 7.17, Engine Brake Switches

Engines

7.13

down 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 using the clutch pedal. If the en-gine brake is engaged when the transmission isin neutral, the braking power of the engine brakecan stall the engine, which could result in loss ofvehicle control, possibly causing personal injuryand property damage.

"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.

For slower descent, select a lower gear, being care-ful not to overspeed the engine. Occasional deactiva-tion of the engine brake may be necessary to main-tain the designated road speed under theseconditions.

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 mph (km/h) above the cruise set speed. Themaximum amount of braking is selected with thedash switches. When the vehicle returns to the setcruise speed, the engine brake will turn off.

The engine brake will only operate when the accel-erator pedal is fully released. Depressing the clutchwill also prevent the engine brake from operating.

Vehicles equipped with ABS have the ability to turnthe engine brake off if wheel slip is detected. Theengine brake will automatically turn back on oncewheel slip is no longer detected.

The DDEC VI system will deactivate the enginebrake when the engine speed falls below 1000 rpmor when the vehicle slows down to a preset speed,

depending on DDEC programming. This preventsstalling the engine.

Engine Brake OperationDepending on the brake type, the engine brake maybe disabled when engine temperature falls below aset level.

NOTICEDo not allow the engine to exceed 2500 rpm. Se-rious engine damage could result.

To activate the engine brake after the engine iswarmed up and the vehicle is in motion:

1. Remove your feet from both the clutch andthrottle pedals.

2. Press the On/Off switch to toggle the enginebrake on. See Fig. 7.17 . The engine brake willengage at the rate last set on the brake intensityswitch.

3. Move the intensity switch to the desired intensity.

On vehicles with a HI/MED/LO intensity switch,LO will provide 1/3 of the full braking capacity ofthe engine, MED will provide 2/3 of the full brak-ing capacity, and HI will provide maximum enginebraking. On vehicles with a HI/LO intensityswitch, LO will provide ½ of the full braking ca-pacity of the engine; HI will provide maximumengine braking.

4. Use the intensity switch set at the LO positionwhen driving on flat, open stretches of road. Ifthe service brakes are still required to slow downon a grade, switch to a higher setting on thedash switch until there is no need for the servicebrakes. Grade descent speed should be suchthat the service brakes are used infrequently andremain cool, thus retaining their effectiveness.

5. For maximum retarding, maintain the top gov-erned speed of the engine through the appropri-ate selection of gears. When shifting gears, theengine brake will disengage when the clutchpedal is depressed, then engage when the clutchpedal is released.

6. To cancel the engine brake application, togglethe On/Off to off.

Engines

7.14

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. 7.18or Fig. 7.19 .

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

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.

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Engines

7.15

• 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

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.

Engines

7.16

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. 7.20 .

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 used with the Allison WorldTransmission MD series, are interfaced with thetransmission electronic control module (ECM). Anexhaust-brake-enabled transmission ECM will usuallyprovide converter lockup in gears two through six.

Effective exhaust braking begins when the transmis-sion automatically downshifts into fifth gear (62 mphor less). Once on, the Pacbrake exhaust brake willcontrol road speed and/or slow the vehicle suffi-ciently that the transmission will automatically down-shift, if necessary, to Allison’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.

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AA

A

A. Lubrication Point

Fig. 7.20, Pacbrake Exhaust Brake and Air Cylinder

Engines

7.17

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26

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

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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.

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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 .

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NOTE: The gear indicator displays the current gear. Inthis example, it displays first gear.

Fig. 8.16, Current Gear Display

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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. 8.12 .

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. 8.13 .

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. 8.14 .

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."

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."

Drivetrain

8.23

Automatic and Manual ModesThe SmartShift control has a slide switch located onthe body of the lever just before the paddle widensout. See Fig. 8.20 . 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. 8.16 .

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 inthe 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.

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. 8.20, Switches, AGS Transmissions

Drivetrain

8.24

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 .

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. 8.17 .

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. 8.18 .


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 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 ofthe currently selected forward gear (1, 2, 3, 4 , 5, or6) displays on the gear indicator.

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 is

Drivetrain

8.25

available, 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.

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 .

Drivetrain

8.26

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. 8.21 ) 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. 8.21 ) 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.

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.

10/26/2001 f610596

Fig. 8.21, Differential Lock Switch

Drivetrain

8.27

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. 8.22 . 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. Letup 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. The

switch 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. 8.23 ) allows the driverto lock both rear axles together. The red interaxlewarning light illuminates on the dash message centerwhen interaxle lock is engaged.

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 both

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. 8.22, Turning Radii

Drivetrain

8.28

sets 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. 8.23 ) 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 rangewhen 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.

10/26/2001 f610595

Fig. 8.23, Interaxle Lock Switch

Drivetrain

8.29

Axle Shift SwitchThe axle shift switch is a two-position guarded rockerswitch (Fig. 8.24 ) 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 axle

shifts. 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. 8.24, Axle Shift Switch

Drivetrain

8.30

9

Steering and Brake SystemsSteering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4Meritor WABCO® Antilock Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5Enhanced Stability Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

Steering SystemThe power steering system includes the power steer-ing gear, hydraulic hoses, power steering pump, res-ervoir, steering wheel and column, and other compo-nents. Some models are also equipped with aseparate hydraulic power cylinder on the right side ofthe front axle, or a right-hand slave gear.

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 anothercause, bring the vehicle to a safe stop. Do not drivethe vehicle until the cause of the problem has beencorrected.

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.

NOTICENever steam clean or high-pressure wash thesteering gear. Internal damage to gear seals, andultimately the steering gear, can result.

Drivers should carefully use the power available witha power steering system. If the front tires becomelodged in a deep hole or rut, drive the vehicle outinstead of using the steering system to lift the tiresout of the hole.

NOTICEAvoid turning the tires when they are against acurb, as this places a heavy load on steeringcomponents and could damage them.

Steering 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.

Air Brake SystemA dual air brake system consists of two independentair systems that use a single set of brake controls.Each system has its own reservoirs, plumbing, andbrake chambers. The primary system operates theservice brakes on the rear axle; the secondary sys-tem operates the service brakes on the front axle.Service brake signals from both systems are sent tothe trailer.

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.

05/10/2007 f462075

10°

10°

1 2

10°

10°

1. 9 o’Clock 2. 3 o’Clock

Fig. 9.1, Steering Wheel Centered

Steering and Brake Systems

9.1

Air Brake System, GeneralInformationThe warning light and buzzer come on if air pressuredrops below 64 to 76 psi (441 to 524 kPa) in eithersystem. If this happens, check the dual system airpressure gauge to determine which system has lowair pressure. Although the vehicle’s speed can bereduced using the brake pedal, either the front orrear service brakes will not be operating at full ca-pacity, causing a longer stopping distance. Bring thevehicle to a safe stop and have the air system re-paired before continuing.

IMPORTANT: In the event of a total loss of ser-vice brakes with full system air pressure, usethe parking brake control valve (yellow knob) tobring the vehicle to a complete stop in the saf-est location possible.

Before a vehicle with insufficient system air pressurecan be moved, the spring parking brakes must bereleased by applying an external air source at thegladhands, or by manually caging the parking brakesprings.

WARNINGDo not release the spring parking brakes andthen drive the vehicle. There would be no meansof stopping the vehicle, which could result in se-rious personal injury or vehicle damage. Beforereleasing the spring parking brakes, make theconnection to a towing vehicle or chock the tires.

After correcting the brake system problem, uncagethe spring parking brakes before resuming normalvehicle operation.

Primary Air Brake SystemLoss of air pressure in the primary air system causesthe rear service brakes to become inoperative. Thesecondary air system will continue to operate thefront brakes and the trailer brakes (if equipped).

Secondary Air SystemLoss of air pressure in the secondary air systemcauses the front axle brakes to become inoperative.The primary air system will continue to operate therear service brakes and the trailer brakes (ifequipped).

Air Brake System OperationBefore driving your vehicle, allow time for the aircompressor to build up a minimum of 100 psi (689kPa) pressure in both the primary and secondarysystems. Monitor the air pressure system by observ-ing the dual system air pressure gauge and the low-air-pressure warning light and buzzer. The warninglight and buzzer shut off when air pressure in bothsystems reaches 64 to 76 psi (441 to 524 kPa).

IMPORTANT: Before driving the vehicle, secureall loose items in the cab so that they will not flyforward during a full brake application. Makesure all passengers are wearing seat belts.

During normal brake stops, depress the brake pedaluntil braking action slows down the vehicle. Increaseor decrease the pressure on the pedal so that thevehicle comes to a smooth, safe stop. Apply theparking brake if the vehicle is to be parked.

IMPORTANT: An air brake proportioning systemmay be used in tractor air brake systems whenthe vehicle is not equipped with antilock brakingsystem (ABS). When operating in bobtail mode,the rear brake chambers (on which the axleload has been greatly reduced) receive reduced(proportional) air pressure, while the front axlebrake chambers receive full (normal) air pres-sure. This results in a different brake pedal"feel," as the pedal seems to require more traveland/or effort to slow or stop the vehicle. How-ever, the air brake proportioning system actuallyimproves vehicle control when the tractor is inbobtail mode. When the tractor is towing atrailer, the rear brake chambers will receive full(normal) application air pressure.

When parking a vehicle attached to a trailer thatdoes not have spring parking brakes, apply the trac-tor parking brake. Chock the trailer tires before dis-connecting the vehicle from the trailer.

WARNINGIf a trailer or combination vehicle is not equippedwith spring parking brakes, do not park it by pull-ing out only the trailer air supply valve knob.This would apply only the trailer service brakes.If air were to bleed from the trailer brake system,


9.2

the trailer brakes would release, possibly causingan unattended runaway vehicle.

NOTICENever apply the service and spring parkingbrakes simultaneously. To do so transmits exces-sive input force to the brake components, whichcould damage or cause eventual failure of brakeactuating components.

Brake ControlsThe 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. 9.2 . Thevalve can be partially or fully applied, but in any par-tially applied position, it will be overridden by a fullapplication of the 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.

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.

The red octagonal-shaped knob in the control panelactuates the trailer air supply valve. See Fig. 9.3 .After the vehicle’s air hoses are connected to atrailer and the pressure in both air systems is at least

65 psi (448 kPa), the trailer air supply valve must bepushed in. It should stay in to charge the trailer airsupply system and to release the trailer spring park-ing brakes.

Pull the trailer air supply valve out before disconnect-ing a trailer or when operating a vehicle without atrailer. If pressure in both air systems drops to 35 to45 psi (242 to 310 kPa), the trailer air supply valveautomatically pops out, exhausting the trailer air sup-ply, and applying the trailer service or spring parkingbrakes.

The yellow diamond-shaped knob in the controlpanel actuates the parking brake valve. See Fig. 9.3 .Pulling out the parking brake valve applies both thetractor and trailer parking brakes and automaticallycauses the trailer air supply valve to pop out.

NOTICEDo not use the spring parking brakes if the ser-vice brakes are hot, such as after descending asteep grade. To do so could damage the brakes.Allow hot brakes to cool before using the springparking brakes.

Do not use the spring parking brakes duringfreezing temperatures if the service brakes arewet. To do so could cause them to freeze. If thebrakes are wet, drive the vehicle in low gear andlightly apply the brakes to heat and dry them.

If the trailer is not equipped with spring parkingbrakes, pulling out the parking brake valve appliesthe tractor parking brake and the trailer servicebrakes. When the tractor and trailer parking brakes(or trailer service brakes) are both applied, the trailer

10/17/2001 f610591

Fig. 9.2, Trailer Brake Lever

f610291

1 2

03/10/99

1. Trailer Air-Supply-Valve Knob2. Parking-Brake-Valve Knob

Fig. 9.3, Brake Valve Knobs


9.3

brakes are released by pushing in the trailer air sup-ply valve, leaving the tractor parking brake applied.Air pressure in the primary or secondary reservoirmust be at least 65 psi (448 kPa) before the tractorspring parking brakes, or the trailer service or springparking brakes, can be released.

Automatic Slack AdjustersAutomatic slack adjusters should never be manuallyadjusted except during routine maintenance of thefoundation brakes (e.g., replacing shoes), duringslack adjuster installation, or in an emergency situa-tion.

When the brake pushrod stroke exceeds the legalbrake adjustment limit on a vehicle, there is likely 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. Before adjusting an automaticslack adjuster, troubleshoot the foundation brakesystem and inspect it for worn or damaged com-ponents. Improperly maintaining the vehicle brak-ing system may lead to brake failure, resulting inproperty damage, personal injury, or death.

Hydraulic Brake SystemHydraulic Brake System, GeneralInformationThe 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.

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). Anelectrical backup pump operates if there is inad-equate fluid flow from the power steering pump tothe power booster.

The brake system warning light illuminates if there isa problem within the system. Bring the vehicle to asafe stop and correct the problem before continuingoperation of the vehicle. See Group 42 of theBusiness Class® M2 Workshop Manual for hydraulicbrake system troubleshooting and adjustment proce-dures.

Hydraulic Brake System OperationIMPORTANT: Make sure that the fluid level inthe master cylinder reservoir is up to the ridgethat surrounds the reservoir. See Fig. 9.4 . Useonly heavy-duty brake fluid, DOT 3 or DOT 4, inthe hydraulic brake system.

IMPORTANT: Before driving the vehicle, secureall loose items in the cab so that they will not flyforward during a full brake application. Makesure all passengers are wearing seat belts.

During normal brake stops, depress the brake pedaluntil braking action slows down the vehicle. Increaseor decrease the pressure on the pedal so that thevehicle comes to a smooth, safe stop. Apply theparking brake if the vehicle is to be parked.

When parking a vehicle attached to a trailer, applythe tractor parking brake. Chock the trailer tires be-fore disconnecting the vehicle from the trailer.

04/26/2012 f460513a

A

B

A. Open caps and check fluid level.B. Fill to this level.

Fig. 9.4, Hydraulic Brake Reservoir


9.4

Meritor WABCO ® AntilockBraking SystemThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel speed monitoring and controlsystem that works with the brake system. ABS pas-sively monitors vehicle wheel speed at all times, andcontrols wheel speed during emergency stops orwheel lock situations.

NOTICEAn 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 ABSfunction and to protect the components from cor-rosion. Clean more frequently when unusuallycorrosive chemicals are being used.

IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit (ECU). Installingdifferent-sized tires could result in a reducedbraking force, leading to longer stopping dis-tances.

The ABS includes signal-generating tone wheels andsensors located in the wheel hubs of each sensedwheel. The sensors transmit vehicle wheel speedinformation to an electronic control unit ECU locatedbehind the center dash. The ECU’s main circuit inter-prets the speed sensor signals and calculates wheelspeed, wheel retardation, and a vehicle referencespeed. If the calculations indicate wheel lockup, themain circuit signals the appropriate modulator valveto reduce braking pressure. During emergency brak-ing, the modulator valve alternately reduces, in-creases, or maintains air pressure supply in thebrake chamber to prevent front and rear wheellockup.

The Meritor WABCO ABS combines one front-axlecontrol channel with one rear-axle control channel toform one control circuit. For example, the sensor andmodulator valve on the left-front axle form a controlcircuit with the sensor and modulator valve on theright-rear axle.

The ECU has a safety circuit that constantly monitorsthe wheel sensors, traction control valve (ifequipped), modulator valves, and the electrical cir-cuitry. If the safety circuit senses a failure in any partof the ABS, the tractor warning lamp (TRACTORABS) illuminates and the control circuit where thefailure occurred is switched to normal braking action.The remaining control circuit will retain the ABS ef-fect. Even if the ABS is completely inoperative, nor-mal braking ability is maintained.

The ABS indicator lamp illuminates after the ignitionis switched on and will go out within three seconds ifthe system is functioning correctly. If the ABS indica-tor lamp does not illuminate, or does not go out afterthree seconds, have the vehicle serviced beforeoperation.

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 will control allwheels to provide steering control and a reducedbraking distance.

Although the ABS improves vehicle control duringemergency braking situations, the driver still has theresponsibility to change driving styles depending onexisting traffic and road conditions. For example, theABS cannot prevent an accident if the driver isspeeding or following too closely.

Trailer ABS CompatibilityThe Meritor WABCO ABS is designed to communi-cate with a trailer ABS, if they are compatible. Com-patibility will result in the illumination of the TRAILERABS lamp during vehicle start-up and fault detection.

The TRAILER ABS lamp will not illuminate unless acompatible trailer is connected to the tractor. Thedash-mounted lamp will operate as follows when acompatible trailer is properly connected to the tractor:

• When the ignition key is turned to the ON posi-tion, the TRAILER ABS lamp will illuminate mo-mentarily, then turn off.


9.5

• If the lamp illuminates momentarily during ve-hicle operation, then shuts off, a fault was de-tected and corrected.

• If the lamp illuminates 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.

IMPORTANT: If a compatible trailer is con-nected, and the lamp is not illuminating momen-tarily when the ignition key is turned to the ONposition, it is possible that the lamp is burnt out.

Automatic Traction ControlVehicles with electronic engines and ABS may haveAutomatic Traction Control (ATC). On these vehicles,the ATC system automatically limits wheel spin dur-ing reduced-traction situations. In normal braking ap-plications, the standard air brake system is in effect.

An additional solenoid valve is installed. Duringreduced-traction situations, the ATC solenoid valvecontrols air pressure to the modulator valves andthey in turn increase, hold, or reduce pressure to theappropriate brake chambers to provide better tractionwhenever wheel spin occurs.

When the ATC system is in the NORMAL mode, itwill apply gentle braking to the spinning wheel, tofeed power to the wheel(s) with better traction. Ifboth wheels are spinning, the system will signal theengine to reduce power.

ATC includes a deep snow and mud option to in-crease available traction on extra soft surfaces likesnow, mud, or gravel. A momentary contact rockerswitch labeled ATC will be located on the dash.Pressing the switch will temporarily allow more wheelspin. The activation of the deep snow and mud op-tion is indicated by a flashing WHEEL SPIN lamp.Pressing the switch again will cycle the system backto normal operation.

NOTICEThe deep snow and mud option is intended to beused under specific slippery conditions that re-quire momentary increased wheel spin. Usingthis option for an extended period of time maydamage the vehicle brake system.

After the ignition switch is turned on, the TRACTORABS lamp and the WHEEL SPIN indicator lamp illu-

minate for about three seconds. After three seconds,the warning lights go out if all of the tractor’s ABScomponents are working.

IMPORTANT: If any of the ABS warning lightsdo not work as described above, or illuminatewhile driving, repair the ABS immediately to en-sure full antilock braking capability.

Enhanced Stability Control

WARNINGEnhanced Stability Control (ESC) is intended onlyas an aid for a conscientious and alert driver.Carefully read the information in this manual tounderstand this system and its limitations. ESCis not a substitute for safe driving procedures.Failure to drive safely, and use the system prop-erly, could result in personal injury and/or deathand property damage.

ESC automatically reduces engine power, applies theengine brake, and/or applies the tractor and trailerbrakes when the acceleration sensor detects that thevehicle is at risk of rolling over. In addition, ESC of-fers the added capability of complete directional sta-bility (yaw control) in oversteer and understeer condi-tions to reduce the likelihood of drift-out or jackknife.The system determines where the driver is attempt-ing to steer the vehicle and how much brake demandis required in order to more precisely control the ve-hicle in an emergency situation.

ESC works by constantly comparing the driver’s in-tention with the vehicle’s actual behavior. The systemdoes this by monitoring systems such as wheelspeed, steering angle, yaw rate, lateral acceleration,throttle position, and brake application. A central mi-crocomputer analyzes the collected data and triggersa response to keep the vehicle on course when anunstable condition is detected.

The roll stability control system automatically reducesengine power, applies the engine brake, and/or ap-plies the tractor and trailer brakes when the accelera-tion sensor detects that the vehicle is at risk of rollingover. The control can intervene even before an advi-sory message is displayed.

When the system detects that the vehicle is at risk ofoversteering or understeering, it applies individualtractor wheel end brakes and trailer brakes, activates


9.6

the engine brake (if equipped), and/or cuts enginepower, depending on the severity. As a result, thedriver has full control over the vehicle until the sys-tem detects a potential risk and intervenes accord-ingly. ESC operates automatically; the driver doesnot monitor or activate the system.


9.7

10

Fifth Wheels and TrailerCouplings

Fifth Wheels, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

Fifth Wheels, GeneralInformation

WARNINGDo not use any fifth wheel that fails to operateproperly. Doing so may cause loss of vehiclecontrol, possibly resulting in severe personal in-jury or death.

Air-Suspension Dump ValveThe air-suspension dump valve may be used to ad-just the tractor height to aid with coupling to or un-coupling from a trailer. See Fig. 10.1 . When theswitch is set to LOWER, the air-suspension dumpvalve deflates the air springs to lower the rear of thevehicle. In the AUTO position, the automatic ride-control valves operate for normal driving.

WARNINGNever exhaust air from the suspension whiledriving. The suspension will not absorb roadshocks, possibly damaging components, and ve-hicle handling may be compromised. This couldresult in loss of vehicle control, possibly result-ing in severe personal injury or death.

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 inflating.

Fifth Wheel Lubrication

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 personalinjury or death.

The standard fifth wheel plate must be kept well lu-bricated with chassis grease to prevent friction andbinding between the tractor fifth wheel plate and thetrailer.

For a low-lube fifth wheel plate, inspect the conditionof the low-lube pads. There should be no damagedor missing pieces. Slight puckering at the outsideedges is normal.

For lubrication instructions, see Group 31 of theBusiness Class M2 Maintenance Manual.

Fifth Wheel CouplingFifth wheel coupling is activated with the lock controlhandle located on either the right side or left side ofthe fifth wheel. Coupling has successfully occurredwhen the kingpin has been forced into the jaws andthe lock control handle has moved to the lockedposition.

NOTICESome fifth wheels may be mounted on slidingrails. Before attempting to couple a trailer to asliding fifth wheel, the slide feature must belocked to prevent the top plate from sliding rap-idly forward or rearward, causing damage to thefifth wheel or kingpin.

Fontaine and Holland Fifth WheelsCoupling1. Chock the front and rear of the trailer tires to

prevent the trailer from moving.

2. Ensure the fifth wheel jaw is fully open and theoperating rod is in the unlocked position. SeeFig. 10.2 or Fig. 10.3 .

3. Make sure the fifth wheel top plate is tilted so theramps are as low as possible.

10/26/2001 f610597

Fig. 10.1, Air-Suspension Dump Valve

Fifth Wheels and Trailer Couplings

10.1

4. 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.

NOTICEAttempting to couple at the wrong height maycause improper coupling, which could result indamage to the fifth wheel or kingpin.

5. Adjust the trailer height if required.

For a standard fifth wheel plate , the trailershould contact the fifth wheel approximately 4 to8 inches (10 to 20 cm) behind the fifth wheelpivot. See Fig. 10.4 .

For a low-lube fifth wheel plate , the fifth wheelmust slide freely under the trailer, and the trailershould contact the fifth wheel at the pivot. SeeFig. 10.5 .

6. With the fifth wheel lock opening aligned with thetrailer kingpin, back the tractor slowly toward thetrailer. After sliding under the trailer, STOP to

prevent from hitting the kingpin too hard, thenresume backing slowly until the fifth wheel locks.

On a standard fifth wheel, the fifth wheel must liftthe trailer.

On a low-lube fifth wheel, do not lift the trailer asthis may damage the fifth wheel plate.

1

1

2

2 10/26/2010 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 Locking Mechanism

1

1

2

3

11/02/2010 f310447

1. Safety Latch2. Operating Rod (locked)3. Operating Rod (unlocked)

Fig. 10.3, Holland Simplex SE Locking Mechanism

10/28/2010 f311124

A

B

C

D

A. Fifth wheel must lifttrailer

B. Adjust trailer height

C. Ramps tilted downD. 4 to 8 inches

Fig. 10.4, Trailer Connection Point, Standard FifthWheel


10.2

7. Apply the tractor parking brakes.

WARNINGA visual inspection is required by law. Some im-proper couplings can pass a pull test. Sound isnot reliable. Get out of the cab and look. Incor-rect coupling could cause the trailer to discon-nect, possibly resulting in serious personal injuryor death.

8. Perform a coupling inspection, checking thatthere is no gap between the bottom of the trailerand the fifth wheel, and that the kingpin is se-curely locked. See Fig. 10.6

When lockup has occurred, the fifth wheel con-trol handle moves to the locked position. Makesure that the safety latch is down over the lockcontrol handle to hold the control handle in thelocked position. (The safety latch will only rotatedown if the operating rod is fully retracted in thelocked position.) See Fig. 10.2 for Fontaine fifthwheels. See Fig. 10.3 for Holland fifth wheels.

9. Release the tractor parking brakes. Test for king-pin lockup slowly inching the tractor forward, pull-ing on the trailer against the chocks.

10. After lockup is completed, connect the tractor-to-trailer air system lines and the electrical cable tothe trailer. Take care to prevent dirt or foreignmaterial from entering the air system lines.

NOTICEAlways make sure the connection hanger keepsthe trailer air hoses and electrical cables posi-tioned so that they do not rub on anything. Rub-bing may wear through hoses or cables, resultingin air leaks, or exposed or broken wires, poten-tially affecting trailer brake or electrical systems.

11. Charge the air brake system with air, checkingthat the air connections do not leak.

WARNINGIncorrect fifth wheel lock adjustment could causethe trailer to disconnect, possibly resulting in se-rious personal injury or death.

12. 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. If slackis present, uncouple the trailer and have the fifthwheel inspected and adjusted by a certifiedtechnician.

Jost Fifth Wheel Coupling1. Tilt the ramp down.

2. Open the kingpin locks. See Fig. 10.7 .

3. Back the vehicle close to the trailer, centering thekingpin on the fifth wheel.

4. Chock the trailer wheels.

5. Connect the air lines and electrical cable.

6. Ensure that the red trailer air supply valve (trailerbrake) is pulled out, and that the trailer parking

09/10/2010 f311125

A

B

A. Adjust trailer height B. Ramps tilted down

Fig. 10.5, Trailer Connection Point, Low-Lube FifthWheel

09/10/2010 f311126

A B

A. No gap between trailerand fifth wheel

B. Kingpin inside lock

Fig. 10.6, Coupling Inspection


10.3

brakes are set. See Chapter 5 in this manual foroperation of the dash-mounted brake controls.

NOTICEAttempting to couple at the wrong height maycause improper coupling, which could result indamage to the fifth wheel or kingpin.

7. Adjust the trailer height (if required).

For a standard fifth wheel plate , the trailershould contact the fifth wheel approximately 4 to8 inches (10 to 20 cm) behind the pivot. SeeFig. 10.4 .

For a low-lube fifth wheel plate , the fifth wheelmust slide freely under the trailer, and the trailershould contact the fifth wheel at the pivot. SeeFig. 10.5 .

8. Back the tractor under the trailer.

On a standard fifth wheel, the fifth wheel must liftthe trailer.

On a low-lube fifth wheel, do not lift the trailer asthis may damage the fifth wheel plate.

9. After sliding under the trailer, STOP to preventfrom hitting the kingpin too hard, then resumebacking slowly until the fifth wheel locks.

WARNINGA visual inspection is required by law. Some im-proper couplings can pass a pull test. Sound isnot reliable. Get out of the cab and look. Incor-rect coupling could cause the trailer to discon-

nect, possibly resulting in serious personal injuryor death.

10. Apply the tractor parking brake, then perform aphysical check for positive kingpin lockup, andthat there is no gap between the trailer and thefifth wheel. See Fig. 10.6 .

11. Ensure that the release handle is in the lockedposition adjacent to the casting. See Fig. 10.8 .

12. Release the tractor parking brakes and test forkingpin lockup by slowly moving the tractor for-ward, pulling on the trailer against the chocks.

Fifth Wheel UncouplingManual Uncoupling1. Apply the tractor and trailer parking brakes.

2. Chock the trailer rear wheels.

3. Lower the trailer landing gear until the weight isremoved from the fifth wheel.

4. Disconnect the tractor-to-trailer air system linesand electrical cable. Plug the air lines to preventdirt or foreign material from entering the lines.

5. Verify that both the yellow parking-brake and redtrailer-air-supply knobs are out, the tractor andtrailer parking brakes are set, and that the traileris prepared for uncoupling.

6. Release the kingpin locking mechanism followingthe instructions for each manufacturer below.

6.1 Fontaine: Lift the safety latch and pull thelock control handle to the unlocked posi-tion.

6.2 Holland: In the locked position the safetyindicator swings freely over the operatingrod. See Fig. 10.9 , View A.

To unlock the mechanism, manually rotatethe safety indicator toward the rear of thefifth wheel. See Fig. 10.9 , View B.

Pull the operating rod out. When theupper operating rod shoulder is outsidethe slot, raise the handle and place theshoulder of the upper rod against the platecasting, above the slot. See Fig. 10.9 ,View C.

09/10/2010 f311128

A

A. Lock held open by catch mechanism

Fig. 10.7, Jost Release Handle Unlocked


10.4

The fifth wheel is now in the lockset posi-tion and is ready for uncoupling. As thetractor pulls away from the trailer the king-pin forces the jaw to rotate, contacting thelock. Continued rotation of the jaw forcesthe lock to move outward, and drops theupper rod back into the slot. See Fig. 10.9View D. The wheel is now ready forcoupling.

6.3 Jost: Pull the retractable handle out, thensecure it in the open position with thecatch.

7. Release the tractor parking brake then drive outslowly, allowing the trailer to slide down the fifthwheel and pick-up ramps.

Air-Actuated UncouplingAn air-actuated kingpin release valve is optional withall fifth wheels. See Fig. 10.10 .

NOTE: In the event of an air system failure, air-actuated kingpins can be manually released fol-lowing the instructions for manual unlocking.

WARNINGOnce the kingpin release valve has been pulledthe kingpin lock is released. The vehicle MUSTNOT be driven with the trailer until the trailer has

been uncoupled and coupled again. Failure to doso may result in separation of the trailer from thetractor, possibly causing serious personal injuryor death.

Preparing the Trailer for UncouplingBefore using the air valve to unlock a fifth wheelkingpin, prepare the trailer as follows.

1. Apply the tractor and trailer parking brakes.

2. Chock the trailer rear wheels.

3. Lower the trailer landing gear until the weight isremoved from the fifth wheel.

4. Disconnect the tractor-to-trailer air lines and elec-trical cable. Plug the air lines to prevent dirt orforeign material from entering the lines.

Fontaine and Holland Fifth Wheels Air-Activated Kingpin Unlock1. Verify that both the yellow parking-brake and red

trailer-air supply knobs are out, the tractor andtrailer parking brakes are set, and that the traileris prepared for uncoupling.

NOTE: On Fontaine and Holland fifth wheels, ifthe tractor parking brake is not set, the air-actuated kingpin-release valve will not activate.

09/10/2010 f311127

OK OK

Fig. 10.8, Jost Release Handle Locked


10.5

2. Pull and hold the kingpin release valve until thekingpin lock mechanism opens and locks inplace. See Fig. 10.10 .

3. Release the pull valve.

4. Release the tractor parking brake.

5. Drive out from under the trailer.

Jost Fifth Wheels Air-Activated KingpinUnlock1. Verify that both the yellow parking-brake and red

trailer-air-supply knobs are out, the tractor andtrailer parking brakes are set, and that the traileris prepared for uncoupling.

11/02/2010 f311133

A

B

C

D

1

2

3

4

A. Locked PositionB. Unlatched Position (safety indicator rotated towards the

rear of the fifth wheel)

C. Lockset Position (upper rod resting against castingabove slot)

D. Open Position (ready for recoupling)1. Safety Indicator2. Operating Rod

3. Upper Rod4. Plate Casting

Fig. 10.9, Holland Kingpin Locking Mechanism


10.6

NOTE: With Jost fifth wheels, if the trailer park-ing brake is not set the air-actuated valve willnot activate.

2. Release the tractor parking brake.

3. Pull and hold the kingpin release valve, thendrive forward slowly.

4. After the trailer has slid down the fifth wheel andpick-up ramps, release the pull valve.

Fifth Wheel Slide

WARNINGAdjust the fifth wheel slide correctly, and do notoverload any tractor axle by incorrectly loadingthe trailer. Incorrect slide adjustment or improperaxle loading could cause erratic steering andloss of vehicle control, possibly resulting in seri-ous personal injury or death.

On sliding fifth wheel assemblies, the fifth-wheelplate is attached to rails that allow forward and rear-ward movement of the fifth wheel to optimally distrib-ute the load across the axles. Slots are evenlyspaced along the slide rails, and retractable wedgesare positioned through the slots to hold the fifthwheel in the desired position.

The amount of load distribution on the front steeringaxle and rear drive axle(s) will have a direct effect onthe steering control of the vehicle. Determine thefront and rear axle weights by weighing the vehicleon scales designed for this purpose.

The maximum axle weight ratings are shown on theFederal Motor Vehicle Safety Standard (FMVSS)label or Canadian Motor Vehicle Safety Standard(CMVSS) label attached to the left rear door post ofthe tractor. The desired load on the axle is no lessthan 80 percent of the maximum axle weight rating,but in no instances should the axle load exceed themaximum axle weight rating given on the FMVSS orCMVSS label.

Manual Slide OperationThe manual slide feature is operated from the fifthwheel plate with a manual release handle using thefollowing procedure. See Fig. 10.11 .

1. Stop the tractor and trailer in a straight line onlevel ground. Pull the red trailer air supply knobto apply the trailer parking brakes.

2. Apply the tractor parking brake, then release thesliding mechanism using the appropriate methodfor the fifth wheel manufacturer.

2.1 Fontaine: Lift the slide release pull handleto disengage it from the guide plate. Then,pull out the handle until it is in the un-locked position and can be positionedagainst the guide plate to hold it out. The

10/26/2010 f611102

Fig. 10.10, Air-Actuated Kingpin Release Valve

07/25/95 f310190

1

2

1. Locking Wedge2. Slide Release Pull Handle

Fig. 10.11, Manual Release Sliding Fifth Wheel(Fontaine shown)


10.7

handle will stay in the unlocked positionuntil it is manually disengaged from theguide plate. See Fig. 10.12 .

2.2 Holland: Pull the operating rod out. Makesure both side plungers have released.See Fig. 10.13 .

3. Lower the trailer landing gear just enough to re-move the weight from the tractor.

4. Chock the front and rear of the trailer tires toprevent the trailer from moving.

5. Release the tractor parking brakes, then slowlymove the tractor forward or backward until thefifth wheel is in the desired location.

NOTICEWhen moving the fifth wheel to the desired posi-tion, be sure the trailer landing gear will not atany time come in contact with the tractor frameor other components. Make sure that the front ofthe trailer will not come in contact with the rearof the cab or with other components if they ex-tend beyond the rear of the cab.

WARNINGCheck that the locking wedges have seated in theslots. Failure to achieve complete lockup mayallow disengagement of the tractor from thetrailer, possibly resulting in serious personal in-jury or death.

6. Apply the tractor parking brakes, then lock thesliding member in position using one of the fol-lowing methods:

6.1 Fontaine: Disengage the slide releasepull handle from the guide plate. The sliderelease pull handle is spring-loaded in thelocked position and will seek the lockedposition when disengaged from the guideplate. After the slide release pull handlereturns to the fully locked position, visuallyand physically check the locking wedgesto make sure they are fully inserted intothe slots in the slide rails. Make sure thehandle is locked in position against theguide plate.

6.2 Holland: Raise the operating rod so that itis free to move inward. Make sure that thelock pins have seated in the base platerail holes and the operating rod movesinto the locked position.

NOTE: The fifth wheel may need to be movedslightly to enable the locking wedges to enterthe fully locked position.

10/26/2010 f310050

Fig. 10.12, Releasing the Sliding Fifth Wheel, (Fontaine)

1

2

3

45

6

3

10/26/2010 f310445

7

8

1. Baseplate2. Bolted Stop3. Baseplate Rail4. Fifth Wheel Mount

5. Slider Saddle Plate6. Safety Latch7. Operating Rod8. Operating Lever

Fig. 10.13, Sliding Fifth Wheel Manual Release,(Holland Simplex)


10.8

Air Slide OperationThe slide feature may be operated with an air switchmounted in the dash, that operates an air cylinderthat locks and unlocks the slide. See Fig. 10.14 .

1. Set the air-slide switch to UNLOCK. SeeFig. 10.14

Ensure the locking plungers have released. SeeFig. 10.15 .

For Jost fifth wheels, the mechanism activates asshown in Fig. 10.16 .

2. Lower the trailer landing gear just enough to re-move the weight from the tractor.

3. Pull the red trailer-air-supply knob to set thetrailer-parking brakes.

4. Slowly move the tractor forward or backwarduntil the fifth wheel is in the desired location.

NOTICEEnsure the trailer landing gear does not come incontact with the tractor frame or other compo-nents, and that the front of the trailer will notcome in contact with the rear of the cab or othercomponents if they extend beyond the rear of thecab.

5. Apply the tractor parking brakes.

WARNINGCheck that the locking wedges have seated in theslots. Failure to achieve complete lockup mayallow disengagement of the tractor from the

02/22/2011 f611114

Fig. 10.14, Air-Slide Switch

07/25/95 f310189

1

2

1. Locking Wedge 2. Air Cylinder

Fig. 10.15, Air-Operated Sliding Fifth Wheel (Fontaineshown)

09/10/2010 f311131

A

B

A. Unlocked B. Locked

Fig. 10.16, Jost Sliding Fifth Wheel


10.9

trailer, possibly resulting in serious personal in-jury or death.

6. Set the air-slide switch to LOCK. Visually inspectthe locking wedges or plungers to make surethat they are fully inserted in the slide rail slots.Verify that the plungers have engaged by tuggingthe tractor forward while the trailer brakes arelocked and the wheels are chocked.

NOTE: The fifth wheel may need to be movedslightly to enable the locking wedges to fullylock.


10.10

11

Pretrip and Post-TripInspections and

MaintenancePre- and Post-Trip Inspection Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Daily Pretrip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3Weekly Post-Trip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.11Monthly Post-Trip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13

Pre- and Post-Trip InspectionChecklistsRegulations in Canada and the U.S. clearly indicatethat it is the driver’s responsibility to perform an in-spection, and ensure the complete road-worthinessof a vehicle, before placing it into service. Commer-cial vehicles may be subject to inspection by autho-rized inspectors, and an unsafe vehicle can be takenout of service until the driver or owner repairs it.

Use the following checklists to ensure that vehiclecomponents are in good working condition beforeeach trip. Careful inspections eliminate stops later tofix overlooked or forgotten items.

The checklists in this chapter can be copied and keptas a record that the procedures have been com-pleted. For details on how to inspect each item onthe checklists, see the corresponding procedure(step number) in this chapter.

NOTE: Checklists in this chapter correspondwith the procedures and steps later in this chap-ter. Your vehicle may not be equipped with allcomponents listed below.

ChecklistsDaily Pretrip Inspection ChecklistsSee the following tables for a list of procedures thatshould be performed daily, before the first trip. Placea check mark in the complete (Comp. ) column toindicate a procedure has been performed.

Inspector Date

Suspension and Slack Adjusters Comp.1 Suspension components2 Slack adjusters

Wheels and Tires Comp.1 Wheel covers2 Tire condition3 Tire inflation4 Rims and wheel components5 Wheel bearing oil seals and lubrication levels6 Mud Flaps

Saddle Tank Areas Comp.

1 Drain air reservoirs (without automatic drainvalves)

2 Fuel tank(s) secure3 Frame rails and crossmembers4 Visible exhaust components

Engine Compartment Comp.1 Leakage under engine2 Air intake system3 Engine oil level4 Power steering reservoir level5 Engine coolant level6 Visible engine wiring7 Frame rails

Cab Comp.

1 Reset dash-mounted air intake restrictionindicator

2 Air-pressure warning system3 Air governor cut-in and cut-out pressures4 Air pressure build-up time5 Air system leakage6 Air pressure reserve8 Mirrors, windows, windshield9 Horn, windshield wipers, windshield washers10 Heater and defroster11 Interior lights12 Exterior lights13 Seat belts and tether belts14 Fuel level15 Mirror adjustment16 Service brakes

Natural Gas Fuel System Inspection Comp.1 Fuel tanks2 Required decals3 Vent caps

4 Plumbing components, fuel fill fitting, fuellines

5 Fuel gauge components, fuel level sendercable, LNG fuel tank pressure

6 Coolant hoses7 LNG fuel tank pressure8 LNG vaporizer

Pretrip and Post-Trip Inspections and Maintenance

11.1

Weekly Post-Trip Inspection ChecklistSee the following table for procedures that should beperformed weekly, post-trip. Place a check mark inthe complete (Comp. ) column to indicate a proce-dure has been performed.

Inspector Date

Engine Compartment Comp.1 Windshield washer reservoir level2 Air intake restriction indicator3 Automatic transmission fluid level4 Water in fuel/water separator5 Steering components6 Serpentine drive belts

Monthly Post-Trip Inspection ChecklistsSee the following tables for procedures that shouldbe performed monthly, post-trip. Place a check markin the complete (Comp. ) column to indicate a proce-dure has been performed.

Inspector Date

Brake Components Comp.1 Brake system components2 Brake chambers3 Air brake lines4 Flex air hoses5 Brake linings and brake drums6 Brake lining thickness

Driver-Side Saddle Tank Area Comp.

1 Drain air reservoirs (with automatic drainvalves)

2 Batteries3 Aerodynamic components

Engine Compartment Comp.1 Hood and bumper2 Hydraulic clutch reservoir3 Radiator and heater hoses4 Steering wheel play

Natural Gas Fuel System Comp.1 System leak test2 Drain CNG high-pressure fuel filter housing

Fluids AddedUse the following table to note any fluids that wereadded during the inspection and maintenance proce-dures.

Fluids Added During InspectionFluid Amount Added

Wheel Bearing Oil SealLubricantEngine OilPower Steering FluidEngine CoolantWindshield Washer FluidAutomatic TransmissionFluidHydraulic Clutch Fluid,DOT4


11.2

Daily Pretrip Inspection andMaintenanceComplete the following inspection and maintenanceprocedures to ensure that vehicle components are ingood working condition before each trip. A driver whois familiar with the vehicle and drives it regularly canperform the daily inspections, then add the weeklyand monthly post-trip inspections as scheduled.

If the driver does not operate the vehicle on a con-sistent basis, all daily, weekly, and monthly inspec-tion and maintenance procedures should be per-formed before the trip.

IMPORTANT: The pre- and post-trip checklists,inspections, and maintenance procedures de-tailed in this chapter are not all-inclusive .Refer to other component and body manufactur-ers’ instructions for specific inspection andmaintenance instructions, as well as local, state,and federal guidelines.

NOTE: If any system or component does notpass this inspection, it must be corrected beforeoperating the vehicle. Whenever equipment re-quires adjustment, replacement, and/or repair,see the Business Class M2 Workshop Manual-for procedures and specifications.

Suspension and Slack AdjusterInspectionWalk around the vehicle and visually inspect suspen-sion and slack adjuster components.

1. Inspect the following suspension components forsigns of structural damage, cracks, or wear.

• springs

• spring hangers

• shocks

• suspension arms

• suspension brackets

• axle seats

• bushings

2. Inspect slack adjusters for signs of damage. SeeFig. 11.1 , Fig. 11.2 , or Fig. 11.3 .

• Inspect slack adjuster boots, if equipped,for cuts or tears.

• Inspect anchor straps, if equipped, fordamage.

• Look for worn clevis pins on brake cham-ber pushrods.

• Look for missing or damaged cotter pinson the clevis pins.

• Ensure chamber piston rods are in linewith the slack adjusters.

Wheel and Tire InspectionWalk around the vehicle and visually inspect eachwheel and tire assembly.

IMPORTANT: Wheel covers decrease drag forceas a vehicle moves, thereby improving fuel effi-ciency. If replacement of a wheel cover is nec-essary, the replacement cover must meet or ex-ceed the drag reduction performance of the

f42139806/17/2003

1

2

3

4 5

6

78

10

9

1. 7/16-inch Adjusting Nut2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston Rod6. Clevis7. 1/2-inch Clevis Pin8. 1/4-inch Clevis Pin9. Grease Relief Opening10. Slack Adjuster Spline

Fig. 11.1, Gunite Automatic Slack Adjuster


11.3

originally installed cover in order to maintaincompliance with greenhouse gas and full effi-ciency regulations (GHG14).

1. If the vehicle was originally equipped with wheelcovers, ensure all wheel covers are present. In-spect wheel covers for damage or wear. Removewheel covers from rear drive wheels, if equipped,prior to inspecting the tires and wheel compo-nents.

NOTE: During wheel cover installation, ensurethe V-notch in the liner inner retaining ring iscentered on the valve stem. The inner and outerretaining rings should be uniformly aligned toeach other and to the wheel rim. The outer re-taining ring of the liner is equipped with twocanvas flaps. When installing the face cover,make sure the cover retaining ring is insertedbetween the two canvas flaps on the liner outer

retaining ring so that the Velcro strips line upbetween the face cover and the liner.

2. Inspect each tire for the following:

• valve stem caps on every tire, screwed onfinger-tight

• bulges, cracks, cuts, and penetrations

• oil contamination (petroleum derivatives willsoften the rubber and destroy the tire)

• tread depth—if tread is less than 4/32 inch(3 mm) on any front tire, or less than 2/32

10/11/2005 f421397

1

2

3

4

5

6

7

8 9

A

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 Arm6. Control-Arm Washers and Nut7. Anchor Strap Slot8. Anchor Strap9. Brake Chamber

Fig. 11.2, Haldex Automatic Slack Adjuster

01/31/2011 f4225301

2

34

5

6

7

8

910

1. Grease Fitting (if equipped)2. Slack Adjuster Housing3. Brake Chamber Pushrod4. Clevis5. Clevis Pin (large)6. Clevis Pin (small)7. Actuator Rod8. Boot9. Manual Adjusting Nut10. Camshaft Splines

Fig. 11.3, Meritor Automatic Slack Adjuster


11.4

inch (1.5 mm) on any rear tire, replace thetire

• debris lodged between duel tire sets

IMPORTANT: Low-rolling resistance (LRR) tiresminimize wasted energy as a tire rolls, therebydecreasing rolling effort and improving fuel effi-ciency. If tire replacement is necessary, replace-ment tires must meet or exceed the rolling resis-tance of the originally installed tires in order tomaintain compliance with greenhouse gas andfull efficiency regulations (GHG14).

Contact your tire manufacturer/supplier to deter-mine the rolling resistance of the originally in-stalled tires. Visit www.epa.gov/smartway foradditional information and resources.

3. Check tire inflation.

For inflation pressures and maximum loads, seethe tire manufacturer’s guidelines. Inflate the tiresto the applicable pressures if needed.

If a tire has been run flat or under-inflated, checkthe wheel and tire for damage before adding air.

Keep compressed air reservoirs and lines dryduring tire inflation. Use well-maintained inlinemoisture traps and service 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.

NOTICEA weekly pressure loss of 4 psi (28 kPa) or morein a tire may indicate damage. The tire should beinspected and, if necessary, repaired or replacedby a qualified tire service facility.

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.Consult the rim or wheel manufacturer for the

correct tire inflation pressure for the vehicleload.

4. Examine each rim and wheel component. Checkthe wheel nuts or rim nuts for indications oflooseness.

4.1 Remove all dirt and debris from the as-sembly. Rust streaks or metal build-uparound stud holes, or out-of-round or wornstud holes, may be caused by loose wheelnuts.

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 couldoccur, possibly resulting in serious personal in-jury or death.

4.2 Inspect for broken, cracked, badly worn,bent, rusty, or sprung rings and rims.

NOTICEUse the recommended torque values and followthe proper tightening sequence. Insufficientwheel nut torque can cause wheel shimmy, re-sulting in wheel damage, stud breakage, and ex-treme tire tread wear. Excessive wheel nut torquecan break studs, damage threads, and crackdiscs in the stud hole area.

4.3 Make sure all wheel nuts are tightened. Iftightening is necessary, use the tighteningpattern in Fig. 11.4 or Fig. 11.5 .

5. Inspect the outboard side of all wheel hubs andthe hub oil seal area on the inboard side of eachwheel for signs of oil leakage. If any oil is foundon wheel and tire or brake components, removethe vehicle from service until the leak has beenfixed.

If needed, fill the hubs to the level indicated onthe hub cap. See Group 35 of the BusinessClass M2 Maintenance Manual for recommendedlubricants.

6. Check that mud flaps are undamaged and hang10 inches (25.4 cm) or less from the ground.


11.5

www.epa.gov/smartway

Saddle Tank Area Inspections

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.

NOTICEIf the water drained from the air reservoirs iscloudy or oily, it may indicate a problem with thecompressor. If oil is allowed to contaminate theair dryer, it will not remove the water from the airbrake system, which could adversely affect brak-ing.

1. Drain the brake system air reservoirs (reservoirswithout automatic drain valves only).

WARNINGNever operate the engine with the fuel tank shut-off valves partly closed. This could damage thefuel pump, causing sudden loss of engine power,possibly resulting in serious personal injury dueto reduced vehicle control.

2. Ensure fuel tanks are secured to their mountingbrackets and that the mounting brackets are se-cured to the frame.

If equipped with fuel tank shutoff valves, be surethe valves are fully open.

3. Inspect visible frame rails for missing bolts, shinyareas, or rust streaks. Check all visible cross-members for damage or signs of looseness.

4. Inspect visible components of the exhaust sys-tem to ensure connections are tight.

Inspect upstream of the aftertreatment device(ATD) for cracking or signs of leaks, such as soottrails. Inspect downstream of the ATD for signs ofexhaust leaks, such as blistering or warping ofnearby components.

Engine Compartment Inspection1. Check the ground underneath the engine for fuel,

oil, or coolant leaks.

2. Inspect the air intake system for leaks or dam-age.

NOTICEFailure 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.

2.1 Push the reset button on the air intakerestriction indicator located on the aircleaner, if equipped.

2.2 Check the air intake duct from the aircleaner to the engine intake. Make surethe duct components are secure and air-tight.

1

2

3

45

6

7

8

9

10

f400081a08/23/93

Fig. 11.4, Tightening Pattern, 10-Hole Wheels

f400052a

1 2

3

4

5 6

7

803/08/2012

Fig. 11.5, Tightening Pattern, 8-Hole Wheels


11.6

2.3 Check the vacuator (spitter) valve(s) fordamage, and make sure the lips of thevalve are pliable and free of debris.

3. Check the engine oil level.

NOTICEOperating 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.

3.1 Check the oil level with the vehicle parkedon a level surface. See the engine manu-facturer’s guidelines for engine shutdowntime requirements prior to checking the oillevel.

IMPORTANT: On engines that comply withEPA07 or newer regulations, use CJ-4 en-gine oil with less than 1% sulfated ash. Fail-ure to use CJ-4 oil may void the warranty onemission aftertreatment components.

3.2 If the oil level is at or below the minimumfill (or "add") mark on the dipstick, addenough oil to maintain the level betweenthe minimum and maximum fill marks. Seethe engine operation manual for recom-mended lubricants.

For natural gas vehicles, use only ExxonBusgard® Geo 15W-40 natural gas engineoil.

4. Check the power steering reservoir fluid level.

The power steering fluid level should be betweenthe MIN COLD mark and the middle mark justabove it. See Fig. 11.6 . If needed, fill the reser-voir with automatic transmission fluid that meetsDexron III or TES-389 specifications.

NOTICELow coolant could result in engine overheating,which could cause engine damage.

IMPORTANT: The surge tank must be cool tocheck the coolant level.

5. Check the engine coolant level in the radiatorsurge tank.

5.1 If the coolant is low, fill the surge tank tothe MAX line with a 50/50 mixture of waterand the type of antifreeze currently in-stalled in your vehicle.

For natural gas vehicles, use only Fleet-guard ES Compleat™ EG Premix 50/50engine coolant.

5.2 If the surge tank was empty, start the en-gine after refilling and check the levelagain when the engine is at operatingtemperature.

6. Inspect visible engine wiring for damage orlooseness.

7. Inspect visible frame rails for missing bolts, shinyareas, or rust streaks.

Cab Inspection1. Push the reset button on the dash-mounted air

intake restriction indicator, if equipped.

2. With the ignition switch in the OFF position,check the air-pressure warning system.

2.1 If not previously drained, drain the air res-ervoirs using moderate brake applicationsuntil pressure in both reservoirs is lessthan 70 psi (483 kPa).

2.2 Turn the ignition to the ON position. TheICU will complete a full gauge sweep andbulb check, and the warning buzzer willsound. Ensure the BRAKE AIR lamp re-mains illuminated and the warning buzzercontinues to sound after the gauge sweepis complete.

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1. Filler Cap

Fig. 11.6, Power Steering Fluid Reservoir


11.7

3. Check air governor cut-in and cut-out pressures.

3.1 Start the engine and ensure the BRAKEAIR lamp goes out and the buzzer si-lences when pressure reaches approxi-mately 70 psi (483 kPa) in both air reser-voirs.

The air governor should cut out at ap-proximately 120 psi (827 kPa). For ve-hicles with an optional dryer reservoirmodule (DRM), the cut-out pressure isapproximately 130 psi (896 kPa).

3.2 With the engine idling, apply the brakepedal several times. The air governorshould cut in when pressure in the primaryair reservoir (top air gauge) reaches ap-proximately 100 psi (689 kPa).

4. Check air pressure build-up time.

4.1 With the air system fully charged, makeone full brake application and note the airpressure reading on the primary airgauge.

4.2 Further reduce air pressure using moder-ate brake applications, then run the en-gine at governed rpm.

4.3 Note the time that the pressure reachesthe previously noted reading on the pri-mary air gauge, then note the time thatthe air pressure reaches cut-out pressure.

4.4 If it takes longer than 30 seconds to reachcut-out pressure after the primary airgauge passes the previously noted pres-sure (noted after one full brake applica-tion), eliminate any leaks or replace the aircompressor before operating the vehicle.

5. Check air leakage in the system.

5.1 With the parking brake applied, the trans-mission out of gear, and the air systemfully charged, release the service brakesand shut down the engine.

5.2 Wait one minute and note the air pressuredrop in psi (kPa) per minute from the pri-mary air reservoir.

If the pressure drop exceeds the limitsshown in Table 11.1 , eliminate any leaksbefore operating the vehicle.

6. Check the air pressure reserve.

With the engine still off, make one full brake ap-plication and observe the pressure drop on theprimary air gauge. If pressure drops more than25 psi (172 kPa), eliminate any leaks before op-erating the vehicle.

Maximum Allowable Air Leakage

DescriptionPressure Drop:

psi (kPa) Per MinuteReleased Applied

Truck or Tractor Only 2 (14) 3 (21)Truck or Tractor w/Single Trailer 3 (21) 4 (28)

Table 11.1, Maximum Allowable Air Leakage

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.

7. Inspect the mirrors, window glass, and wind-shield for cracks or other damage.

8. Ensure that the horn, windshield wipers, andwindshield washers are operating properly.These devices must be in good working order forsafe vehicle operation.

9. Ensure the heater and defroster are operatingproperly.

10. Check the operation of all interior lights.

10.1 Turn on the headlights and leave them on.Ensure all equipped gauge bulbs illumi-nate in the dash message center.

10.2 Ensure all equipped driver controlswitches illuminate.

10.3 Ensure both turn signal indicator bulbsilluminate in the dash message centerwhen the turn signal switch is activated.

11. Check the operation of all exterior lights. SeeFig. 11.7 .

11.1 Activate the high-beam headlights andhazard warning lights.


11.8

11.2 Exit the cab and check that all exteriorlights and reflectors are clean and intact.

11.3 Check that the brake lights, taillights,headlights, turn signals, marker lights,identification lights, and clearance lightsare working properly.

12. Inspect the seat belts and tether belts.

WARNINGInspect and maintain seat belts. When any part ofa seat belt system needs replacement, the entireseat belt must be replaced, both retractor andbuckle side. Any time a vehicle is involved in anaccident, and the seat belt system was in use,the entire vehicle seat belt system must be re-placed before operating the vehicle. Do not at-tempt to modify the seat belt system; doing socould change the effectiveness of the system.Failure to replace worn or damaged seat belts, or

making any modifications to the system, may re-sult in personal injury or death.

12.1 Check the web for fraying, cuts, extremedirt and dust, or for severe fading fromexposure to sunlight, especially near thebuckle latch plate and in the D-loop guidearea.

12.2 Check operation of the buckle, latch, Kom-fort Latch or Sliding Komfort Latch (ifequipped), web retractor, and upper seatbelt mount on the door pillar. Check allvisible components for wear or damage.

12.3 Check the seat belt and tether belt con-nection points and tighten any that areloose.

WARNINGNever fill fuel tanks to more than 95 percent oftheir liquid capacity. This could make them morelikely to rupture from impact, possibly causingfire and resulting in serious personal injury ordeath by burning.

Do 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: On engines that comply withEPA07 or newer regulations, use ultralow-sulfurdiesel (ULSD) with 15 ppm sulfur content orless. Failure to use ULSD fuel may void thewarranty on emission components.

13. Check the fuel level in the fuel tank(s). To keepcondensation to a minimum, fuel tanks should befilled at the end of each day.

14. Adjust the rearview and down view mirrors asnecessary.

15. Test the service brakes.

15.1 With the engine running and air systemfully charged, set the parking brake.

15.2 Put the vehicle in the lowest gear andgently attempt to move it forward. The ve-hicle should not move.

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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


11.9

If the vehicle moves, the parking brakesare not operating correctly and must berepaired before the vehicle is operated.

Natural Gas Fuel System Inspection,If Equipped1. Inspect fuel tanks for dents, scratches, gouges,

or other signs of damage. Inspect the fuel linesand connections for leaks.

Check that the fuel tanks are securely mounted.Look for signs of abrasion between components.

Compressed Natural Gas (CNG) Fuel System:Ensure that the CNG fuel cylinder storage box issecured to the frame. Inspect for signs of loose-ness.

Liquefied Natural Gas (LNG) Fuel System: En-sure that the LNG fuel tank is secured to themounting brackets and that the mountingbrackets are secured to the frame. Ensure allrubber isolator straps are secure around the LNGfuel tank.

2. Check for the presence of all required decalspresent in the following locations:

• Gas detection system overhead console;

• Above the door handle on both doors;

• Left front bumper;

• End-of-frame crossmember;

• LNG fuel tank fill port (maximum psi), ifequipped.

3. Check for the presence of vent caps on pressurerelief valves and devices. If any caps are miss-ing, have the fuel system inspected by a quali-fied technician.

CNG Fuel System: Each fuel cylinder shouldhave two caps (one on each end), which are vis-ible on the back of the CNG fuel cylinder storagebox. One additional cap is located on the pres-sure relief valve on the inboard side of the CNGfuel box, next to the fuel outlet line.

LNG Fuel System: A red cap should be presenton the secondary relief valve (Fig. 11.8 ).

4. Inspect all plumbing components, including thefuel shutoff valve(s), primary and secondary reliefvalves, and the LNG vapor shutoff and excess

flow valves, if equipped, for signs of damage orleaks. See Fig. 11.8 or Fig. 11.9 .

Inspect the fuel fill fitting for signs of damage orleaks.

Inspect all lines for signs of leaks or damage,and check all threaded connections.

5. Inspect all fuel gauge components for signs ofleaks or damage. Inspect the fuel level sendercable and wiring.

6. Inspect all coolant hoses for signs of chafing,kinks, or leaks. The LNG fuel system utilizescoolant hoses between the engine and the va-porizer; the CNG fuel system utilizes coolanthoses between the engine and the pressureregulator inside the fuel panel.

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1. Pressure Control Regulator2. Vapor Shutoff Valve3. Fuel Fill Hose4. Secondary Relief Valve (red cap)5. Fuel Fill Fitting6. Fuel Level Sender Box7. Primary Relief Valve8. Tank Pressure Gauge9. Fill Vent Fitting10. Excess Flow Valve11. Fuel Shutoff Valve (liquid)12. Fill Check Valve

Fig. 11.8, LNG Tank Plumbing Components


11.10

7. If equipped with an LNG fuel system, check thefuel tank pressure gauge to ensure that pressureis within the normal range of 120 to 150 psi (827to 1034 kPa). If tank pressure exceeds 230 psi(1586 kPa) and the pressure relief valve doesnot open automatically, vent the tank immedi-ately.

8. Inspect the LNG vaporizer for signs of damageor leaks. See Fig. 11.10 . Inspect the vaporizermounting brackets for signs of looseness.

Weekly Post-Trip Inspectionand MaintenanceEngine Compartment Inspection

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.

1. Check the windshield washer reservoir fluid level.The reservoir is usually located near the right-hand frame rail.

2. After resetting the air intake restriction indicatorduring the daily pretrip inspection, check the indi-cator again with the engine off.

2.1 Check an indicator with graduations to seeif air restriction exceeds the value shownin Table 11.2 .

Check a go/no-go indicator without gradu-ations to see if the colored bar showsthrough the clear window.

Air Cleaner Element Maximum Restriction

EnginePre-EPA07

EnginesEPA07 and

Newer EnginesCaterpillar 25 inH 2O —Cummins 25 inH 2O 25 inH 2ODetroit Diesel 20 inH 2O 22 inH 2OMercedes-Benz 22 inH 2O 22 inH 2O

Table 11.2, Air Cleaner Element Maximum Restriction

2.2 If air restriction exceeds the maximum al-lowable value, operate the vehicle for onemore day, making sure not to run the en-gine over rated rpm. Refer to the engineoperation manual for more information onrated rpm for your engine.

2.3 If air restriction exceeds the maximumvalue again, replace the air cleaner. Forinstructions, refer to Group 09 of theBusiness Class M2 Workshop Manual.

3. If the vehicle is equipped with an Allison auto-matic transmission, check the automatic trans-mission fluid level.

4. Check for water in the fuel/water separator, ifequipped.

IMPORTANT: When draining fluid from afuel/water separator, drain the fluid into anappropriate container and dispose of it prop-erly. Many jurisdictions now issue fines fordraining fuel/water separators onto theground.

4.1 Place a suitable container under the fuel/water separator.

NOTE: A hose may be used to direct waterinto the container. Use a hose with a ½-inchpipe thread on DAVCO models.

HIGH PRESSURE PRESSURELOW

CYLINDERSINSPECT CYLINDERS

EVERY 36 MONTHSOR 36000 MILES

WHICHEVER OCCURS FIRST

NATURALGAS

VEHICLE110 PSIG

ON

MANUAL

SHUT O

FFVALV

E

OPEN VALVESLOWLY

3600 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. 11.9, CNG Fuel Panel


11.11

4.2 If the engine is equipped with a built-inwater separator, loosen the drain valve,and allow the water to run out. Close thedrain valve, taking care not to overtightenit.

4.3 Alliance/Racor Models: Turn the drain plugcounterclockwise to open it. SeeFig. 11.11 .

DAVCO Models: Remove the vent capand open the drain. See Fig. 11.12 .

4.4 Stop draining fluid when fuel begins todrain out.

Alliance/Racor Models: turn the drain plugclockwise to close it.

DAVCO Models: close the drain valve.Install and hand-tighten the vent cap.

5. Inspect the steering components. See Fig. 11.13 .

5.1 Inspect tie rods, steering arms, and thedrag link for signs of looseness (i.e., shinyspots or rust tracks).

5.2 Check the steering gear mounting boltsand pitman arm nut for signs of loose-ness.

5.3 Check the drag link nuts for missing cotterpins.

5.4 Inspect the steering intermediate shaft andend yokes for excessive looseness orother damage.

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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. 11.10, LNG Vaporizer Assembly


11.12

NOTICEDo not drive with a drive belt that is visibly wornor damaged. If it fails, the lack of coolant flowcould rapidly cause damage to engine compo-nents.

6. Inspect the serpentine drive belts for signs ofglazing, frayed edges, breaks, cracks, or oil con-tamination.

Monthly Post-Trip Inspectionand MaintenanceBrake Component InspectionWalk around the vehicle and visually the brake sys-tem components for visible damage.

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1. Washers (qty 2)2. Nuts (qty 2)3. Frame Rail4. Fuel Outlet Port5. Fuel Inlet Port6. Priming Pump

7. Mounting Head8. Mounting Bolts (qty 2)9. Filter Element10. Sight Bowl11. Drain Plug

Fig. 11.11, Alliance Fuel/Water Separator Assembly andInstallation

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1. Inlet Port/Check Valve2. Lower Housing3. Bypass Valve4. Filter Element5. Spring6. Cover O-Ring7. Clear Cover

8. Vent Cap O-Ring9. Vent Cap10. Collar11. 120VAC Pre-Heater12. 12VDC Pre-Heater13. Drain Valve

Fig. 11.12, DAVCO Fuel/Water Separator (Fuel Pro 482shown)


11.13

1. Inspect all visible brake system components formissing fasteners or signs of looseness, such asrust tracks.

NOTICEIf 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.

2. Inspect the exterior surfaces of brake chambersfor damage. Make sure that breather holes areopen and free of debris.

NOTE: Do not route air brake lines on top ofanything likely to be stepped on.

3. Inspect air brake lines for dents, swelling, kinks,twisting, abrasion, and damage, especially nearmoving parts.

4. Inspect flex air lines for deterioration or signs ofabrasion.

5. Inspect for cracked, worn, or oil-contaminatedbrake linings and brake drums (or rotors).

6. Check the thickness of the brake linings. Re-place brake linings on all brake assemblies onthe axle if any brake linings are worn to less thanapproximately 1/4 inch (6.4 mm) at the thinnestpoint.

Saddle Tank Area Inspections

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.

NOTICEIf the water drained from the air reservoirs iscloudy or oily, it may indicate a problem with thecompressor. If oil is allowed to contaminate theair dryer, it will not remove the water from the airbrake system, which could adversely affect brak-ing.

1. Drain the brake system air reservoirs (reservoirswith automatic drain valves only).

NOTE: Battery locations vary between vehicles.

2. Inspect the batteries.

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.

2.1 Remove the battery box cover and inspectall visible battery cables for loose wiring ordamage.

2.2 Check that the battery hold-down is se-cure.

IMPORTANT: Aerodynamic components de-crease drag force as a vehicle moves, therebyimproving fuel efficiency. If replacement of anaerodynamic component is necessary, replace-ment components must meet or exceed the

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1. Steering Gear Mounting Bolt2. Pitman Arm Pinch Bolt Nut3. Drag Link Nut

Fig. 11.13, Steering Gear Fasteners


11.14

drag reduction performance of the originally in-stalled component in order to maintain compli-ance with greenhouse gas and full efficiencyregulations (GHG14).

3. Inspect the following aerodynamic components, ifequipped, for structural damage, cracks, or wear.

• Chassis fairings

• Roof fairing/deflector

• Side skirts

• Cab extenders

• Battery access cover

Engine Compartment Inspection andAdjustmentsIMPORTANT: If replacement of the hood orbumper is necessary, the replacement compo-nent must meet or exceed the drag reductionperformance of the originally installed item inorder to maintain compliance with greenhousegas and full efficiency regulations (GHG14).

1. Inspect the bumper and hood for structural dam-age, cracks, or wear.

2. Check the hydraulic clutch reservoir, if equipped.If necessary, add DOT 4 brake fluid.

3. Inspect the radiator and heater hoses, includingthe clamps and support brackets.

3.1 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).

3.2 Make sure the radiator inlet and outlethoses are pliable and are not cracking orballooning.

3.3 Make sure the heater hoses are pliableand are not cracking or ballooning.

3.4 Tighten hose clamps as necessary.

IMPORTANT: Do not overtighten hoseclamps, as hose life can be adversely af-fected.

3.5 Ensure hose support brackets are se-curely fastened. Make sure hoses are notlocated near sources of wear, abrasion, orhigh heat.

IMPORTANT: When replacing hoses, installservice-type knitted or braided yarn-reinforcedneoprene hose. Extended-service-life siliconehoses may also be used. See the Alliance PartsCatalog at www.alliancebrandparts.com orcontact your Freightliner Dealer.

4. Check the steering wheel for excessive play.

4.1 Start the engine. With the front tiresstraight ahead, turn the steering wheeluntil motion is observed at the frontwheels.

4.2 Align a reference mark on the steeringwheel to a rule, then slowly turn the steer-ing wheel in the opposite direction untilmotion is again detected at the wheels.

4.3 Measure the lash (free play) at the rim ofthe steering wheel. Excessive lash existsif steering wheel movement exceeds 2-1/2inches (64 mm) with a 20-inch (508-mm)steering wheel, or 2-1/4 inches (57 mm)with an 18-inch (450-mm) steering wheel.

4.4 If there is excessive lash, check the steer-ing system for wear or incorrect adjust-ment before operating the vehicle.

Natural Gas Fuel System Inspection,If Equipped1. Leak test all fuel system components, joints, and

fittings using a methane detector. A bubble solu-tion can be used to pinpoint the exact location ofleaks.

Replace any leaking or damaged fuel tanks andfuel lines; repair or replace leaking or damagedfittings.

2. Drain the CNG high-pressure fuel filter housing,if equipped.


11.15

www.alliancebrandparts.com

2.1 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).

2.2 Close the manual fuel shutoff valve on thefuel panel.

2.3 Remove the two capscrews that securethe access cover to the fuel panel, thenremove the access cover. See Fig. 11.14 .Save the capscrews for installation.

2.4 Slowly open the bleed valve on the mani-fold to relieve remaining fuel pressurewithin the system. See Fig. 11.15 .

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.

2.5 Put a clean receptacle under the filter as-sembly.

2.6 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.

2.7 Close the bleed valve on the manifold andopen the manual fuel shutoff valve on thefuel panel.

Open the fuel cylinder shutoff valves.

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1. Fuel Panel Access Cover2. Capscrews (qty 2)3. Wiring Harness4. Pressure Relief Valve and Cap5. Coolant Outlet Line6. Coolant Inlet Line7. Fuel Inlet Line (to fuel cylinders)8. Fuel Outlet Line (to engine)

Fig. 11.14, CNG Fuel Panel Assembly

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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. High-Pressure Filter11. Filter Bowl12. Filter Drain Plug13. Solenoid Valve14. Fuel Line To Cylinders

Fig. 11.15, CNG Fuel Panel Components


11.16

2.8 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.

2.9 Install the access cover on the fuel panel.


11.17

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

12

3

4

5

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

1

2

3

4

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

1

2

4

6

7

5

8

11/14/2001

3

9

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

1

2

3

4

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

OK

OK

1

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

Preliminary ChecksBefore checking or adjusting the headlight aim, dothe following:

• Check that the hood is closed and latched.

• Remove any large amounts of mud or ice fromthe underside 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. Use a soft clothwith mild, non-caustic soap or detergent, andwater.

Checking Headlight Aim1. Park the vehicle on a level surface, 25 ft (7.6 m)

away from, and perpendicular to, a verticalscreen or wall. Shut down the engine and set theparking brake. Chock the tires.

2. Each headlight has a height adjusting dot. SeeFig. 14.1 . Measure the distance from the groundto the height adjusting dot on each headlight(Fig. 14.2 , Item A). Note those distances.

3. On the screen or wall, mark the locations of eachheadlight bulb center using the distances foundin step 2. See Fig. 14.2 , Items 2 and 3.

4. Turn on the low-beam headlights.

5. Check the vertical adjustment of the low beams.The center of each beam projection should fallon or near the marks made during step 3. SeeFig. 14.3 .

6. Use Table 14.1 to determine the maximum verti-cal distance allowable between the marks on thewall and the center of each low-beam projection.

If the distance between either projection centerand the mark made on the wall or screen isgreater than the maximum distance given inTable 14.1 , adjust the vertical positioning of thatheadlight.

Adjusting Headlight AimNOTE: Freightliner vehicles are offered withvarious headlight assembly options. Because ofthe various options, the location of adjustmentscrews on your vehicle’s headlight assemblymay vary from what is shown here.

1. Lift the flap over the rear end of the headlightbucket to expose the two plastic adjusting knobson each headlight. See Fig. 14.4 .

NOTE: Horizontal aim should not be adjusted inthe field.

2. Turn both adjusting knobs as needed to adjustthe lights until the beam pattern meets the ac-ceptable standard.

11/06/2002 f544236

Measure beam height from the ground to the small dotroughly in the center of the headlight lens.

Fig. 14.1, Headlight Beam Height Adjusting Dot

Headlight Aiming

14.1

f545850b01/11/2012

B

B

1

23

25 ft (7.6 m)

AA

A. Measure the distance from the ground to the center of each headlight bulb.B. Mark where the center of each headlight projection should appear.1. Screen or Wall2. Center of Right-Hand Headlight Projection

3. Center of Left-Hand Headlight Projection

Fig. 14.2, Headlight Aiming Screen/Wall

01/11/2012 f545851b

A

12

3

1. Low-Beam Angle Upper Limit2. Ideal Low-Beam Projection

3. Low-Beam Angle Lower Limit

Fig. 14.3, Vertical Low-Beam Headlight Variation Limits

Headlight Aiming

14.2

Vertical Low-Beam Headlight Variation LimitsDistance Between Ground

and Headlight: in (mm)Desired Variation ( Fig. 14.3,

Item 2): in (mm)Upper Limit ( Fig. 14.3, Item

1): in (mm) upLower Limit ( Fig. 14.3, Item

3): in (mm) down22–36 (560–900) 0 3.9 (100) 3.9 (100)

36–48 (900–1200) 2 (50) down 2 (50) 6 (150)48–54 (1200–1400) 2.5 (64) down 1.6 (40) 6.5 (165)

Table 14.1, Vertical Low-Beam Headlight Variation Limits

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

14.3

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

Fig. 16.7, Ignition Switch Positions

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 . . . . . . . . . . . . . . . . . 4.13Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 14.1Air Bag, Optional . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

Air Bag Safety Guidelines . . . . . . . . . . . . . . . . 5.10Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

Air Brake System, GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Air Brake System Operation . . . . . . . . . . . . . . . . 9.2Automatic Slack Adjusters . . . . . . . . . . . . . . . . . 9.4

Allison MD Series . . . . . . . . . . . . . . . . . . . . . . . . 8.5Operating Instructions, MD

Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 8.5

Allison On-HighwayTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3Operating Instructions, On-

Highway Transmissions . . . . . . . . . . . . . . . . . 8.4Range Inhibit Indicator, 2000

and 2400 Series . . . . . . . . . . . . . . . . . . . . . . 8.3Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 8.3

All-Wheel-Drive Controls,Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11AWD 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 . . . . . . . . . . . . . . . . . . 4.13Trailer 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 . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

Subject Page

Entering from the Driver’sSide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

Entering from thePassenger’s Side . . . . . . . . . . . . . . . . . . . . . 2.5

Exiting 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 Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1Care 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 . . . . . . . . . . . . . . . . . . . 7.10Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . 7.9Component GWR Label . . . . . . . . . . . . . . . . . . . . 1.1Component Information Label . . . . . . . . . . . . . . . . 1.1Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

Dash-Mounted Switches . . . . . . . . . . . . . . . . . 7.11Shift Knob Controls, Optional . . . . . . . . . . . . . . 7.12

DDaily Pretrip Inspection and

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3Cab Inspection . . . . . . . . . . . . . . . . . . . . . . . . 11.7Engine Compartment

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6

Index

I-1

Subject Page

Natural Gas Fuel SystemInspection, If Equipped . . . . . . . . . . . . . . . . 11.10

Saddle Tank AreaInspections . . . . . . . . . . . . . . . . . . . . . . . . . 11.6

Suspension and SlackAdjuster Inspection . . . . . . . . . . . . . . . . . . . . 11.3

Wheel and Tire Inspection . . . . . . . . . . . . . . . . 11.3Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . 12.1Diesel Exhaust Fluid and Tank,

EPA10 and Newer Engines . . . . . . . . . . . . . . . . . 7.3DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4DEF Warnings and Engine

Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 7.3Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . . 7.4

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 . . . . . . . . . . . . . . . . . . . . . . . . 13.2Emission Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Subject Page

Aftertreatment SystemIndicators Label . . . . . . . . . . . . . . . . . . . . . . 1.2

Certified Clean Idle Label . . . . . . . . . . . . . . . . . 1.3EPA Noise Emission Control

Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Vehicle Emission Control

Information Label . . . . . . . . . . . . . . . . . . . . . 1.3Emissions and Fuel Efficiency . . . . . . . . . . . . . . . . 7.1

ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 7.3EPA07 Engines . . . . . . . . . . . . . . . . . . . . . . . . 7.1EPA10 and Newer Engines . . . . . . . . . . . . . . . . 7.1Greenhouse Gas Emissions

and Fuel ConsumptionStandards . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . 7.13Engine Brake Operation . . . . . . . . . . . . . . . . . 7.14

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

Normal Operation . . . . . . . . . . . . . . . . . . . . . . 7.9Safety and Environmental

Considerations . . . . . . . . . . . . . . . . . . . . . . . 7.9Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 7.10Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7Enhanced Stability Control . . . . . . . . . . . . . . . . . . 9.6Exhaust Braking Systems . . . . . . . . . . . . . . . . . . 7.15

Exhaust Brake Switch . . . . . . . . . . . . . . . . . . . 7.15Mercedes-Benz Exhaust

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15Pacbrake® Exhaust Brake . . . . . . . . . . . . . . . . 7.16

FFederal Motor Vehicle Safety

Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . 10.1

Fontaine and Holland FifthWheels Coupling . . . . . . . . . . . . . . . . . . . . . 10.1

Jost Fifth Wheel Coupling . . . . . . . . . . . . . . . . 10.3Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . 10.7

Air Slide Operation . . . . . . . . . . . . . . . . . . . . . 10.9Manual Slide Operation . . . . . . . . . . . . . . . . . . 10.7

Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . 10.4Air-Actuated Uncoupling . . . . . . . . . . . . . . . . . 10.5Manual Uncoupling . . . . . . . . . . . . . . . . . . . . . 10.4

Fifth Wheels, GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Air-Suspension Dump Valve . . . . . . . . . . . . . . . 10.1Fifth Wheel Lubrication . . . . . . . . . . . . . . . . . . 10.1

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 13.1Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 13.6

In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 13.6

Index

I-2

Subject PageFreightliner SmartShift Shift

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . 13.1Heater/Air Conditioner Control

Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15High-Altitude Operation . . . . . . . . . . . . . . . . . . . . 7.10Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.7

To 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 . . . . . . . . . . . . . . . . . . . . 9.4Hydraulic Brake System,

General Information . . . . . . . . . . . . . . . . . . . . 9.4Hydraulic Brake System

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

IIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . 4.1

Subject PageInstrumentation Control Unit . . . . . . . . . . . . . . . . . . 3.1

Audible Warnings . . . . . . . . . . . . . . . . . . . . . . . 3.4Dash Message Center . . . . . . . . . . . . . . . . . . . 3.1Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 3.2Mode/Reset Button . . . . . . . . . . . . . . . . . . . . . 3.4Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

JJumpstarting (HEV) . . . . . . . . . . . . . . . . . . . . . . 15.3

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 . . . . . . . . . . . . . . . . . . . . . . 8.26General Information, AGS . . . . . . . . . . . . . . . . 8.22Operation, AGS . . . . . . . . . . . . . . . . . . . . . . . 8.23

Mercedes-Benz ManualTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.22

Meritor WABCO® AntilockBraking System . . . . . . . . . . . . . . . . . . . . . . . . . 9.5Automatic Traction Control . . . . . . . . . . . . . . . . 9.6Trailer ABS Compatibility . . . . . . . . . . . . . . . . . . 9.5

Meritor™ Drive Axles . . . . . . . . . . . . . . . . . . . . . . 8.26Axle Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29Drive Axles With Differential

Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27Tandem Drive Axles With

Interaxle Lock . . . . . . . . . . . . . . . . . . . . . . . 8.28Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Down View Mirror, Optional . . . . . . . . . . . . . . . . 5.1Mirror Heat Switch, Optional . . . . . . . . . . . . . . . 5.1Power Mirrors, Optional . . . . . . . . . . . . . . . . . . 5.1

Monthly Post-Trip Inspectionand Maintenance . . . . . . . . . . . . . . . . . . . . . . 11.13Brake Component Inspection . . . . . . . . . . . . . 11.13Engine Compartment

Inspection andAdjustments . . . . . . . . . . . . . . . . . . . . . . . 11.15

Natural Gas Fuel SystemInspection, If Equipped . . . . . . . . . . . . . . . . 11.15

Saddle Tank AreaInspections . . . . . . . . . . . . . . . . . . . . . . . . 11.14

Index

I-3

Subject PageMultifunction Turn Signal Switch . . . . . . . . . . . . . . . 4.5

Hazard Warning Flasher . . . . . . . . . . . . . . . . . . 4.7Headlight High Beams . . . . . . . . . . . . . . . . . . . 4.6Turn-Signal Controls . . . . . . . . . . . . . . . . . . . . . 4.5Windshield Wiper/Washer

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

OOptional Instruments . . . . . . . . . . . . . . . . . . . . . . 3.12

Air Restriction Gauge . . . . . . . . . . . . . . . . . . . 3.12Ambient Temperature Gauge . . . . . . . . . . . . . . 3.13Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . 3.13Drive Axle Oil Temperature

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14Engine Oil Temperature

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14Transmission Fluid

Temperature Gauge . . . . . . . . . . . . . . . . . . . 3.15Turbocharger Boost

Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 3.15Other Dash-Mounted Controls . . . . . . . . . . . . . . . 4.14

CB Radio Connections . . . . . . . . . . . . . . . . . . 4.14Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . 4.14Suspension Autofill Override

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Suspension Dump Switch . . . . . . . . . . . . . . . . 4.14Windshield-Fan Switches,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14Overhead Instrument Panel . . . . . . . . . . . . . . . . . 3.15

PPower Takeoff (PTO) Governor . . . . . . . . . . . . . . . 7.12Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 4.7

After-Treatment System(ATS) Request/InhibitRegen Switch . . . . . . . . . . . . . . . . . . . . . . . . 4.7

Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . 4.10Cruise Control Switches . . . . . . . . . . . . . . . . . . 4.8Engine Brake Switch,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8Engine Fan Switch, Optional . . . . . . . . . . . . . . . 4.9Exhaust Brake Switch,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9Transmission Controls . . . . . . . . . . . . . . . . . . . 4.9

Pre- and Post-Trip InspectionChecklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 14.1

Subject Page

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Bench Seat Adjustment

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Suspension 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

Standard Instruments . . . . . . . . . . . . . . . . . . . . . . 3.9Air Pressure Gauges . . . . . . . . . . . . . . . . . . . . 3.9Coolant Temperature Gauge . . . . . . . . . . . . . . 3.10Engine Oil Pressure Gauge . . . . . . . . . . . . . . . 3.10Fuel Gauge, Pre-EPA10 . . . . . . . . . . . . . . . . . 3.10Fuel/Diesel Exhaust Fluid

(DEF) Gauge, EPA10 . . . . . . . . . . . . . . . . . . 3.11Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 3.11Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

Starting After ExtendedShutdown or Oil Change . . . . . . . . . . . . . . . . . . . 7.9

Starting, and Engine Shutdown(HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . 15.2Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2The Cranking System . . . . . . . . . . . . . . . . . . . 15.2

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Steering Wheel Adjustment . . . . . . . . . . . . . . . . 9.1

TTowing (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5

Front Towing Hookup . . . . . . . . . . . . . . . . . . . 13.5Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 13.5

VVelour Upholstery Cleaning . . . . . . . . . . . . . . . . . 12.2

Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 12.3Grease and Oil-Based Stains . . . . . . . . . . . . . . 12.3Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3Sugar and Water-Based

Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3

Index

I-4

Subject PageVinyl 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 . . . . . . . . . . . . . . . . . . . . . . . . 12.2Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 12.2

WWarning and Indicator Lights . . . . . . . . . . . . . . . . . 3.5

Engine Protection System . . . . . . . . . . . . . . . . . 3.5Weekly Post-Trip Inspection

and Maintenance . . . . . . . . . . . . . . . . . . . . . . 11.11Engine Compartment

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 11.11Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Windshield Washer Reservoir . . . . . . . . . . . . . . . . 5.11

Index

I-5

manual de conduccion camion freightliner business class m2

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