User manual | freightliner 108sd and 114sd driver's manual

108SD and 114SD
Driver’s Manual
Part Number STI-496
Publication Number STI-496-6
Foreword
Introduction
This manual provides information needed to operate
and understand the vehicle and its components.
More detailed information is contained in the Owner’s
Warranty Information for North America booklet, and
in the vehicle’s workshop and maintenance manuals.
Custom-built Freightliner vehicles are equipped with
various chassis and cab components. Not all of the
information contained in this manual applies to every
vehicle. For details about components in your vehicle, refer to the chassis specification pages included in all new vehicles and to the vehicle specification decal, located inside the vehicle.
For your reference, keep this manual in the vehicle
at all times.
IMPORTANT: Descriptions and specifications in
this manual were in effect at the time of printing.
Freightliner Trucks reserves the right to discontinue models and to change specifications or
design at any time without notice and without
incurring obligation. Descriptions and specifications contained in this publication provide no
warranty, expressed or implied, and are subject
to revisions and editions without notice.
Environmental Concerns and
Recommendations
Whenever you see instructions in this manual to discard materials, you should first attempt to reclaim
and recycle them. To preserve our environment, follow appropriate environmental rules and regulations
when disposing of materials.
Event Data Recorder
This vehicle is equipped with one or more devices
that record specific vehicle data. The type and
amount of data recorded varies depending on how
the vehicle is equipped (such as the brand of engine,
if an air bag is installed, or if the vehicle features a
collision avoidance system, etc.).
This vehicle is equipped with an event data recorder
(EDR). The main purpose of an EDR is to record
data in certain crash or near-crash situations, such
as air bag deployment or hitting a road obstacle, that
will assist in understanding how a vehicle’s systems
performed. The EDR is designed to record data related to vehicle dynamics and safety systems for approximately 60 seconds. This data can help provide
a better understanding of the circumstances in which
crashes and injuries occur. Data recorded includes
the following items:
• how various systems in the vehicle were oper-
ating
• engine system information
• how far (if at all) the driver was depressing the
accelerator
• if the driver was depressing the brake pedal
• how fast the vehicle was traveling
NOTE: Data is not recorded by the EDR under
normal driving conditions. Personal data such
as name, gender, age, and crash location are
not recorded. However, other parties such as
law enforcement could combine the EDR data
with the type of personally identifying data routinely acquired during a crash investigation.
To read data recorded by an EDR, special equipment
is required, and access to the vehicle or the EDR is
needed. In addition to the vehicle manufacturer, other
parties that have the special equipment, such as law
enforcement, can read the information if they have
access to the vehicle or the EDR.
Emissions and Fuel Efficiency
Compliance
This vehicle must be regularly inspected and maintained as indicated in the 108SD and 114SD Maintenance Manual, and in the Pre- and Post-Trip Inspections and Maintenance chapter in this manual, in
order to continue satisfactory performance and ensure coverage of the vehicle under the manufacturer’s warranty. Many maintenance procedures ensure
that the vehicle and engine continue to comply with
applicable emissions standards. Maintenance procedures, using components engineered to comply with
greenhouse gas emissions and fuel efficiency regulations, may be performed by an authorized Daimler
Trucks North America dealer, an independent outlet,
or the vehicle owner or operator.
The vehicle owner is responsible for determining the
suitability of replacement components to maintain
STI-496-6 (11/14)
Part Number STI-496
Printed in U.S.A.
Foreword
compliance with federal and local jurisdictional regulations. Components including, but not limited to,
tires, cab/sleeper side extenders, chassis fairings,
bumper, hood, vehicle speed limiters, and idle reduction timers are specifically designed and manufactured to exacting standards for regulatory fuel efficiency and greenhouse gas emissions compliance. It
is important that these components are always replaced with components that meet or exceed the performance of the originally installed components.
hotline 1-800-333-0510, or contact Transport
Canada by mail at: Transport Canada, ASFAD,
Place de Ville Tower C, 330 Sparks Street, Ottawa, Ontario, Canada K1A 0N5.
For additional road safety information, please visit
the Road Safety website at: www.tc.gc.ca/
roadsafety.
Customer Assistance Center
Having trouble finding service? Call the Customer
Assistance Center at 1-800-385-4357 or 1-800-FTLHELP. Call night or day, weekdays or weekends, for
dealer referral, vehicle information, breakdown coordination, or Fleetpack assistance. Our people are
knowledgeable, professional, and committed to following through to help you keep your truck moving.
Reporting Safety Defects
If you believe that your vehicle has a defect which
could cause a crash or could cause injury or
death, you should immediately inform the National
Highway Traffic Safety Administration (NHTSA) in
addition to notifying Daimler Trucks North America
LLC.
If NHTSA receives similar complaints, it may open
an investigation, and if it finds that a safety defect
exists in a group of vehicles, it may order a recall
and remedy campaign. However, NHTSA cannot
become involved in individual problems between
you, your dealer, or Daimler Trucks North America
LLC.
To contact NHTSA, you may call the Vehicle
Safety Hotline toll-free at 1-888-327-4236 (TTY:
1-800-424-9153); go to www.safercar.gov; or
write to: Administrator, NHTSA, 1200 New Jersey
Avenue, SE, Washington, DC 20590. You can also
obtain other information about motor vehicle safety
from www.safercar.gov.
Canadian customers who wish to report a safetyrelated defect to Transport Canada, Defect Investigations and Recalls, may telephone the toll-free
© 2011-2015 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler
company.
No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmitted
in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks North
America LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer to
www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com.
Contents
Chapter
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Page
Introduction, Environmental Concerns and Recommendations,
Event Data Recorder, Emissions and Fuel Efficiency Compliance,
Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword
Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Seats and Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Engine Starting, Operation, and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Optional Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Emissions and Fuel Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Manual Transmissions and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Automated and Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Natural Gas Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1
1
Vehicle Identification
Component Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Federal Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Canadian Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component GWR Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.1
1.1
1.1
1.1
Vehicle Identification
Component Information Label
NOTE: Labels shown in this chapter are examples only. Actual specifications may vary from
vehicle to vehicle.
The component information label lists the vehicle
model, identification number, and major component
models. It also lists the major assemblies and installations shown on the chassis specification sheet.
One copy of the component information label is attached to the inside of the glove box; another copy is
inside the rear cover of the Owner’s Warranty Information for North America booklet. An illustration of
the label is shown in Fig. 1.1.
tire and rim label, then the tires and rims determine
the load limitations on each of the axles.
Trucks built without a cargo body that are intended
for service in the U.S. have an incomplete vehicle
certification label attached by the final-stage manufacturer. See Fig. 1.4. This label will be attached to
the incomplete vehicle document included with the
vehicle, and certifies that the vehicle conforms to all
applicable FMVSS regulations in effect on the date of
completion.
Canadian Motor Vehicle Safety
Standard Labels
In Canada, tractors with fifth wheels are marked as
certified by means of a statement of compliance label
with the Canadian National Safety Mark attached to
the driver-side door frame B-pillar. See Fig. 1.5.
02/20/2012
f080176
Fig. 1.1, Component Information Label
Federal Motor Vehicle Safety
Standard Labels
NOTE: Due to the variety of Federal Motor Vehicle Safety Standard (FMVSS) certification requirements, not all of the labels shown will apply
to your vehicle.
Tractors with or without fifth wheels purchased in the
U.S. are marked as certified by means of an FMVSS
certification label. See Fig. 1.2. This label is attached
to the driver-side B-pillar, as shown in Fig. 1.3.
The tire and rim portion of the FMVSS certification
label certifies suitable tire and rim combinations that
can be installed on the vehicle, for the given gross
axle weight rating. Tires and rims installed on the
vehicle at the time of manufacture may have a higher
load capacity than that certified by the tire and rim
label. If the tires and rims currently on the vehicle
have a lower load capacity than that shown on the
1.1
Trucks built without a cargo body and tractors built
without a fifth wheel that are intended for service in
Canada have an incomplete vehicle certification label
attached to the driver-side B-pillar. After completion
of the vehicle, a complete certification label must be
attached by the final-stage manufacturer to certify
that the vehicle conforms to all applicable Canada
Motor Vehicle Safety Standard (CMVSS) regulations
in effect on the date of completion.
Component GWR Label
The component GWR label is located on the
passenger-side B-pillar. The label provides maximum
GWR ratings for each component.
See Fig. 1.6 for a typical component GWR label.
Emissions Labels
Aftertreatment System Indicators
Label
Engines and vehicles manufactured after December
31, 2006 and domiciled in the U.S. or Canada are
required to meet all EPA regulations effective as of
the vehicle build date, and are equipped with an
emission aftertreatment system (ATS). Vehicles domiciled outside of the U.S. and Canada may not
have aftertreatment equipment, depending upon local
statutory emissions guidelines. See Table 1.1.
Vehicle Identification
02/20/2012
f080177
Fig. 1.2, Vehicle Certification Label
1
02/28/2012
f080180
Fig. 1.4, Incomplete Vehicle Certification Label
10/10/2006
f080024
Fig. 1.5, Canadian National Safety Mark
certification requirements [Ref: 42 U.S.C. S7522(a)
(3)]. It is the owner’s responsibility to maintain the
vehicle so that it conforms to EPA regulations.
2
02/28/2012
f080182
1. EPA Noise Emission Control Label
2. FMVSS Certification Label
Fig. 1.3, Label Locations
A warning label on the driver-side visor contains important warning indicators in the instrument cluster
that pertain to the ATS. See Fig. 1.7.
It is a violation of U.S. federal law to alter exhaust
plumbing, ATS, or other components in any way that
would bring the engine/vehicle out of compliance with
EPA Noise Emission Control Label
A vehicle noise emission control label (Fig. 1.8) is
located on the driver-side B-pillar as shown in
Fig. 1.3. It is the owner’s responsibility to maintain
the vehicle so that it conforms to EPA regulations.
IMPORTANT: Certain Freightliner incomplete
vehicles may be produced with incomplete noise
control hardware. Such vehicles will not have a
vehicle noise emission control information label.
For such vehicles, it is the final-stage manufacturer’s responsibility to complete the vehicle in
conformity to U.S. EPA regulations (40 CFR Part
205) and label it for compliance.
1.2
Vehicle Identification
Applicable Emissions System Based on Build Date and EPA Regulations
Build Date
Regulation: Emissions Components
EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): Aftertreatment device (ATD)
January 1, 2010–December 31,
containing a diesel particulate filter that traps soot and ash, with selective catalyst
2012
reduction (SCR) technology that utilizes diesel exhaust fluid (DEF) to convert NOx to
nitrogen and water vapor.
GHG14: Aerodynamic and fuel efficiency components including, but not limited to,
tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speed
From March 5, 2012
limiters, and idle reduction timers specifically designed to meet regulatory fuel
efficiency and greenhouse gas emissions standards.
Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations
02/20/2012
f080178
Fig. 1.6, Component GWR Label
IMPORTANT
DPF Regen Needed
Hot Exhaust
Diesel Particulate Filter (DPF)
regeneration is needed.
If flashing, regenerate as soon as
possible. Engine derate possible.
Hot exhaust can cause fire.
Keep flammables and people away
from exhaust.
DEF Refill Needed
DEF
Diesel Exhaust Fluid (DEF) level is
low. Engine derate likely.
Refill tank with certified DEF.
See operator’s manual for complete instructions.
11/30/2010
f080162
Fig. 1.7, ATS Indicators
1.3
24−01656−000
Vehicle Identification
VEHICLE NOISE EMISSION CONTROL INFORMATION
DATE OF MANUFACTURE 01/96
FREIGHTLINER CORPORATION
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION
APPLICABLE TO MEDIUM AND HEAVY TRUCKS.
THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY
THE 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.
24−00273−020
10/06/98
CERTIFIED
CLEAN IDLE
f080026
Fig. 1.8, Vehicle Noise Emission Control Label
Vehicle Emission Control Information
Label
Model year 2013 and later vehicles meet additional
requirements as specified by federal greenhouse gas
and fuel efficiency regulations (GHG14). These vehicles are equipped with components that increase
fuel efficiency and reduce GHG emissions. Components may include, but are not limited to, low-rolling
resistance tires; aerodynamic devices such as hood,
cab side extenders, and fuel tank fairings; vehicle
speed limiters; and idle shutdown timers.
02/20/2012
f080179
Fig. 1.10, CARB Clean Idle Label
A Vehicle Emission Control Information Label is located on the driver-side door. See Fig. 1.9. It is the
owner’s responsibility to maintain the vehicle so that
it conforms to EPA and NHTSA regulations.
MANUFACTURED BY:
VIN:
VEH FAMILY CD:
GVWR−KG
GVWR−LBS
VEHICLE EMISSION CONTROL INFORMATION
DATE OF MANUFACTURE:
REGULATORY CLASS:
EMISSION CONTROL IDENTIFIERS:
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
02/29/2012
f080181
Fig. 1.9, Vehicle Emission Control Information Label
Certified Clean Idle Label
The California Air Resources Board (CARB) requires
model year 2008 and newer heavy-duty diesel engines to be equipped with a non-programmable engine shutdown system that automatically shuts down
the engine after five minutes of idling in order to limit
emissions of particulate matter and NOx.
Certified vehicles are equipped with a label placed
near the bottom edge of the driver-side door. See
Fig. 1.10.
1.4
2
Vehicle Access
Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
2.2
2.4
2.5
Vehicle Access
Door Locks and Handles
red dot will show below the lock button when it is
unlocked.
One key operates the ignition switch and all of the
door locks.
1
2
IMPORTANT: Each key is numbered. Record
the number so a duplicate key can be made, if
needed.
3
4
To unlock the driver’s door from outside the cab, insert the key in the lockset and turn it one-quarter turn
clockwise (Fig. 2.1). To remove the key, turn it counterclockwise to its original position. Pull out on the
door pull handle to open the door.
5
2
1
f720398
10/25/2001
3
10/22/2001
1. Key
2. Lock
To open the door from the inside, lift up on the door lever
(arrow).
f720397
1. Lock Button
2. Armrest/Handle
3. Door Lever
3. Door Pull Handle
4. Window Crank
5. Inner Door Grab
Handle (optional)
Fig. 2.2, Door Interior
Fig. 2.1, Exterior Door Handle
To unlock the passenger’s door from outside the cab,
insert the key in the lockset and turn it one-quarter
turn counterclockwise. Turn the key clockwise to the
original position to remove it.
2
To open the door from the inside, lift up on the door
lever. This will unlatch the door whether or not it is
locked. See Fig. 2.2.
NOTE: The cab door locks can be operated
when the doors are open.
To lock a door from outside the cab, insert the key in
the lockset and turn it in the direction opposite to the
unlocking direction (counterclockwise for the driver’s
door, clockwise for the passenger’s door). Close the
door if it is open.
To lock either door from inside the cab, push the lock
button downwards (Fig. 2.3). To unlock the door
without unlatching it, push the lock button upwards. A
2.1
3
1
10/24/2001
f720401
Move the button down to lock, and up to unlock (arrows).
The door is unlocked when the red dot shows.
1. Door
2. Lock Button
3. Red Dot
Fig. 2.3, Door Lock Button
Vehicle Access
Cab Entry and Exit
6
For ease of entry and exit, there are three grab
handles, one on the A-pillar, one on the inner B-pillar,
and an optional one on the inside of the door. In addition, the steering wheel may be used to provide
secure handholds. There are at least two access
steps to provide secure footholds.
5
NOTE: The A-pillar grab handle is not installed
on the driver’s side.
4
The grab handles, access steps, and steering wheel
are 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.
Entering from the Driver’s Side
To enter the cab on the driver’s side, use the grab
handles and access steps as follows:
1.
Open the driver-side door and place anything
that you are carrying in the cab.
2.
Grasp the B-pillar grab handle with your right
hand. See Fig. 2.4.
3.
Grasp the door grab handle with your left hand.
4.
Place your right foot on the bottom step, and pull
yourself up.
5.
Place your left foot on the top step.
6.
Grasp the steering wheel with your left hand, and
step up.
7.
Step into the cab with your right foot first, and
grasp the steering wheel with your right hand.
7
3
2
1
12/20/2010
1.
2.
3.
4.
IMPORTANT: Do not attempt to exit the cab
while carrying any items in your hands.
1.
If you wish to take any items with you out of the
cab, place them in an accessible location on the
seat or cab floor. Make sure they will not get in
your way as you exit.
5. Steering Wheel
6. Sidewall Grab Handle
7. B-Pillar Grab Handle
Fig. 2.4, Cab Access System, Driver’s Side
WARNING
Exiting from the Driver’s Side
To exit the cab from the driver’s side, use the grab
handles and access steps as follows:
f720726
Bottom Step
Top Step
Door Grab Handle
Armrest
Always face in when exiting the cab. Do not attempt to exit with your back to the cab, as you
would going down a flight of stairs. It is easier to
slip or lose your balance. If you slip when exiting
in this way, there is a greater likelihood of personal injury.
2.
Grasp the steering wheel with both hands, place
your left foot on the top step, then stand on the
threshold facing into the cab. See Fig. 2.4.
3.
Using your right hand, grasp the B-pillar grab
handle.
4.
Move your right foot to the bottom step.
2.2
Vehicle Access
5.
Move your left hand to the door grab handle.
6.
Step to the ground with your left foot first.
7.
Retrieve from the cab any items that you wish to
take with you.
Entering from the Passenger’s Side
To enter the cab on the passenger side, use the grab
handles and access steps as follows:
1.
Open the passenger-side door and place anything that you are carrying in the cab.
2.
Using your left hand, grasp the B-pillar grab
handle. See Fig. 2.5.
3.
Using your right hand, grasp the door grab
handle.
4.
Place your left foot on the bottom step.
5.
Place your right foot on the top step.
6.
Move your right hand to the A-pillar grab handle.
7.
Place your left foot on the top step, then move
your left hand to the A-pillar grab handle.
8.
Step into the cab with your left foot first.
Exiting from the Passenger’s Side
To exit the cab from the passenger side, use the
grab handles and access steps as follows:
IMPORTANT: Do not attempt to exit the cab
while carrying any items in your hands.
4
1.
6
If you wish to take any items with you out of the
cab, place them in an accessible location on the
seat or cab floor. Make sure they will not get in
your way as you exit.
WARNING
5
Always face in when exiting the cab. Do not attempt to exit with your back to the cab, as you
would going down a flight of stairs. It is easier to
slip or lose your balance. If you slip when exiting
in this way, there is a greater likelihood of personal injury.
7
3
2
1
12/17/2010
1.
2.
3.
4.
Bottom Step
Top Step
B-Pillar Grab Handle
ATD Grab Handle
(optional)
f720727
5. A-Pillar Grab Handle
6. Armrest
7. Door Grab Handle
Fig. 2.5, Cab Access System, Passenger’s Side and
Back of Cab
2.3
2.
Grasp the A-pillar grab handle with both hands,
then place your right foot on the top step while
standing up from the seat facing inward. See
Fig. 2.5.
3.
Place your left foot on the top step.
4.
Move your left hand to the B-pillar grab handle.
5.
Move your left foot to the bottom step.
6.
Move your right hand to the door grab handle.
7.
Step to the ground with your right foot first.
8.
Retrieve from the cab any items that you wish to
take with you.
Vehicle Access
Back-of-Cab Access
WARNING
External surfaces of the exhaust system remain
hot after the engine has been shut down. When
accessing the back of the cab or sleeper, do not
touch any part of the exhaust system, or severe
burns could occur.
When trailer air and electrical connections cannot be
reached conveniently from the ground, Federal Motor
Carrier Safety Regulations require commercial carriers to provide back-of-cab access.
2
3
Optional grab handles are mounted on each cab
sidewall, or on the left sidewall only. See Fig. 2.6.
Steps are mounted either on the fuel tank(s) or on
metal brackets. When a deck plate is necessary, it is
mounted across the top of the frame rails.
IMPORTANT: Climb onto, and down from, backof-cab access facing in toward the vehicle, as
you would on a ladder. Do not climb up or down
facing out away from the vehicle.
1
WARNING
12/17/2010
Wet or dirty shoe soles greatly increase the
chance of slipping or falling. If your soles are wet
or dirty, be especially careful when climbing
onto, or leaving, the back-of-cab area.
Always maintain three-point contact with the
back-of-cab access supports while entering and
exiting the back-of-cab area. Three-point contact
means both feet and one hand, or both hands
and one foot, on the grab handles, steps, and
deck plates. Other areas are not meant to support back-of-cab access, and grabbing or stepping in the wrong place could lead to a fall, and
personal injury.
Be careful not to get hands or feet tangled in
hoses or other back-of-cab equipment. Carelessness could cause a person to trip and fall, with
possible injury.
Climbing Up to Back-of-Cab
1. Steps
2. Grab Handle
Grasp the sidewall grab handle with both hands.
Reach up as far as is comfortable.
f602442
3. Deck Plate
Fig. 2.6, Back-of-Cab Access Supports (typical)
2.
Place one foot on the bottom step and pull yourself up.
3.
Place your other foot on the top step.
4.
Move your lower hand to a higher position on the
grab handle.
5.
Step onto the deck plate.
Climbing Down from Back-of-Cab
To 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 the
grab handle.
4.
Move one foot to the bottom step.
When climbing onto the deck plate, do the following:
1.
1
2.4
Vehicle Access
5.
Move your upper hand to a lower position on the
grab handle.
6.
Step to the ground with your upper foot first.
Hood Opening and Closing
The hood can be raised to a full-open position. A
strut helps you to raise the hood, and to lower it to
the operating position. Hood restraint cables prevent
the hood from overtravel. The hood strut limits the
closing speed. In the operating position, the hood is
secured to the cab-mounted cowl by a hold-down
latch on each side of the hood.
To Tilt the Hood
1.
Apply the parking brakes.
2.
Release both hood hold-down latches by pulling
the ends outward. See Fig. 2.7.
02/02/2011
f602441
Fig. 2.8, Hood Tilting
To Return the Hood
3
2
4
1
10/24/2001
f880555
1. Fender
2. Latch Hook
3. Latch Handle
4. Cowl
Fig. 2.7, Hood Hold-Down Latch
NOTICE
Do not let the hood free-fall to the full-open position. To do so could cause damage to the hood
or hood straps.
3.
2.5
Standing in front of the hood, raise the rear of
the hood upward until it reaches the over-center
position (45 degrees from vertical). See Fig. 2.8.
Then slowly bring it to a stop.
1.
Push the hood over center.
2.
As the hood goes over center, the strut automatically slows its rate of descent. If needed, you
can also slow its descent with your hand.
3.
Make sure the hood is flush with the cowl, then
secure the hood by engaging both hood holddown latches.
IMPORTANT: Make sure that both hold-down
latches are fully engaged before operating the
vehicle.
3
Electrical System
Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Load Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Electrical System
Vehicle Power Distribution
WARNING
Do not attempt to modify, add, splice, or remove
electrical wiring on this vehicle. Doing so could
damage the electrical system and result in a fire
that could cause serious personal injury or property damage.
1
2
Power Distribution Modules
3
The main power distribution module (PDM) is located
under the hood on the driver-side splash shield. See
Fig. 3.1. The PDM contains the circuit breakers and
fuses required to protect the vehicle cab circuits. The
label on the inside of the PDM cover identifies typical
set of fuses.
4
The powertrain PDM (PTPDM) is mounted in the engine compartment near the main PDM. See Fig. 3.1.
It controls power to the engine, aftertreatment system
(ATS), transmission, and other powertrain-related
circuits.
The auxiliary PDM is located on the cab back wall,
behind the driver’s seat. See Fig. 3.2. The auxiliary
PDM may contain the auxiliary powernet distribution
box, the body lighting PDM, and the trailer PDM, if
so equipped.
Main Powernet Distribution Box
The main powernet distribution box (PNDB) is
mounted on the cab frontwall next to the bulkhead
module. See Fig. 3.1. It supplies power to the
PTPDM and main PDM, and powers other vehicle
functions, including the clock. The label on the PNDB
fuse cover identifies typical circuits.
An auxiliary PNDB may also be located on the cab
back wall, behind the driver’s seat.
Load Disconnect Switch
WARNING
Turning the load disconnect switch to the OFF
position does not disconnect the connection between the battery and the starter. To work on the
vehicle safely, the negative leads must be disconnected from the battery.
3.1
11/24/2010
1.
2.
3.
4.
f545704
Bulkhead Module
Powernet Distribution Box (PNDB)
Main Power Distribution Module (PDM)
Powertrain PDM (PTPDM)
Fig. 3.1, Power Distribution Module Locations
The optional load disconnect switch (Fig. 3.3) is
used to avoid excessive draw on the battery when
the vehicle is parked for an extended period of time.
When the load disconnect switch is set to OFF, it signals the PNDB to disconnect battery power to powertrain and accessory loads.
The load disconnect switch is mounted in one of two
locations:
• inside the cab on the left side of the driver’s
seat;
• on/near the battery box;
IMPORTANT: The ignition should be turned OFF
before using the load disconnect switch.
Electrical System
2
3
1
1
2
12/15/2010
3
f545719
1. Auxiliary PNDB
2. Trailer PDM
3. Body Lighting PDM
Fig. 3.2, Auxiliary Power Distribution Module
12/03/2010
1. Back-of-Cab
2. Fuel Tank
f545714
3. Battery Compartment
Fig. 3.4, Standard Battery Compartment Location
05/13/2009
f545527
Fig. 3.3, Load Disconnect Switch
Battery Access
The batteries on a standard vehicle are located on
the driver’s side, behind the fuel tank. See Fig. 3.4.
To access the batteries, pull the cotter pin from the
latch on the battery box cover, then release the latch
and lift off the cover.
3.2
4
Instruments
Instrumentation Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Driver Message Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Overhead Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Instruments
• "Instruments"
Instrumentation Control Unit
• "Driver Message Center"
The instrumentation control unit (ICU) provides the
driver with engine and vehicle information. It is comprised of standard and optional gauges, an audible
warning, a driver message center, and a lightbar containing warning and indicator lamps (also known as
telltales). Warning and indicator lamps illuminate in
red (danger), amber (caution), green (status advisory), or blue (high-beam headlights active).
Ignition Sequence
When the ignition is turned on, the ICU runs a selfcheck. See Fig. 4.2. Observing the ignition sequence
is a good way to ensure the ICU is functioning
properly.
Figure 4.1 shows a typical ICU3 instrument cluster.
IMPORTANT: Do not crank the engine until the
ICU self-check is complete.
The following headings in this chapter provide additional information and operating instructions for ICU
components:
When the ignition is turned on, the following actions
should occur:
• "Warning and Indicator Lights"
2
3
4
5
1
6
12
7
8
09/10/2009
11
10
9
f610525a
NOTE: This instrument cluster is shown with the U.S. speedometer, which shows miles per hour (mph) more prominently
than kilometers per hour (km/h).
1.
2.
3.
4.
Engine Oil Pressure Gauge
Lightbar
Driver Message Center
Headlight High-Beam Indicator
5.
6.
7.
8.
Fuel/DEF Level Gauge
Primary Air Pressure Gauge
Mode/Reset Button
Secondary Air Pressure Gauge
Fig. 4.1, Typical ICU3 (U.S. shown)
4.1
9.
10.
11.
12.
Speedometer (U.S. version)
Tachometer
Transmission Temperature Gauge
Coolant Temperature Gauge
Instruments
use Table 4.1 to determine if the lamp illuminated indicates a problem requiring service.
IGNITION SWITCH
TURNED TO ON
If the ICU receives active fault codes, it displays
them one after the other until the parking brake is
released or the ignition is turned off. Once the parking brake is completely released, the ICU displays
the odometer. If there are no active faults, the ICU
displays the odometer after the self-check completes.
ICU PERFORMS
SELF−TEST
IF NO FAULTS
WERE DETECTED
123456.7
IF FAULT DETECTED
APU 190
Audible Alerts
MI
12.3 VOLTS
PARKING BRAKE
RELEASED
NOTE: If active faults are present, take the vehicle to an authorized Freightliner service facility
as soon as possible.
An audible alert sounds during the ignition sequence
and whenever one of the following conditions exists:
PARKING BRAKE
RELEASED
• Engine oil pressure falls below the minimum
123456.7
MI
12.3 VOLTS
01/18/2012
preset value.
f040420c
Fig. 4.2, Ignition Sequence
• electronic gauges complete a full sweep of
their dials
• some warning and indicator lamps illuminate,
then are extinguished
• audible alert sounds until sufficient air pressure
builds up in the primary and secondary air systems
• DEF level indicator illuminates all segments
green, then turns them off one at a time before
turning the leftmost segment amber, then red
• software revision level of the ICU is displayed
on the driver message center, followed by active faults
NOTE: Air gauges do not complete a sweep of
their dials during the ignition sequence.
IMPORTANT: If any red or amber warning and
indicator lamps, or telltales, do not illuminate
during the ICU self-check, take the vehicle to an
authorized Freightliner service facility as soon
as possible. If any of the red or amber telltales
or do not go out after the self-check completes,
• Coolant temperature rises above the maximum
preset value.
• Air pressure falls below about 70 psi (483
kPa).
• Parking brake is set with the vehicle moving
faster than two miles per hour.
• System voltage falls below 12 volts.
• Door is open with the headlights on and the
parking brake off.
• Driver seat belt is not fastened with the parking
brake off (optional).
• Outside temperature falls below 35°F (1.7°C)
(optional).
Warning and Indicator Lights
There can be up to 28 telltales installed in the ICU. If
an optional lamp is not requested, the position is
blank.
See Table 4.1 for a list of standard and commonly
used warning and indicator lamps.
Warning and indicator lamps illuminate in red (danger), amber (caution), green (status advisory), or
blue (high-beam headlights active).
4.2
Instruments
Common Warning and Indicator Lamps
Lamp Description
Indicates a serious fault that requires engine shutdown
immediately. The engine protection system will reduce the
maximum engine torque and speed, and, if the condition
does not improve, will shut down the engine within 30 to 60
seconds.
STOP
STOP Engine*
Color
Safely bring the vehicle to a stop on the side of the road
and shut down the engine as soon as the red light is seen.
If the engine shuts down while the vehicle is in a
hazardous location, turn the key to the OFF position for
a few seconds, then restart the engine and move the
vehicle to a safer location.
High Coolant Temperature
Indicates the coolant temperature is above the maximum
allowable temperature.
Low Air Pressure
Indicates air pressure in the primary or secondary reservoir
has dropped below approximately 70 psi (483 kPa).
Low Engine Oil Pressure
Indicates the engine oil pressure is below the minimum
allowable pressure.
Transmission Overheat
Indicates high transmission temperature.
Parking Brake
Indicates the parking brake is engaged.
Low Battery Voltage
Indicates that battery voltage is 11.9 volts or less.
Red
Unfastened Seat Belt
CHECK
CHECK Engine*
High Exhaust System
Temperature (HEST)*
Activates with an audible alert when the system detects that
the parking brake is off and the driver seat belt is not
fastened on some vehicles. On other vehicles, this lamp
illuminates for 15 seconds when the ignition is first turned
on.
Indicates an engine condition (low oil pressure, low coolant
level, high coolant temperature, high DPF soot level, or
uncontrolled DPF regeneration) that requires correction.
Correct the condition as soon as possible. If the condition
worsens, the STOP engine lamp will illuminate.
Slow (10-second) flashing indicates a regeneration (regen)
is in progress.
IMPORTANT: When the HEST lamp is illuminated, do
not park the vehicle near flammable material.
Solid illumination indicates high exhaust temperatures at the
outlet of the tail pipe when speed is below 5 mph (8 km/h).
4.3
Amber
Instruments
Common Warning and Indicator Lamps
Lamp Description
Solid illumination indicates a regen is required. Change to a
more challenging duty cycle (such as highway driving ) to
raise exhaust temperatures for at least twenty minutes, or
Diesel Particulate Filter
perform a parked regen.
(DPF) Status
Blinking indicates that a parked regen is required
immediately. An engine derate and shutdown will occur.
Malfunction Indicator
Lamp (MIL)
Color
Indicates an emissions-related fault. See the engine
operation manual for details.
Momentary illumination indicates the vehicle ABS is
engaged.
NO
CHARGE
IDLE
MGMT
WAIT
TO START
Vehicle ABS
Solid illumination indicates a problem with the vehicle ABS.
Repair the ABS immediately to ensure full braking
capability.
Momentary illumination indicates the trailer ABS is engaged.
Trailer ABS
Solid illumination indicates a problem with the trailer ABS.
Repair the ABS immediately to ensure full braking
capability.
No Charge
Indicates the alternator is not properly powering the
electrical system.
Water in Fuel
Indicates the fuel may contain water. Drain any water
collected in the fuel/water separators.
Fuel Filter Restriction
Indicates the fuel filter is clogged and requires service.
Optimized Idle
Indicates optimized idle is enabled.
Check Transmission
Indicates an undesirable transmission condition.
Wait To Start (EPA10)
Indicates that the system is preventing the starter from
cranking. This can occur when the ignition switch is turned
to START before the gauge sweep has completed, or if the
starter has overheated.
Amber
Turn the ignition switch back to ON, wait for the lamp to go
out, then turn the ignition switch to START again.
4.4
Instruments
START
BLOCKED
Common Warning and Indicator Lamps
Lamp Description
Indicates that the system is preventing the starter from
cranking. This can occur when the ignition switch is turned
to START before the gauge sweep has completed, or if the
starter has overheated.
Start Blocked (GHG14)
NOTE: Illumination of the Start Blocked lamp does not
indicate a problem with the starter.
Color
Turn the ignition switch back to ON, wait for the lamp to go
out, then turn the ignition switch to START again.
Flashing indicates the ATC system is active, or the ATC
button has been pressed to allow wheel slip.
WHEEL
SPIN
Wheel Spin
Solid illumination indicates a problem with the ATC system.
Repair the ATC system immediately to ensure full braking
capability.
Momentary illumination indicates that a stability event has
occurred.
Roll Stability
On vehicles that are also equipped with ATC, flashing
indicates the ATC button has been pressed to allow wheel
slip.
Hill Start Aid (HSA)
Override
Indicates the HSA switch has been pressed to override the
hill start assist feature.
Engine Brake
Indicates the engine brake is enabled.
Left-Turn Signal
Flashing indicates the outside left-turn signal lights are
activated.
Right-Turn Signal
Flashing indicates the outside right-turn signal lights are
activated.
Amber
Green
Indicates the cruise control is enabled.
Cruise Control
NOTE: The ICU4Me does not have a green cruise control
telltale.
High-Beam Headlights
Indicates the high-beam headlights are on.
Blue
* See Fig. 4.3 for an explanation of the aftertreatment system (ATS) warning indicators, and actions required to avoid further engine protection steps.
Table 4.1, Common Warning and Indicator Lamps
4.5
Instruments
gine shuts down while the vehicle is in a hazardous location, turn the key to the OFF position
for a few seconds, then restart the engine and
move the vehicle to a safer location.
Engine Protection System
WARNING
When the red STOP engine lamp illuminates,
most engines are programmed to shut down automatically within 30 seconds. The driver must
immediately move the vehicle to a safe location
at the side of the road to prevent causing a hazardous situation that could cause bodily injury,
property damage, or severe damage to the engine.
On other engines, the engine protection system will
shut down the engine. It will first derate the engine,
then shut it down completely 30 to 60 seconds after
the indicator illuminates (depending on the critical
fault type) if the condition does not improve. Bring
the vehicle to a stop on the side of the road before
the engine shuts down.
Some vehicles may have a shutdown-override
switch, which may be used to momentarily override
the shutdown sequence. See Chapter 10 for detailed
See Fig. 4.3 for an explanation of the aftertreatment
system (ATS) warning indicators, and actions required to avoid further engine protection steps.
EXHAUST AFTERTREATMENT SYSTEM INFORMATION
INDICATOR
LAMP(S)
STOP
CHECK
(Solid)
Level 1
(Flashing)
WARNING
(Flashing)
Level 3
Level 4
Indicator Lamp
Message(s)
Filter Regeneration
Recommended.
Filter
Regeneration
Necessary
Level 2
Parked Regeneration
Required − Engine
Derate
Service Regeneration Required.
Engine Derate To Idle Only.
Diesel Particulate
Filter Condition
Filter is reaching
capacity.
Filter is now
reaching maximum
capacity.
Switch.
Filter has reached
maximum capacity.
Filter has exceeded maximum
capacity.
Required Action
Bring vehicle to
highway speeds to
allow for an
Automatic
Regeneration or
perform a Parked
Regeneration.
To avoid engine
derate, bring vehicle
to highway speeds
to allow for an
Automatic
Regeneration, or
perform a Parked
Regeneration as
soon as possible.
Vehicle must be
parked, and a Parked
Regeneration must
be performed.
Engine will begin
derate.
Vehicle must be parked, and a
Service Regeneration must be
performed. Check engine
operator’s manual for details.
Engine will shut down.
HEST (High Exhaust
System Temperature)
Flashing
A regeneration is in
progress.
Solid
Exhaust components
and exhaust gas are at
high temperature. When
stationary, keep away
from people and
flammable materials or
vapors.
For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.
02/20/2009
f080156
Fig. 4.3, ATS Warning Lamps
The STOP engine lamp illuminates when the engine
protection system is activated in one of two ways. On
some engines, the engine protection system will derate the engine, allowing it to run at lower rpm and
slower vehicle speed. Drive the vehicle to a safe location or to a service facility.
IMPORTANT: Safely bring the vehicle to a stop
on the side of the road and shut down the engine as soon as the red light is seen. If the en-
information regarding the shutdown process.
IMPORTANT: Do not attempt to restart the engine while the vehicle is moving. Bring the vehicle to a safe stop, then restart the engine.
To restart the engine, turn the ignition to OFF, leave
it there a few seconds, then turn the ignition to
START. The engine will run for a short period and
shut down again if the condition does not improve.
4.6
Instruments
Driver Message Center
The driver message center is controlled using the
mode/reset switch, located on the right side of the
ICU. See Fig. 4.1. Tap the mode/reset switch to advance one screen; press and hold the switch to select a menu choice or reset the display. When the
display resets, an audible chirp sounds.
Driving Screens
The following screens are available when the parking
brake is off (when the vehicle is mobile) and no active fault codes are found. Use the mode/reset switch
to scroll through the screens. To reset any values,
press and hold the mode/reset switch. The driving
screens appear in the following order:
i.
Odometer
ii.
Trip distance
iii. Trip hours
iv. Outside temperature
Parked Screens/Menus
The parked screens and menus are available when
the parking brake is on and no active fault codes are
found. See Fig. 4.4. Use the mode/reset switch to
scroll through the parked screens. To reset any values, press and hold the mode/reset switch. The
parked screens appear in the following order:
alert sounds. Tap the mode/reset switch to acknowledge the message. The audible alert will not sound
again unless the temperature cycles above 37°F
(4°C) and back to 35°F (1.7°C) or less. This warning
only occurs while the ignition is on and the parking
brake is released.
The temperature alert message allows the driver to
enable or disable the ambient temperature warning.
Press and hold the mode/reset switch to toggle between on and off. Release the mode/reset switch,
then tap it to select the displayed choice.
Diagnostics
When the DIAG screen is displayed, press and hold
the mode/reset switch to access the various diagnostic screens.
The diagnostic screens are used by trained technicians to retrieve fault codes and other diagnostic information pertaining to the vehicle. If active fault
codes display during start-up or at any other time,
make a note of the fault code and take the vehicle to
an authorized Freightliner service facility
If fault codes are displayed, press and hold the
mode/reset switch to view the next fault code until
reaching the DIAG screen.
Engine Miles/Hours
i.
Odometer
When the engine miles/hours screen is displayed,
press and hold the mode/reset switch to access the
engines screen submenu.
ii.
Trip distance
Setup
iii. Trip hours
iv. Outside temperature
v.
Select units
vi. Temperature alert
vii. Diagnostics
viii. Engine miles
ix. Engine hours
x.
Setup
Temperature Alert
When the outside temperature drops to 35°F (1.7°C)
or less, the ICU displays a caution text at onesecond intervals for five seconds, and an audible
4.7
The setup menu allows the driver to manage ICU
parameters. The setup screen submenu allows the
driver to enable and change service intervals.
If service intervals are enabled and service distance
or time has been exceeded, the text SERVICE
HOUR/MI (KM) will display at start-up to indicate vehicle service is required.
For each parameter, press and hold the mode/reset
switch to navigate to the parameter change screen.
In each change screen, tap the mode/reset switch to
toggle between options.
The last screen in the setup menu, RESET EE, is for
resetting certain parameters to the original settings.
Press and hold the mode/reset switch to reset the
Instruments
123456.7
CLEAr
Default Odometer
Dispay Screen
MI
12.3 VOLTS
Push
Clear Defaults
Push
123456.7
TRIP
MI
12.3 VOLTS
Hold
123456.7
MI
To Reset Trip Miles
To Dispay Total Engine Miles
EC = Engine Control
EC
Push
Push
123456.7
123456.7
HOURS
TRIP
Hold
To Reset Trip Hours
12.3 VOLTS
EC
Push
HOURS To Dispay Total Engine Hours
EC = Engine Control
Push
SELECt
MI
Hold
To Toggle between Units
MI<−−−−>KM
EnG oIL
Hold
*Lo
Push
dIAG
MI
SEtUP
HOURS
Hold
**MI
Dispay Diagnostics
**no
n = Number of Active Fault Codes
MI = CYCLE Miles Enabled
HOURS = Cycle Hours Enabled
Dispay Oil Level
*Lo = Oil Level Low
HI = Oil Level High
Blank = Oil Level OK
− − = No Message
Push
n
Push
Hold
**HOURS
Hold
Dispay Service Interval
Cycle Screens
**MI = CYCLE Miles Active Mode
**HOURS = CYCLE Hours Active Mode
Push
**no = Service CYCLE Inactive
03/26/2004
f040636a
NOTE: The engine oil level screen displays for Mercedes-Benz engines only (if equipped and enabled).
Fig. 4.4, ICU3 Stationary Screens
antilock braking system (ABS), SAMs roll call, automated transmission display, transmission heartbeat,
sensor fault codes, seat belt switch learning, and engine oil level.
the engine compartment. As an option for easier
viewing, the air intake restriction indicator (see
Fig. 4.5) can be mounted on the dash, usually on the
right-hand control panel.
Instruments
NOTE: Rain or snow can wet the filter and
cause a temporary high reading.
Standard instruments are present on every vehicle.
They are listed here in alphabetical order to make
the information easier to find.
Air intake restriction vacuum is measured in inches
of water (inH2O). For vehicles equipped with a
graduated indicator or a restriction gauge on the
dash, check the gauge with the engine off. If the yellow signal stays locked in the red zone once the engine is shut down, or is at or above the values
shown in Table 4.2, the air cleaner element needs to
be replaced.
Optional instruments, typically located on the auxiliary dash panel or right-hand control panel, are not
found on every vehicle. They are listed here in alphabetical order, to make the information easier to find.
Air Intake Restriction Gauge
The air intake restriction gauge indicates the vacuum
on the engine side of the air cleaner. On standard
installations, it is mounted on the air intake duct in
Vehicles may be equipped with a go/no-go restriction
indicator without graduations (see Fig. 4.6) instead of
a graduated indicator.
4.8
Instruments
Coolant Temperature Gauge
NOTICE
A sudden increase in coolant temperature may
indicate engine or cooling system failure. Bring
the vehicle to a safe stop and investigate the
cause to prevent further damage. Do not operate
the engine until the cause has been determined
and corrected.
During normal engine operation, the coolant temperature gauge, as shown in Fig. 4.7, should read
175 to 195°F (79 to 91°C). If the temperature remains below 160°F (71°C), inspect the cooling system to determine the cause.
10/10/2001
f610568
Fig. 4.5, Air Intake Restriction Indicator
150
Air Intake Maximum Restriction Values (inH2O)
Maximum
Engine
Initial Restriction
Restriction
Cummins
10
25
Detroit™
10
22
200
F°
100
250
WATER
Table 4.2, Air Cleaner Element Maximum Restriction
10/09/2001
f610565
Fig. 4.7, Coolant Temperature Gauge
If coolant temperature rises above the maximum
temperature listed in Table 4.3, the CHECK engine
lamp will illuminate. If the condition does not improve, the STOP engine lamp will also illuminate and
an audible warning will sound. The engine will then
derate or shut down, depending on the type of engine protection system installed.
04/08/2005
f090431
Fig. 4.6, Manual-Reset Air Restriction Indicator, Go/
No-Go
Maximum Coolant Temperature
Engine Make
Temperature: °F (°C)
Caterpillar
230 (110)
Cummins
225 (107)
Detroit
215 (101)
Mercedes-Benz
222 (105)
Table 4.3, Maximum Coolant Temperature
4.9
Instruments
Drive Axle Oil Temperature Gauges
NOTICE
A sudden increase in oil temperature that is not
caused by a load increase may indicate mechanical failure. Bring the vehicle to a safe stop and
investigate the cause to prevent further damage.
Do not operate the vehicle until the cause has
been determined and corrected.
the condition does not improve, the STOP engine
lamp will also illuminate and an audible warning will
sound. The engine will then derate or shut down, depending on the type of engine protection system
installed.
50
During normal operation, drive axle oil temperature
gauges (see Fig. 4.8) should read between 160 and
220°F (71 and 104°C).
PSI
0
100
OIL
10/09/2001
FWD
150
Fig. 4.9, Engine Oil Pressure Gauge
250
°F
100
300
04/19/2013
f610528
f611205
Fig. 4.8, Forward-Rear Drive Axle Oil Temperature
Gauge
Under heavy loads, such as when climbing steep
grades, temperatures that exceed the normal oil temperature range for a short period are not unusual. If
the temperature returns to normal when the load decreases, there is no problem.
Minimum Oil Pressure *
At Idle Speed:
At Rated RPM:
Engine Model
psi (kPa)
psi (kPa)
Caterpillar
10–20 (69–138) 30–45 (207–310)
Cummins
15 (103)
35 (241)
Detroit
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 vary
from the listed pressures; observe and record pressures when the engine
is new to create a guide for checking engine condition.
Table 4.4, Minimum Oil Pressure
Engine Oil Temperature Gauge
Engine Oil Pressure Gauge
NOTICE
A sudden decrease or absence of oil pressure
may indicate mechanical failure. Bring the vehicle
to a safe stop and investigate the cause to prevent further damage. Do not operate the engine
until the cause has been determined and corrected.
The engine oil pressure gauge, as shown in Fig. 4.9,
displays the current engine oil pressure. If engine oil
pressure falls below the minimum levels shown in
Table 4.4, the CHECK engine lamp will illuminate. If
NOTICE
A sudden increase in oil temperature that is not
caused by a load increase may indicate mechanical failure. Bring the vehicle to a safe stop and
investigate the cause to prevent further damage.
Do not operate the engine until the cause has
been determined and corrected.
During normal operation, the optional engine oil temperature gauge ( Fig. 4.10) should read in the following temperature ranges:
• 160 to 195°F (71 to 91°C) for Caterpillar en-
gines
4.10
Instruments
• 200 to 260°F (93 to 126°C) for Detroit and
Cummins engines
1
• 177 to 203°F (81 to 95°C) for Mercedes-Benz
1/2
engines
ULTRA LOW SULFUR
DIESEL FUEL ONLY
Under heavy loads, such as when climbing steep
grades, temperatures that exceed the normal oil temperature range for a short period are not unusual. If
the temperature returns to normal when the load decreases, there is no problem.
E
4
F
DEF
E
F
3
08/21/2009
1.
2.
3.
4.
2
f611045
Diesel Fuel Level Indicator
DEF Level Indicator
Low DEF Warning Lamp (amber below 10% DEF)
Low Fuel Warning Lamp (amber at 1/8 tank of fuel)
Fig. 4.11, Fuel/DEF Gauge, EPA10
10/10/2001
f610569
Fig. 4.10, Engine Oil Temperature Gauge
Fuel/Diesel Exhaust Fluid (DEF)
Gauge
For engines that are EPA10-compliant or newer, the
fuel and DEF levels are measured in a dual purpose
fuel/DEF level gauge. See Fig. 4.11.
the vehicle down and bring it to a gradual stop.
Do not attempt to move the vehicle until air pressure has risen above the minimum level. Moving
a vehicle without adequate braking power could
cause an accident resulting in property damage,
personal injury, or death.
Air pressure gauges, as shown in Fig. 4.12, register
the pressure in the primary and secondary air systems. The gauges are labeled for the A or B reservoir. Normal pressure with the engine running is 100
to 120 psi (689 to 827 kPa) in both systems.
The diesel fuel level is indicated at the top of the
gauge, with a low-fuel warning lamp that illuminates
when the diesel fuel level registers 1/8th of capacity.
The DEF level is indicated in the lightbar on the
lower portion of the gauge. There is a low DEF level
warning lamp that illuminates amber when the DEF
level reaches 10% of capacity. See Chapter 7 for
details of the DEF gauge functions.
Primary and Secondary Air Pressure
Gauges
WARNING
If air pressure falls below minimum pressure, the
braking ability of the vehicle will be limited. Slow
4.11
05/14/2001
f610556
Fig. 4.12, Air Pressure Gauge (reservoir A shown)
Instruments
A low-air-pressure warning light and audible alert,
connected to both the primary and secondary systems, activate when air pressure in either system
drops below approximately 70 psi (483 kPa).
When the engine is started, the warning light and
audible warning remain on until air pressure in both
systems exceeds minimum pressure.
Speedometer
Three speedometer options are available. The U.S.
version of the speedometer registers speed in both
miles per hour (mph) and kilometers per hour (km/h),
with mph in larger numbers. The metric version of
the speedometer face reverses this arrangement,
with km/h in larger numbers. The metric-only version
shows km/h exclusively.
Tachometer
The tachometer indicates engine speed in revolutions
per minute (rpm) and serves as a guide for shifting
the transmission and keeping the engine in the appropriate rpm range. For low idle and rated rpm, see
the engine identification plate.
Transmission Fluid Temperature
Gauge
The transmission fluid temperature gauge, shown in
Fig. 4.13, measures the transmission lubricant operating temperature. Temperatures vary by application,
but the transmission fluid temperature gauge reading
should not exceed 250°F (121°C).
200
Under heavy loads, such as when climbing steep
grades, temperatures that exceed the normal oil temperature range for a short period are not unusual. If
the temperature returns to normal when the load decreases, there is no problem.
Turbocharger Boost Pressure Gauge
A turbocharger boost pressure gauge indicates the
pressure in the intake manifold, in excess of atmospheric pressure, being created by the turbocharger.
Voltmeter
The voltmeter indicates the vehicle charging system
voltage when the engine is running and the battery
voltage when the engine is off. By monitoring the
voltmeter, the driver can stay aware of potential battery charging problems and have them fixed before
the batteries discharge enough to create starting difficulties. Cascadia vehicles are equipped with either a
voltmeter gauge, or a digital voltmeter readout located on the bottom line of the dash message center.
The voltmeter will normally show approximately 13.7
to 14.1 volts when the engine is running. The voltage
of a fully charged battery is 12.7 to 12.8 volts when
the engine is off. Battery voltage under 12.0 volts is
considered a low battery, and a completely discharged battery will produce only about 11.0 volts.
If the voltmeter shows an undercharged or overcharged condition for an extended period, have the
charging system and batteries checked at an authorized Freightliner service facility.
350
On a vehicle equipped with a battery isolator system,
the voltmeter measures the average voltage of all the
batteries when the engine is running. When the engine is off, the voltmeter shows only the isolated battery voltage and does not indicate the voltage of the
engine-starting batteries.
TRANS
10/30/2001
A sudden increase in transmission fluid temperature that is not caused by a load increase may
indicate mechanical failure. Bring the vehicle to a
safe stop and investigate the cause to prevent
further damage. Do not operate the vehicle until
the cause has been determined and corrected.
275
F
125
NOTICE
f610600
Fig. 4.13, Transmission Fluid Temperature Gauge
4.12
Instruments
Overhead Instrument Panel
The optional overhead instrument panel (Fig. 4.14)
may hold a citizen’s band (C/B) radio, a microphone
clip, and any switches that can not be accommodated on the driver’s or auxiliary dash panels.
1
2
3
4
1
f680028
04/19/2002
1. Storage Area with Netting
2. C/B Radio
3. Microphone Clip
4. Dome/Reading Light Assembly
Fig. 4.14, Overhead Instrument Panel
The underside of the overhead console also holds
the sun visors and the optional dome/reading light
assembly. For more information on the dome/reading
light assembly, see Chapter 8.
4.13
5
Driver Controls
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Multifunction Turn Signal Lever Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
All Wheel Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Adjustable Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Suspension Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Driver Controls
Ignition Switch
NOTE: Freightliner vehicles are offered with
various chassis and body components. Because
of the various options, the information contained
in this chapter may not apply to every vehicle.
The ignition switch (Fig. 5.1) is located on the lower
portion of the left-hand dash. The switch has four
positions: OFF, ACCESSORY, ON, and START.
Turn the key counterclockwise to reach the ACCESSORY position. In addition to all the functions that
are operable with the ignition switch in the OFF position, the following functions are operable when the
switch is in the ACCESSORY position:
• radio or stereo system
• mirror heat
• air dryer
• backup lights
• windshield fan(s)
Turn the key clockwise past the OFF position to
reach the ON position. With the switch in the ON position, all electrical systems are operable and the instrument control unit (ICU3) runs through the ignition
sequence. See Fig. 5.2.
When the ignition switch is turned to the ON position,
all electronic gauges complete a full sweep of their
dials, the warning and indicator lamps illuminate, and
the buzzer sounds for three seconds. Wait for the
gauge sweep to complete before starting the engine.
07/19/2006
f610805
Fig. 5.1, Ignition Switch Positions
In the OFF position, the key slot is vertical. The key
can be inserted and removed only in the OFF position.
The following functions are operable when the ignition switch is in the OFF position (regardless of
whether the key is inserted):
• low-beam headlights
• taillights
• brake lights
• dome lights
• clearance lights
• turn signals
• hazard warning lights
• horn
• CB radio
• power windows
• cigarette lighter
• clock
5.1
Switching on the ignition and releasing the parking
brakes automatically activates the daytime running
lights, if equipped. The daytime running lights will
operate until the parking brakes are applied or the
headlights are turned on.
NOTE: Daytime running lights are standard on
all vehicles domiciled in Canada.
Turn the key clockwise past the ON position to reach
the START position and start the engine. Do not operate the starter longer than thirty seconds, and wait
at least two minutes between starting attempts to
allow the starter to cool. Release the key the moment the engine starts.
Control Panels
The left-hand control panel (Fig. 5.3, Item 1) contains a face vent and four switches arranged in a
vertical line. In the standard cab, the four switches
usually consist of the headlight, panel light increase/
decrease, and the cruise control on/off and set/
resume switches.
The instrument cluster is located directly behind the
steering wheel. The mode/reset button, located on
the right side of the instrument cluster, allows the
Driver Controls
HEADLIGHTS ON
POWER ON
IGNITION ON
888888.8
MI
ICU INITIALIZES
ELECTRONIC GAUGE NEEDLES
SWEEP, WARNING/INDICATOR
LIGHTS COME ON, BUZZER SOUNDS
ODOMETER
SCREEN
IF NO FAULTS
WERE DETECTED
123456.7
IF FAULT DETECTED
ABS 136
MI
12.3 VOLTS
FAULT CODE
SCREEN
PARK BRAKE
RELEASED − MOVING
123456.7
RELEASE PARK BRAKE
MI
12.3 VOLTS
02/14/2003
f040420a
Fig. 5.2, Ignition Sequence
driver to scroll through a number of options on the
driver display screen.
2
3
4
1
The radio panel contains the radio controls and two
face vents on either side of the radio.
5
f610579a
10/15/2001
1.
2.
3.
4.
5.
The right-hand control panel (Fig. 5.3, Item 3) usually contains the transmission push-button shift selector (vehicles with an automatic transmission) and the
trailer brake valve. On vehicles with a manual transmission, a variety of switches are installed here. If
there is a dash-mounted air intake restriction indicator, it is often mounted on the right-hand panel.
Left-Hand Control Panel
Instrumentation Cluster
Right-Hand Control Panel
Radio Panel
Auxiliary Dash Panel
The auxiliary dash panel (Fig. 5.3, Item 5), located
below the radio panel, contains the parking brake
control and trailer air supply valves, the cigarette
lighter (push the knob in to heat the element; the
knob will pop out when the element is hot), and a
variety of switch options. The auxiliary panel may
also contain an antenna connection and positive (+)
and negative (–) power connections for a citizen’s
band (CB) radio.
The climate control panel is located below the auxiliary dash panel, between the cupholders.
Fig. 5.3, Control Panels
5.2
Driver Controls
When the switch is in the uppermost position, the
headlights and all other exterior lights (excluding the
optional fog, spot, and utility lights) are on. All vehicle
lighting is off when the switch is in the middle position. When the switch is in the downward position,
only the clearance lights, marker lights, and the taillights are illuminated.
The optional overhead instrument panel (Fig. 5.4)
holds the CB radio, a microphone clip, any switches
that can not be accommodated on the lower control
panels, sun visors, and an optional dome/reading
light assembly.
Lighting Controls
When the any exterior lights are on, the instrument
panel lights also illuminate.
When the panel lights are on, most switch legends
are backlit with a colored light, typically green, to
allow the driver to find switches more easily in the
dark. When a switch is activated, the switch icon is
backlit with a colored light, typically amber.
High-Beam Headlight Control
With the low-beam headlights on, push the turn signal lever forward (toward the windshield) to turn on
the high-beam headlights. Pull the turn signal lever
back to the neutral position to turn the high-beams
off. See Fig. 5.7.
Exterior Light Controls
Exterior light controls are listed here in alphabetical
order.
With the low-beam headlights on, pull the lever towards you to flash the high-beam headlights momentarily.
Hazard Warning Light Switch
The hazard warning light flasher (Fig. 5.5) is a red
rocker switch located on the top of the steering column.
When the high-beam headlights are on, a blue light
illuminates on the instrument cluster between the tachometer and speedometer.
To activate the hazard warning lights, press the
upper part of the rocker (pushing towards the dash).
To deactivate the hazard warning lights, press the
lower part of the switch (towards the steering wheel).
The low-beam headlights remain on continuously
during high-beam headlight operation. If the lowbeams are turned off, the high-beams turn off also.
Headlight Switch
Marker Light Interrupt Switch
A three-position headlight paddle switch (Fig. 5.6) on
the left-hand dash is used to operate the low-beam
headlights.
The marker light interrupt (MRKR INT) paddle switch
(Fig. 5.8) temporarily deactivates the marker lights
and taillights, if equipped.
1
2
3
4
1
f680028
04/19/2002
1. Storage Area with Netting
2. C/B Radio
3. Microphone Clip
4. Dome/Reading Light Assembly
Fig. 5.4, Overhead Control Panel
5.3
Driver Controls
4
1
5
2
1
2
3
11/16/2001
f820386
Press the upper part of the rocker switch to activate the
hazard warning lights.
1. Windshield Washer Button
2. Windshield Wiper Control Dial
3. Turn Signal Lever
4. Hazard Warning Light Switch
5. Multifunction Switch Module
10/17/2001
Pull the lever towards you to flash the high-beam
headlights momentarily.
1. Turn Signal Lever
Fig. 5.5, Hazard Warning Light Switch
f820385
Push the lever away from you to turn on the high-beam
headlights. Pull the lever back to the neutral position to
turn them off.
2. Boot
Fig. 5.7, High-Beam Headlight Operation
f610580
10/15/2001
Raise the paddle to illuminate the low-beam headlights.
05/09/2002
Lower the paddle to illuminate the clearance lights,
marker lights, and taillights.
Raise the paddle to flash the marker lights.
f610581
Fig. 5.8, Marker Light Interrupt Switch
Fig. 5.6, Headlight Switch
With the vehicle lights on, raise and hold the paddle
switch to briefly turn off the marker lights and taillights. The dash lights will flash with the marker lights
when the switch is actuated. When the paddle is released the marker lights will return to normal operation. With the vehicle lights off, raise the paddle
switch briefly to turn the marker lights on.
Panel Light Increase/Decrease Switch
When the instrument panel lights are on, they can be
brightened or dimmed by using the INCR/DECR
rocker switch (Fig. 5.9), located just below the headlight switch.
To brighten the panel lights, press the upper part of
the rocker switch. To dim the panel lights, press the
lower part of the rocker switch.
5.4
Driver Controls
Interior Light Controls
Overhead Console Lights
In cabs with an overhead console, there is an optional overhead light assembly containing a diffuse
dome light and clear reading lights. See Fig. 5.11.
Like the rear dome light, the reading lights are
door-activated.
10/29/2001
1
f610598
Fig. 5.9, Panel Light Increase/Decrease Switch
2
Spotlight Switch
The spotlight switch is located on the pivoting handle
of the spotlight. There may be a single spotlight assembly mounted on the driver’s door, or one on each
door.
3
Utility Light Switch
10/17/2001
The utility light switch, if equipped, operates one of
the following lights or sets of lights:
1. Overhead Console
2. Trim Plate
• A single utility light swivel-mounted in the cen-
ter of the cab roof;
• Two fixed utility lights mounted on each side of
the cab roof;
• Two flush-mounted utility lights mounted on
each side of the back of the cab.
To turn the utility light(s) on, press the upper part of
the utility light (UTLY LAMP) rocker switch
(Fig. 5.10). To turn the utility light(s) off, press the
lower part of the rocker switch.
f610587
3. Light Assembly
Fig. 5.11, Overhead Console Dome Lights
Rear Dome Light
The standard rear dome light is installed on the back
of the cab above the rear window.
In the standard cab, there is one switch in the
driver’s door that controls dome light illumination
when the driver’s door is open. A second optional
switch may be installed that controls illumination
when the passenger-side door is open.
Multifunction Turn Signal
Lever Controls
The turn signal lever is mounted on the steering column. The lever operates the following functions:
• Turn signals
• Windshield wipers and washers
• Headlight high-beams (see "Light Controls"
section above)
f610583
10/15/2001
Fig. 5.10, Utility Light Switch
5.5
Driver Controls
Turn Signal Controls
Moving the turn signal lever down (Fig. 5.12) turns
on the left-turn signal; moving it up turns on the rightturn signal.
2
1
3
4
5
10/29/2001
f820383
Rotate the control dial away from you to turn the wipers
on or speed them up.
Rotate the control dial towards you to slow the wipers
down or turn them off.
10/17/2001
f820384
Move the lever down to turn on the left turn signal.
Move the lever up to turn on the right turn signal.
Fig. 5.12, Turn Signal Controls
When a turn signal is activated, a green indicator
light flashes on the right or left side of the instrument
cluster.
1. Windshield Washer
2. OFF Position
3. Delay Settings
4. Low Speed Setting
5. High Speed Setting
Fig. 5.13, Windshield Wiper/Washer Controls
Rotating the control dial toward you (clockwise)
causes the wipers to slow down. Rotating the control
dial clockwise as far as it will go turns the wipers off.
The windshield washers are operated by a yellow
button at the end of the turn signal lever. To operate
the washers, press and hold the button in until you
want the washers to stop.
The turn signal lever automatically returns to the
neutral position (self-cancels) when the steering
wheel returns to the straight ahead position after a
turn. To manually cancel the signal, move the lever
to the neutral position.
Horn Controls
Windshield Wiper/Washer Controls
NOTE: It is possible to have both types of horn
installed on one vehicle.
NOTICE
Air Horn
Do not attempt to manually move the windshield
wiper arms. Wiper motor damage will occur if the
arms are forcibly moved.
The air horn is controlled by a wire lanyard hanging
just inboard of the driver’s door. See Fig. 5.14. Pull
downward on the lanyard to sound the air horn.
The wipers are operated by a rotary dial located at
the end of the turn signal lever. See Fig. 5.13. There
are five delay settings (marked on the dial by lines of
increasing length) and two steady speed settings, LO
and HI.
Electric Horn
Rotating the control dial away from you (counterclockwise) turns the wipers on. If they are already
on, rotating the handle further forward increases the
speed of the wipers through the various delay settings, then to LO and HI.
The electric horn button is located in the center of
the steering wheel. To sound the horn, press down
on the button. See Fig. 5.15. The horn will sound as
long as the button is pressed, up to 60 seconds.
5.6
Driver Controls
1
f461918
10/17/2001
10/17/2001
f610592
Fig. 5.14, Air Horn Control
To sound the electric horn, press down on the horn
button.
1. Horn Button
Powertrain Controls
Fig. 5.15, Electric Horn Control
Powertrain controls are listed here in alphabetical
order.
Aftertreatment System Regeneration
Switches
NOTE: See Chapter 11 for detailed information
about the operation of the regeneration (regen)
switches and the aftertreatment system (ATS).
The regen switch (Fig. 5.16), located on the dash, is
used to initiate a parked regen.
RGEN
f610848
03/09/2012
When activated, the optional regen-inhibit switch
(Fig. 5.17) stops a regen in progress and prevents
the start of a regen until the switch is no longer active.
Fig. 5.16, Regen Switch
Axle Switches
NOTE: See Chapter 15 for detailed information
about axle switch functions.
Differential Lock Switch
The differential lock provides maximum traction for
slippery conditions by forcing the wheels on each
drive axle governed by the switch to rotate together.
f610944
07/30/2009
NOTICE
The differential lock should only be engaged
when the vehicle is moving slowly at low throttle.
Engagement at high speed or power can damage
the axle(s).
5.7
Fig. 5.17, Regen-Inhibit Switch
See Fig. 5.18 for the differential lock switch on a vehicle with a single drive axle.
Driver Controls
For a vehicle with tandem axles, there are several
differential lock switch options available:
• one switch to control the differential lock on
only one of the drive axles (this switch will
show only one dot on one drive axle, varying
slightly from the switch shown in Fig. 5.19).
• one switch to control the differential locks on
both drive axles (Fig. 5.19).
• two switches, each of which controls the differ-
ential lock on one drive axle.
10/26/2001
f610596
Fig. 5.18, Differential Lock on Single Drive Axle
NOTICE
The interaxle lock should only be engaged when
the vehicle is moving slowly at low throttle. Engagement at high speed or power can damage
the axle(s).
When the interaxle lock switch is pressed, the LED in
the switch blinks until the interaxle lock is engaged.
When the interaxle lock is fully engaged, the LED
illuminates steadily.
10/26/2001
f610595
Fig. 5.20, Interaxle Lock Switch
Cruise Control Switches
NOTE: See Chapter 10 for detailed information
about cruise control operation.
Cruise control is activated by two dash-mounted
switches (Fig. 5.21).
• On/Off Switch—a two-position rocker labeled
02/17/2006
f610797
Fig. 5.19, Differential Lock on Both Axles
When the differential lock switch is pressed, the LED
in the switch blinks until the differential lock is engaged. When the differential lock is fully engaged,
the LED illuminates steadily.
Interaxle Lock Switch
The interaxle lock switch (Fig. 5.20) allows the driver
to lock the drive axles together, causing the drive
axle shafts to rotate together. Use this feature only
under adverse road conditions where greater traction
is needed.
SPD CNTL on the lower half of the switch.
When cruise control is on, an amber light illuminates the top part of the switch.
• Set/Resume Switch—a three-position paddle
switch labeled RES/ACC above the paddle and
SET/CST below the paddle.
NOTICE
When the cruise control is engaged, do not attempt to shift gears without using the clutch
pedal. Failure to follow this precaution will result
in a temporarily uncontrolled increase in engine
speed. Transmission damage and gear stripping
could result.
5.8
Driver Controls
1
2
1
f610588
10/17/2001
1. Engine Brake On/Off
2. Engine Brake Intensity Switch
2
Fig. 5.22, Engine Brake Switches
unless the coolant temperature is high enough to
continue the fan operation.
f610510
09/13/2001
To turn cruise control on, press the upper half of the On/
Off switch. To turn cruise control off, press the lower half
of the On/Off switch.
To turn the engine fan on, press the upper part of the
rocker switch. See Fig. 5.23. Press the bottom of the
switch to deactivate it.
To increase cruise speed, raise and hold the paddle of
the Set/Resume switch to RES/ACC until the vehicle
accelerates to the desired speed. To decrease cruise
speed, lower and the paddle of the Set/Resume switch to
SET/CST until the vehicle decelerates to the desired
speed.
1. Cruise Control On/Off Switch
2. Cruise Control Set/Resume Switch
Fig. 5.21, Cruise Control Switches
Engine Brake Switch
NOTE: See Chapter 10 for detailed information
about engine brake operation.
Two dash-mounted switches control the engine
brake:
• The On/Off switch (ENG BRK), is used to turn
the engine brake on and off. See Fig. 5.22.
• The engine brake intensity switch (HI/MED/LO
or, in some cases, HI/LO) controls the amount
of engine braking.
Engine Fan Switch
The engine cooling fan can be manually activated
with the engine fan switch. The fan will continue to
operate for a set amount of time and then turn off
5.9
f610590
01/04/2011
Fig. 5.23, Engine Fan Switch
Exhaust Brake Switch
NOTE: See Chapter 10 for detailed information
about exhaust brake operation.
An exhaust brake may be used in conjunction with
the service brakes during off-highway and mountain
driving as well as in traffic or high-speed highway
driving. Exhaust brakes are not intended for use as
the primary braking system during vehicle operation.
The exhaust brake is controlled by a dash-mounted
rocker switch. See Fig. 5.24 or Fig. 5.25.
Driver Controls
The SmartShift electronic transmission control is installed with the Eaton® Fuller® UltraShift™, UltraShift
PLUS, and AutoShift™ transmissions. The SmartShift
control is operated by the fingers of the driver’s right
hand, allowing both hands to remain on the steering
wheel.
A two-position driving mode slide switch is mounted
on the body of the control lever just before the
paddle widens out. The slide switch allows the driver
to choose automatic (AUTO) or manual (MAN) mode.
See Fig. 5.26.
11/28/2001
f610589
5
Fig. 5.24, Exhaust Brake Switch
7
8
4
3
1
6
9
2
10
11
01/24/2003
03/31/2009
f610589a
Fig. 5.25, Exhaust Brake Switch
Transmission Controls
Manual Transmissions
NOTE: See Chapter 13 for complete manual
transmission operating instructions.
If so equipped, the transmission range control and
splitter valves are attached to the gear shift knob.
12
f270120
To upshift manually, pull the lever back (towards the
driver). To downshift manually, push the lever forward
(away from the driver).
1. SmartShift Control Lever
2. Slide Switch (forward driving mode switch)
3. MAN Mode (of slide switch)
4. AUTO Mode (of slide switch)
5. Upshift Direction
6. Reverse Position (of selector switch)
7. Selector Switch
8. Neutral Lock Button
9. Neutral Position (of selector switch)
10. Drive Position (of selector switch)
11. Low Position (of selector switch)
12. Downshift Direction
The range-preselection lever allows the selection of
the low or high range for each transmission ratio. It is
used once during an upshift sequence and once during a downshift sequence.
Allison Automatic Transmissions
Dependent on the transmission model, some ratios
can be split using the splitter-control button.
NOTE: See Chapter 14 for complete automatic
transmission operating instructions.
Eaton Automated Transmissions
Automatic transmissions have up to six forward
speeds and one reverse speed. These transmissions
have electronic shift controls that can be programmed to allow the use of different geared
speeds. See Fig. 5.27.
NOTE: See Chapter 14 for complete automated
transmission operating instructions.
Fig. 5.26, SmartShift Control (Eaton Fuller UltraShift,
UltraShift PLUS, and AutoShift transmissions)
5.10
Driver Controls
AWD Range Switch
NOTICE
To prevent damage to the transfer case and the
driveline, stop the vehicle and apply the parking
brake before using the range switch.
1
2
IMPORTANT: Use this switch only when AWD
has been engaged.
In most cases, the AWD range switch is a twoposition rocker switch with the legend LO RANGE at
the upper end and HIGH RANGE at the lower end.
On vehicles with a power take-off (PTO) unit, the
three-position switch has a neutral (N-TRL) position
in the middle. See Fig. 5.29.
f600369a
10/31/94
1. Indicator Panel
2. Mode ID
Fig. 5.27, Allison Push Button Shift Selector
Use the AWD high range when driving at normal
speeds under off-road conditions or on non-paved
surfaces. Use the low range when extra traction is
needed at lower speeds (i.e., in muddy, snowy, or icy
conditions).
All Wheel Drive Controls
1
All wheel drive (AWD) allows the driver to direct
driveline power to all drive and steer axles.
2
LO
RANGE
LO
N−TRL
HIGH
RANGE
HIGH
RANGE
AWD Operation Switch
The AWD operation switch (LOCKED AWD) is a twoposition rocker switch. See Fig. 5.28.
07/21/2006
f610808
1. Two-Position Switch
2. Three-Position Switch
LOCKED
Fig. 5.29, AWD Range Switches
AWD
08/10/2006
Two-Position Switch (No PTO)
f610807
Fig. 5.28, AWD Operation Switch
To engage AWD, press the upper half of the rocker
switch. To disengage AWD, press the lower half of
the switch.
On vehicles without a PTO, high range is considered
standard operation. To activate the low range, press
the upper half of the switch. To switch back to HIGH
RANGE, press the lower half of the switch.
Three-Position Switch (With PTO)
IMPORTANT: Always use the N-TRL range
when operating the PTO.
On vehicles with a PTO, neutral is considered standard operation (switch in the middle position).
5.11
Driver Controls
To activate the high range, press the lower half of the
switch. Press the upper half to return to N-TRL.
in) to charge the trailer air supply system and release
the trailer spring parking brakes.
To activate the low range, press the upper half of the
switch. Press the lower half of the switch to return to
N-TRL, and then press the lower half again to switch
to the high range.
Pull the trailer air supply valve out before disconnecting a trailer or when operating a vehicle without a
trailer.
Brake Controls
Parking Brake Control Valve
NOTE: See Chapter 12 for detailed information
about brake systems.
NOTICE
Do not step on the service brake pedal while the
parking brakes are applied. To do so can cause
damage to the brake mechanisms.
Trailer Brake Lever
The trailer brake lever is used for applying the trailer
service brakes without applying the truck or tractor
service brakes. It is usually mounted on the righthand control panel. See Fig. 5.31. The valve can be
partially or fully applied, but in any partially on position it will be overridden by a full application of the
service brake pedal. Moving the lever down applies
the trailer brakes, while moving it up releases the
trailer brakes. The lever will automatically return to
the up position when it is released.
The yellow diamond-shaped knob operates the parking brake valve. Pulling the knob out applies both the
tractor and trailer spring parking brakes. See
Fig. 5.30. Pushing the knob in releases the tractor
spring parking brakes.
If the trailer is not equipped with spring parking
brakes, pulling out the parking brake valve applies
the tractor parking brakes and the trailer service
brakes.
1
2
f610591
10/17/2001
Fig. 5.31, Trailer Brake Lever
Antilock Braking System
f610291
03/10/99
1. Trailer Air Supply Valve (red knob)
2. Parking Brake Control Valve (yellow knob)
Fig. 5.30, Brake Valve Control Knobs
Trailer Air Supply Valve
The red octagonal-shaped knob operates the trailer
air supply valve. See Fig. 5.30. After the vehicle and
its air hoses are connected to a trailer and the pressure in the air system is at least 65 psi (447 kPa),
push the trailer air supply valve knob in (and leave it
The Meritor™ WABCO® Antilock Braking System
(ABS) passively monitors vehicle wheel speed at all
times, and controls wheel speed during emergency
stops or wheel lock situations.
During emergency or reduced-traction stops, fully
depress the brake pedal until the vehicle comes to a
safe stop. Do not pump the brake pedal. With the
brake pedal fully depressed, the ABS will control all
wheels to provide steering control and a reduced
braking distance.
The ABS is designed to communicate with a trailer
ABS, if they are compatible. Compatibility will result
in the illumination of the TRAILER ABS lamp during
vehicle start-up and fault detection. The TRAILER
5.12
Driver Controls
ABS lamp will not illuminate unless a compatible
trailer is connected to the tractor.
Vehicles with ABS may have Automatic Traction Control (ATC). On these vehicles, the ATC system automatically limits wheel spin during reduced-traction
situations. In normal braking applications, the standard air brake system is in effect.
To prevent the suspension from filling automatically,
turn off the ignition and push the override valve in.
When the ignition is turned on, the override valve will
release automatically and the suspension will autofill.
ATC includes a deep snow and mud option to increase available traction on extra-soft surfaces like
snow, mud, or gravel. A rocker switch labeled ATC
will be located on the dash. Pressing the switch will
temporarily allow more drive wheel spin. The activation of the deep snow and mud option is indicated by
a flashing WHEEL SPIN lamp. Pressing the switch
again will shift the system back to normal operation.
SH TO
PU
NOTICE
The deep snow and mud option is intended to be
used under specific slippery conditions that require momentary increased wheel spin. Using
this option for an extended period of time may
damage the brake system.
Adjustable Steering Column
Controls
Adjust the seat to the desired ride position, then tilt
or telescope the steering column as needed.
To tilt the steering column, press down on the foot
pedal located on the steering column. Tilt the steering column up or down to the desired position. Release the foot pedal to lock the steering column in
place.
To telescope the steering column, press down on the
foot pedal located on the steering column. Pull the
steering wheel closer to you or push the steering
wheel away from you. Release the foot pedal to lock
the steering column in place.
Suspension Controls
Other right-hand control panel options are listed here
in alphabetical order.
Air Suspension Autofill Override Valve
The suspension autofill override option is a dash air
valve (Fig. 5.32) that keeps the suspension deflated
when the ignition is turned off.
5.13
09/11/2007
f321102
Fig. 5.32, Suspension Autofill Override Valve
Air Suspension Dump Control Switch
NOTICE
Do not operate the vehicle over uneven ground
such as ramps, speed bumps, curbs, etc. with
the air springs deflated. Doing this may lead to
air bag separation from the piston, preventing the
suspension air springs from reinflating.
The suspension dump switch is a two-position rocker
switch (Fig. 5.33) that allows the air in the air suspension to be quickly exhausted, lowering the rear of
the vehicle. This makes it easier to connect to, or
disconnect from, a trailer.
NOTICE
Never exhaust air from the suspension while
driving. When the air is exhausted, the suspension will not absorb road shocks and components may be damaged.
To lower the rear of the vehicle, press the upper half
of the rocker momentarily. To raise the suspension to
its normal height, press the upper half of the rocker
again.
Driver Controls
The fan switch controls the fan speed and forces
fresh or recirculated air through the air outlets.
The air selection switch allows you to control the flow
of air through the face outlets, the floor outlets, the
defrost (windshield) outlets, or a combination of
these outlets.
The temperature control switch is used to select the
desired temperature.
10/26/2001
f610597
Fig. 5.33, Suspension Dump Switch
When the suspension dump switch is pressed, the
LED in the switch blinks while the suspension deflates or fills. When the suspension is completely deflated or filled, the LED illuminates steadily.
The optional recirculation button minimizes the
amount of outside air entering the cab. It may be
used in dusty or smoky conditions, or when there is
a large difference between the outside air temperature and the desired cab temperature. When the recirculation mode is on, the recirculation indicator will
illuminate.
If the ignition is turned off while the vehicle is in
dump mode, the power to the dump solenoid is cut
off to prevent battery drain and the suspension system will autofill. The suspension will also autofill if the
vehicle is operated with the suspension dumped at a
speed over 5 mph.
Seat Controls
Climate Controls
Keep hands, tools, and other objects away from
the scissor points under the seats. Failure to do
so could cause personal injury.
NOTE: See Chapter 7 for detailed climate control panel operating instructions.
The climate control panel without air conditioning is
shown in Fig. 5.34. The climate control panel with air
conditioning is shown in Fig. 5.35.
1
NOTE: See Chapter 6 for detailed information
about seat controls and adjustments.
WARNING
The following is a description of adjustments that can
be made to various seats. Not all seats have all of
the adjustments listed below. See Fig. 5.36.
2
3
2
1
0
3
4
06/17/2003
1. Fan Switch
f831452a
2. Air Selection Switch
3. Temperature Control Switch
Fig. 5.34, Climate Control Panel Without Air Conditioning
5.14
Driver Controls
2
1
3
2
3
1
0
4
5
06/18/2003
1. Fan Switch
2. Air Selection Switch
4
f831453a
3. Temperature Control Switch
4. Recirculation Button
5. Recirculation Indicator
Fig. 5.35, Climate Control Panel With Air Conditioning
1
3
4
2
8
5
6
7
f910149a
10/26/2000
1.
2.
3.
4.
Backrest Tilt
Lumbar Support
Isolator Feature
Height Adjustment
5. Bottom Cushion Angle (fore-andaft cushion height)
6. Fore-and-Aft Seat Slide (seat
track adjustment)
7. Seat Tilt
8. Upper Backrest Adjustment
Fig. 5.36, General Seat Adjustments
• Backrest tilt
• Height adjustment
• Lumbar support
• Bottom cushion angle (fore-and-aft bottom
• Isolator
5.15
cushion height)
• Fore-and-aft seat slide (seat track adjustment)
Driver Controls
• Seat tilt
• Headrest adjustment
Bench Seats
The full bench seat (Fig. 5.37) is optional. The full
bench seat has a seat slide adjustment to allow more
or less leg room for the driver and passengers. Release the seat slide lever and push backwards or
forwards to move the seat along its track.
No adjustments are possible on the two-person
bench seat or the non-suspended passenger seat.
1
2
10/05/2001
f910481
1. Bench Seat
2. Seat Slide Lever
Fig. 5.37, Full Bench Seat
5.16
6
Seats and Restraints
Seats, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freightliner High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sears Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
National 2000 Series Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
6.2
6.3
6.4
6.5
6.6
Seats and Restraints
Seats, General Information
Unless otherwise noted, all seat adjustments should
be made while seated and before the engine is
started.
Due to the maximum adjustability of mid- and highback air suspension seats, it is possible to combine
the seat back recline adjustment and the seat slide
adjustment so that the seat back contacts the backwall. It is the responsibility of the driver to adjust the
seat to prevent damage to the seat and the cab
interior.
1.
Backrest Tilt: This adjustment enables the backrest to pivot forward or backward.
2.
Lumbar Support: Lumbar support changes the
shape of the seat back to give more or less support to the occupant’s lumbar (lower back) area.
This adjustment is either mechanical or air controlled, depending on make and model of the
seat.
3.
Isolator: This feature reduces the amount of road
shock by isolating the occupant from the motion
of the vehicle, and allowing the upper seat to
move in a simple pendulum motion. A lockout
feature is used whenever the isolator is not desired.
4.
Height Adjustment: This adjustment moves the
entire seat up or down. The adjustment is either
manually- or air-controlled, depending on the
make of the seat.
5.
Bottom Cushion Angle, or Fore-and-Aft Bottom
Cushion Height: This adjustment enables the occupant to raise or lower the front or back of the
WARNING
Keep hands, tools, and other objects away from
the scissor points under the seats. Failure to do
so could cause personal injury.
The following is a description of adjustments that can
be made to various Freightliner-installed seats. Not
all seats have all of the adjustments listed below.
See Fig. 6.1.
1
3
4
2
8
5
6
7
f910149a
10/26/2000
1.
2.
3.
4.
Backrest Tilt
Lumbar Support
Isolator Feature
Height Adjustment
5. Bottom Cushion Angle (fore-andaft cushion height)
6. Fore-and-Aft Seat Slide (seat
track adjustment)
Fig. 6.1, General Seat Adjustments
6.1
7. Seat Tilt
8. Upper Backrest Adjustment
Seats and Restraints
bottom cushion. This adjustment is easier to perform when all weight is removed from the seat.
6.
Fore-and-Aft Seat Slide, or Seat Track Adjustment: This adjustment moves the entire seat forward or backward on its track.
7.
Seat Tilt: This adjustment allows the seat assembly (back and bottom cushions) to tilt forward or
backward.
8.
Headrest Adjustment: This adjustment changes
the angle of the upper part of the backrest to
provide head and upper back support.
Bench Seats
Freightliner High-Back Seat
See Fig. 6.3 for seat adjustment controls. Not all
models of the seat have all the adjustments listed
below.
Backrest Tilt
To tilt the backrest, lean forward slightly to remove
pressure from the cushion, then turn the knob forward or rearward to achieve the desired position.
Lumbar Support
To adjust the lumbar support, use the lumbar support
switches on the side of the seat.
The full bench seat is optional. See Fig. 6.2.
Height Adjustment
To raise or lower the height of the seat, use the
height adjustment switch on the side of the seat.
1
Bottom Cushion Extension
To adjust the fore-and-aft position of the seat cushion, remove your weight from the seat, then lift up
and pull forward on the cushion adjustment handle.
To return the cushion to the aft position, lift up and
push rearward.
Fore/Aft Seat Slide
2
10/05/2001
f910481
1. Bench Seat
2. Seat Slide Lever
Fig. 6.2, Full Bench Seat
The full bench seat has a seat slide adjustment to
allow more or less leg room for the driver and passengers. Release the seat slide lever and push backwards or forwards to move the seat along its track.
High-back air suspension seats are optional for both
driver’s and passenger’s seats. Also available are a
non-suspended passenger’s seat, and a two-person
bench seat with a safe or tool box located under the
seat.
To adjust the fore-and-aft position of the entire seat,
move the fore-and-aft seat adjustment lever to the
left and slide the seat forward or backward to the
desired position. Move the lever back to its original
position to lock the seat in place.
Fore/Aft Isolator
To engage the isolator, turn the isolator knob rearward to the unlocked position. Turn the isolator knob
forward to the locked position when the isolator feature is not desired.
Shock Absorber
To adjust the amount of damping the shock absorber
provides, move the lever up to increase damping;
move the lever down to decrease damping.
No adjustments are possible on the two-person
bench seat or the non-suspended passenger seat.
6.2
Seats and Restraints
1
6
4
2
10
9
3
5
8
7
07/18/2007
f910576
NOTE: Not all models of the seat have all the adjustment controls shown.
1. Rear Cushion Height Adjustment
Knob
2. Fore/Aft Isolator
3. Front Cushion Height Adjustment
Knob
4.
5.
6.
7.
Bottom Cushion Extension Handle
Fore/Aft Seat Slide Lever
Backrest Tilt Knob
Heater Button
8. Shock Absorber Lever
9. Height Adjustment Switch
10 Lumbar Support Switches
Fig. 6.3, Freightliner High-Back Seat
Front Cushion Height
Heater
To adjust the height of the front of the cushion, remove your weight from the seat, then turn the adjustment knob toward the front of the seat (clockwise) to
increase cushion height. To lower the cushion height,
turn the adjustment knob toward the rear of the seat
(counterclockwise).
To turn on the heat option, press the button. To turn
off the heat option, press the button again. If the vehicle has Optimized Idle, seat heating will not operate with the key in accessory mode. Optimized Idle
may also turn seat heating off to reduce stress on
the batteries.
Rear Cushion Height
Bostrom Seat
To adjust the height of the rear of the seat cushion,
remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions.
See Fig. 6.4 for Bostrom seat adjustment controls.
6.3
Seats and Restraints
Bottom Cushion Tilt, Bostrom Seat
To adjust the bottom cushion tilt, rotate the bottom
cushion tilt knob to increase or decrease bottom
cushion tilt.
Fore-and-Aft Seat Adjustment,
Bostrom Seat
1
6
To adjust the fore-and-aft position of the entire seat,
hold the fore-and-aft adjustment lever to the left and
slide the seat forward or backward to the desired
position.
Isolator, Bostrom Seat
To engage the isolator, put the isolator lever in the
center position. Lock out the isolator by moving the
lever to the right.
2
5
3
12/03/2010
1.
2.
3.
4.
5.
6.
4
f910131a
Backrest Tilt Lever
Lumbar Support Switches (LSO models)
Height Adjustment Switch
Bottom Cushion Tilt Knob
Fore-and-Aft Seat Adjustment and Isolator Lever
Lumbar Support Knob (non-LSO models)
Fig. 6.4, Bostrom Seat Adjustment Controls
Backrest Tilt, Bostrom Seat
To tilt the backrest, lean forward slightly to remove
pressure from the cushion and hold the backrest tilt
lever rearward. Lean backward slowly to the desired
position and release the lever to lock the backrest in
place. To adjust backrest forward, hold the backrest
tilt lever rearward while leaning forward.
Sears Atlas Seat
See Fig. 6.5 for seat adjustment controls.
Seat Tilt/Extension Adjustment, Sears
Atlas Seat
To adjust the seat tilt/extension, lift the handle upward and move the seat cushion to the desired position. Three positions are available.
Fore-and-Aft Seat Adjustment, Sears
Atlas Seat
To adjust the fore-and-aft position of the entire seat,
lift the bar and slide the seat to the desired positon.
Lumbar Support, Bostrom Seat
Isolator
To increase lumbar support on luxury seat option
(LSO) models, press the plus sign on the lumbar
support switch. To decrease lumbar support on LSO
models, press the minus sign on the switch.
To engage the isolator, put the isolator lever in the
left position. Lock out the isolator by moving the lever
to the right.
To increase lumbar support on non-LSO models, rotate the lumbar support knob forward. To decrease
lumbar support on non-LSO models, rotate the knob
rearward.
Height Adjustment, Sears Atlas Seat
Height Adjustment, Bostrom Seat
To inflate and raise the suspension, push forward on
the front rocker switch. To deflate and lower the suspension, push rearward to deflate and lower the
suspension.
To raise the seat, press the upper portion of the
height adjustment switch. To lower the seat, press
the lower portion of the switch.
6.4
Seats and Restraints
the desired position and release the lever to lock the
backrest in place. To adjust backrest forward, pull
upward on the recliner handle while leaning forward.
Armrest Adjustment, Sears Atlas Seat
To adjust the armrest the the desired angle, rotate
the control knob (located on the underside of the
armrest).
National 2000 Series Seat
See Fig. 6.6 for seat adjustment controls.
7
7
1
6
2
6
3
5
1
5
4
11/24/2009
1.
2.
3.
4.
5.
6.
7.
Seat Tilt/Extension Adjustment Handle
Fore-and-Aft Slide Adjustment Bar
Isolatior Lever
Suspension (Ride) Adjustment Switch
Lumbar Support Switches
Backrest Adjustment Handle
Armrest
Fig. 6.5, Sears Atlas Seat Adjustment Controls
Lumbar Support, Sears Atlas Seat
To inflate or deflate the lower lumbar bag, push the
rear rocker switch.
to inflate or deflate the upper lumbar bag, push the
center rocker switch.
Backrest Tilt, Sears Atlas Seat
To tilt the backrest, lean forward slightly to remove
pressure from the cushion and pull upward on the
backrest adjustment handle. Lean backward slowly to
6.5
4
f910615
11/14/2000
1.
2.
3.
4.
5.
6.
7.
3
2
f910445
Backrest Tilt Knob
Lumbar Support Switch
Height Adjustment Switch
Fore-and-Aft Seat Adjustment Lever
Bottom Cushion Fore-and-Aft Adjustment Handle
Isolator Handle
Rear Cushion Adjustment Knob
Fig. 6.6, National 2000 Series Seat Adjustment Controls
Backrest Tilt, National 2000 Series
Seat
To tilt the backrest, turn the backrest tilt knob until
the desired position is reached.
Seats and Restraints
Lumbar Support, National 2000
Series Seat
To adjust the lumbar support, use the lumbar support
switch on the side of the seat to give more or less
support to your lower back.
den stops. For this reason, Daimler Trucks North
America LLC urges that the driver and all passengers, regardless of age or physical condition, use
seat belts when riding in the vehicle.
WARNING
Height Adjustment, National 2000
Series Seat
Always use the vehicle’s seat belt system when
operating the vehicle. Failure to do so can result
in severe personal injury or death.
To raise or lower the height of the seat, use the
height adjustment switch on the side of the seat.
Seat belt assemblies in Daimler Trucks North
America (DTNA) vehicles meet Federal Motor Vehicle Safety Standard 209, "Type 1" and "Type 2" requirements.
Fore-and-Aft Seat Adjustment,
National 2000 Series Seat
To adjust the fore-and-aft position of the entire seat,
move the fore-and-aft seat adjustment lever to the
left and slide the seat forward or backward to the
desired position. Move the lever back to its original
position to lock the seat in place.
Bottom Cushion Fore-and-Aft
Adjustment, National 2000 Series
Seat
To adjust just bottom cushion, lift the bottom cushion
adjustment handle and pull forward or push back to
the desired setting.
Isolator, National 2000 Series Seat
To engage the isolator, turn the isolator handle to the
horizontal position. Lock out the isolator by turning
the isolator handle down.
Rear Cushion Adjustment, National
2000 Series Seat
To adjust the height of the rear of the seat cushion,
remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions.
Seat Belts and Tether Belts
General Information, Seat Belts and
Tether Belts
Seat belt assemblies are designed to secure persons
in the vehicle to help reduce the chance of injury, or
the amount of injury, resulting from accidents or sud-
When transporting a child, always use a child restraint system or the vehicle seat belts as appropriate. To determine whether a child restraint system is
required, review and comply with applicable state
and local laws. Any child restraint used must comply
with Federal Motor Vehicle Safety Standard 213,
"Child Restraint Systems." When providing a child
restraint system, always carefully read and follow all
instructions pertaining to installation and usage for
the child. Make certain the child remains in the restraint system at all times when the vehicle is in motion.
In addition to seat belt assemblies, tether belts are
installed on suspension-type seats. Tether belts provide a flexible extension of the cab structure. They
help secure the seat to the floor, and are intended to
restrain the seat and seat belt in case of an accident
or sudden stop.
IMPORTANT: Seat belts and tethers have a finite life which may be much shorter than the life
of the vehicle. Regular inspections and replacement as needed are the only assurance of adequate seat belt security over the life of the
vehicle.
Inspection, Seat Belts and Tether
Belts
WARNING
Inspect and maintain seat belts. When any part of
a seat belt system needs replacement, the entire
seat belt must be replaced, both retractor and
buckle side. Any time a vehicle is involved in an
accident, and the seat belt system was in use,
6.6
Seats and Restraints
the entire vehicle seat belt system must be replaced before operating the vehicle. Do not attempt to modify the seat belt system; doing so
could change the effectiveness of the system.
Failure to replace worn or damaged seat belts, or
making any modifications to the system, may result in personal injury or death.
B
A
Inspect the seat belts and tether belts (if so
equipped).
1.
Check the web for fraying, cuts, extreme dirt and
dust, or for severe fading from exposure to sunlight, especially near the buckle latch plate and in
the D-loop guide area.
2.
Check operation of the buckle, latch, Komfort
Latch or Sliding Komfort Latch (if equipped), web
retractor, and upper seat belt mount on the door
pillar. Check all visible components for wear or
damage.
3.
Check the seat belt and tether belt connection
points and tighten any that are loose.
03/11/2010
f910620
A. Disengaged
Seat Belt Operation
B. Engaged
Fig. 6.7, Komfort Latch
Three-Point Seat Belt With Komfort Latch
or Sliding Komfort Latch
NOTE: For vehicles not equipped with the Komfort Latch or the Sliding Komfort Latch, see the
seat belt operation under the heading "ThreePoint Seat Belt."
WARNING
Wear three-point seat belts only as described
below. Three-point seat belts are designed to be
worn by one person at a time. In case of an accident or sudden stop, personal injury or death
could result from misuse.
Fasten the seat belts before driving. Fastening a
three-point seat belt while driving creates a hazard.
When engaged and used properly, the Komfort Latch
(Fig. 6.7) and the Sliding Komfort Latch (Fig. 6.8)
introduce a small amount of slack into the seat belt,
resulting in a more comfortable ride.
1.
6.7
Slowly pull the latch end of the three-point seat
belt out of the retractor and pull it across your
lap (from outboard to inboard) far enough to en-
11/18/2010
f910621a
Fig. 6.8, Sliding Komfort Latch
gage the buckle. If the retractor locks too soon,
allow the belt to retract slightly, then slowly pull it
out again. See Fig. 6.9.
2.
Fasten the three-point seat belt by pushing the
latch into the buckle. Listen for an audible click.
Seats and Restraints
and neck. See Fig. 6.10. If desired, engage the
Komfort Latch or Sliding Komfort Latch as follows.
If equipped with a Sliding Komfort Latch, make
sure that the shoulder strap is snug against your
chest. Without loosening the shoulder strap,
push the Sliding Komfort Latch switch to the
"ON" position. See Fig. 6.8. To activate the latch
lean forward until you hear a click. This will allow
for approximately 1 inch (2.5 cm) of slack between your chest and the shoulder harness.
Once engaged, the latch will allow you to lean
forward about 5 inches (13 cm) without having to
reset the latch. Leaning forward more than 5
inches (13 cm) will disengage the Sliding Komfort Latch, requiring it to be reset.
If equipped with a Komfort Latch, pull on the
shoulder strap to lessen the pressure of the strap
on your shoulder and chest. Allow no more than
1 inch (2.5 cm) of slack between your chest and
the shoulder harness. More slack can significantly reduce the seat belt effectiveness in an
accident or a sudden stop. While holding the belt
slack, press the Komfort Latch lever up, clamping the seat belt webbing (Fig. 6.11 and
Fig. 6.12).
1
2
07/02/2007
1. Latch
f910578
2. Buckle
Fig. 6.9, Three-Point Seat Belt Operation
3.
4.
Tug on the seat belt to make sure it is securely
fastened. If the buckle unlatches, repeat this
step. If the problem continues, replace the threepoint seat belt.
Snug the seat belt to your waist.
WARNING
Before activating the Komfort Latch or the Sliding Komfort Latch, make sure the amount of
slack in the shoulder strap is set as described
below. Excess slack in the shoulder strap reduces the effectiveness of the seat belt, and increases the risk of injury or death in an accident.
5.
Position the shoulder strap diagonally across
your chest with the adjustable D-loop bracket (if
equipped). The shoulder strap must be centered
on your shoulder and chest, away from your face
A
B
C
08/09/2010
f910634
A. Correct—Belt is centered on your shoulder and
chest, away from your face and neck.
B. Wrong—Belt must not rub against face or neck.
C. Wrong—Belt must not hang off shoulder.
Fig. 6.10, Proper Shoulder Strap Fit
6.
Unbuckle the three-point seat belt and release
the Komfort Latch or the Sliding Komfort Latch
as follows.
If equipped with a Sliding Komfort Latch, unbuckle the seat belt, then tug on the shoulder
belt to release the Sliding Komfort Latch, or
press the Sliding Komfort latch to the "OFF" position, then unbuckle the seat belt.
6.8
Seats and Restraints
Three-Point Seat Belt
NOTE: For vehicles equipped with the Komfort
Latch or the Sliding Komfort Latch, see the seat
belt operation under the heading "Three-Point
Seat Belt With Komfort Latch or Sliding Komfort
Latch."
A
WARNING
f910048a
01/06/95
A. 1 Inch (2.5 cm) Maximum
Fig. 6.11, Adjusting Shoulder Harness Clearance,
Komfort Latch
11/02/95
f910144
Fig. 6.12, Locking the Komfort Latch
If equipped with a Komfort Latch, unbuckle the
seat belt, then release the Komfort Latch by giving the shoulder belt a quick tug. If you lean forward against the shoulder belt, the Komfort Latch
will automatically release, and will need to be
reset.
NOTE: Neither the Komfort Latch nor the Sliding
Komfort Latch need to be manually released in
an emergency situation. Each will release by
itself under rough road or other abnormal conditions. Make sure the three-point seat belt is
completely retracted when it is not in use.
6.9
Wear three-point seat belts only as described
below. Three-point seat belts are designed to be
worn by one person at a time. In case of an accident or sudden stop, personal injury or death
could result from misuse.
Fasten the seat belts before driving. Fastening a
three-point seat belt while driving creates a hazard.
1.
Slowly pull the link end of the three-point seat
belt out of the retractor and pull it across your
lap (from outboard to inboard) far enough to engage the buckle. If the retractor locks too soon,
allow the belt to retract slightly, then slowly pull it
out again. See Fig. 6.8.
2.
Fasten the three-point seat belt by pushing the
latch into the buckle. Listen for an audible click.
3.
Tug on the seat belt to make sure it is securely
fastened. If the buckle unlatches, repeat this
step. If the problem continues, replace the threepoint seat belt.
4.
Snug the seat belt to your waist.
5.
Position the shoulder strap diagonally across
your chest with the adjustable D-loop bracket (if
equipped). The shoulder strap must be centered
on your shoulder and chest, away from your face
and neck. See Fig. 6.10.
6.
To unbuckle the three-point seat belt, press the
release button on the buckle.
NOTE: Make sure the three-point seat belt is
completely retracted when it is not in use.
7
Climate Control
Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Climate Control
Climate Control Panel
The climate control panel allows you to control the
heating, ventilating, defrosting, and air conditioning
functions. The climate control panel without air conditioning is shown in Fig. 7.1. The climate control
panel with air conditioning is shown in Fig. 7.2.
Fan Switch
The fan switch controls the fan speed and forces
fresh or recirculated air through the air outlets. The
fan switch has eight fan speeds and an off position.
To increase airflow, turn the fan switch to the right
toward a higher number. To decrease the airflow, turn
the switch to the left toward a lower number.
Air Selection Switch
The air selection switch allows you to control the flow
of air through the face outlets, the floor outlets, the
defrost (windshield) outlets, or a combination of
these outlets to give you nine air selection modes on
a system without air conditioning. See Fig. 7.3. A
system with air conditioning has eleven air selection
1
2
3
2
1
3
0
4
06/17/2003
f831452a
1. Fan Switch
2. Air Selection Switch
3. Temperature Control Switch
Fig. 7.1, Climate Control Panel Without Air Conditioning
2
1
3
2
3
1
0
06/18/2003
1. Fan Switch
2. Air Selection Switch
4
5
4
3. Temperature Control Switch
4. Recirculation Button
f831453a
5. Recirculation Indicator
Fig. 7.2, Climate Control Panel With Air Conditioning
7.1
Climate Control
4
3
6
5
5
2
6
1
7
4
7
8
3
9
2
10
A
8
9
06/17/2003
1
f831455
1.
2.
3.
4.
5.
6.
Face Mode
Selection Between Face Mode and Bi-Level Mode
Bi-Level Mode
Selection Between Bi-Level Mode and Floor Mode
Floor Mode
Selection Between Floor Mode and Floor/Defrost
Mode
7. Floor/Defrost Mode
8. Selection Between Floor/Defrost Mode and Defrost
Mode
9. Defrost Mode
Fig. 7.3, Air Selection Switch Without Air Conditioning
modes, four of which are air conditioning modes. See
Fig. 7.4.
06/18/2003
2.
3.
4.
Face Mode: Directs all airflow through the face
or instrument panel outlets.
f831462
A. Air Conditioning Modes
1. Air Conditioning Face Mode
2. Selection Between Air Conditioning Face Mode and
Air Conditioning Bi-Level Mode
3. Air Conditioning Bi-Level Mode
4. Selection Between Air Conditioning Bi-Level Mode
and Face Mode
5. Face Mode
6. Selection Between Face Mode and Floor Mode
7. Floor Mode
8. Selection between Floor Mode and Floor/Defrost
Mode
9. Floor/Defrost Mode
10. Selection between Floor/Defrost Mode and Defrost
Mode
11. Defrost Mode
Fig. 7.4, Air Selection Switch With Air Conditioning
Air Selection Switch Without Air
Conditioning
1.
11
through the floor outlets and 25 percent through
the defrost outlets.
7.
Floor/Defrost Mode: Directs the airflow equally
to the floor outlets and the defrost outlets.
8.
Bi-Level Mode: Directs the airflow equally to the
face outlets and the floor outlets.
Selection between Floor/Defrost Mode and
Defrost Mode: Directs 75 percent of the airflow
through the defrost outlets and 25 percent
through the floor outlets.
9.
Selection between Bi-Level Mode and Floor
Mode: Directs 25 percent of the airflow through
the face outlets and 75 percent through the floor
outlets.
Defrost Mode: Directs all airflow through the
defrost outlets.
Air Selection Switch With Air
Conditioning
Selection between Face Mode and Bi-Level
Mode: Directs 75 percent of the airflow through
the face outlets and 25 percent through the floor
outlets.
5.
Floor Mode: Directs all airflow through the floor
outlets.
1.
Air Conditioning Face Mode: Directs all airflow
through the face or instrument panel outlets.
6.
Selection between Floor Mode and Floor/
Defrost Mode: Directs 75 percent of the airflow
2.
Selection between the Air Conditioning Face
Mode and the Air Conditioning Bi-Level
7.2
Climate Control
Mode: Directs 75 percent of the airflow to the
face outlets and 25 percent to the floor outlets.
3.
Air Conditioning Bi-Level Mode: Directs the
airflow equally to the face outlets and the floor
outlets.
4.
Selection between the Air Conditioning BiLevel Mode and the Face Mode: Directs 25
percent of the airflow to the face outlets and 75
percent to the floor outlets.
5.
Face Mode: Directs all airflow through the face
outlets.
6.
Selection between Face Mode and Floor
Mode: Directs the airflow equally through the
face outlets and the floor outlets.
7.
8.
9.
The recirculation mode is only available on vehicles
with air conditioning.
The recirculation mode limits the amount of outside
air entering the cab. Press the recirculation button to
prevent dusty or smoky air from entering the cab.
The recirculation mode can also be used to decrease
the time required to cool or heat the cab interior during extreme outside temperature conditions. When
the recirculation mode is on, the recirculation indicator will illuminate. See Fig. 7.2.
The recirculation mode is not available when the air
selection switch is in one of the following modes:
• floor/defrost mode
Floor Mode: Directs all airflow through the floor
outlets.
• selection between floor/defrost mode and de-
Selection between Floor Mode and Floor/
Defrost Mode: Directs 75 percent of the airflow
through the floor outlets and 25 percent through
the defrost outlets.
• defrost mode
Floor/Defrost Mode: Directs the airflow equally
to the floor outlets and the defrost outlets. The
recirculation button will not work in this mode.
10. Selection between Floor/Defrost Mode and
Defrost Mode: Directs 75 percent of the airflow
through the defrost outlets and 25 percent
through the floor outlets. The recirculation button
will not work in this mode.
11. Defrost Mode: Directs all airflow through the
defrost outlets. The recirculation button will not
work in this mode.
Temperature Control Switch
The temperature control switch is used to select the
desired temperature. Turn the switch to the left
(counterclockwise) for cool air, or to the right (clockwise) for hot air. There are 21 positions on the temperature control switch ranging from full cool air to
full hot air.
Fresh Air Mode
Fresh air, or outside air, is circulated through the
heating and air conditioning system unless the recirculation mode, if equipped, is turned on.
7.3
Recirculation Mode
frost mode
When the recirculation mode is turned on, it will stay
on for 20 minutes, or until the recirculation button is
pressed again, or the air selection switch is turned to
a defrost mode.
IMPORTANT: The system will enter a partial recirculation mode for five minutes after being in
full recirculation mode for twenty minutes. This
cycle will repeat as long as the system is in recirculation mode.
Defrosting
Before using any of the defrost modes, clear the
screen at the base of the windshield of any ice or
snow.
Air Conditioning, Optional
The four air conditioning settings on the air selection
switch, as well as the selection between the air conditioning bi-level mode and the face mode, are blue.
NOTE: The heating and air conditioning system
has a brushless blower motor with a protection
or shutdown mode to prevent damage due to
overheating and overcurrent conditions. If the
brushless blower motor goes into protection
mode, the motor will operate at a slower speed.
If the overheating or overcurrent condition continues, the motor will shut down and stop completely.
Climate Control
The motor will resume proper operation after the
motor has cooled or the overcurrent condition
has been resolved. It will be necessary to cycle
the fan switch off and then on, to reset the
motor. If the problem appears repeatedly, take
the vehicle to a Freightliner dealer or authorized
service outlet for repairs.
Accessory Heaters
Optional accessary heaters are available from the
factory in several configurations. Familiarize yourself
with the equipment on your specific vehicle, and follow the manufacturer’s operating and maintenance
instructions.
WARNING
Do not operate fuel-operated heaters in an area
where flammable vapors, including gasoline or
diesel fumes, are present, such as at filling stations and tank farms. Turn off a fuel-operated
heater and allow it shut down completely before
entering an area where flammable gases or liquids are present. Heaters continue to operate for
up to three minutes after being turned off.
Failure to observe these precautions could cause
an explosion or fire, resulting in serious property
damage, and personal injury or death.
7.4
8
Cab Features
Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Mirrors and Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Cab Features
Cab Amenities
The center storage console may also be equipped
with an optional printer top with a paper slot in it.
See Fig. 8.2.
Cup Holders
There are two cup holders molded into the lower part
of the auxiliary dash panel, one on either side of the
climate control panel.
1
Cab Storage
There are storage bins in the dash and the overhead
console.
2
Vehicles without an overhead console have two storage bins located above the windshield.
Some vehicles equipped with an overhead console
may have a storage bin located in the overhead console. Those that don’t have a storage bin in the overhead console will have a CB radio in its place.
3
On vehicles with individual driver’s and passenger’s
seats, a center storage console can be installed between the seats.
10/08/2001
The center storage console has a table top that can
be lifted to deploy a writing surface. See Fig. 8.1.
1. Printer Top
2. Printer/Paper Area
f680025
3. Storage Console Base
Fig. 8.2, Center Storage Console (printer option)
Mirrors and Windows
Mirrors
1
The standard outside mirrors are mounted on the
door frame. There is a primary rear view mirror and a
convex mirror.
2
Mirror Heat Switch, Optional
3
One or both outside door mirrors can be heated to
keep them clear of fog, frost, and ice.
To heat the mirrors, press the upper part of the mirror heat switch (MIRR HEAT) on the dash. See
Fig. 8.3. When the mirror heat switch is on, an
amber indicator light illuminates inside the switch.
4
Power Mirrors, Optional
10/08/2001
1. Table Top
2. Storage Console
Cover
f680026
3. Storage Area
4. Storage Console Base
Fig. 8.1, Center Storage Console (with writing surface)
8.1
The main outside mirrors, if heated, can be equipped
with an electrical remote control located on the
driver’s door. See Fig. 8.4.
Cab Features
MIRR
HEAT
10/09/2001
1
f610524
To heat the mirrors, press up on the switch. To turn off
heat to the mirrors, press down on the switch.
f720396
10/05/2001
1. Mirror
Fig. 8.3, Mirror Heat Switch
Fig. 8.5, Down View Mirror (optional)
2
Windows
Standard windows operate mechanically using a
hand crank.
1
10/05/2001
f610523
Power windows are optional, and can be installed on
one side or both sides. One power window switch
will be installed on the dash for each window. See
Fig. 8.6. To raise the window, press up on the
switch. To lower the window, press down on the
switch. Releasing the switch will cause the window to
stop.
To adjust the mirror position, press the keypad on the
door in the direction you want the mirror to move.
1. Mirror Select Switch
2. Keypad
Fig. 8.4, Power Mirror Switch Pad
To select the mirrors on the left-hand side, press the
left side of the mirror select switch. To select the mirrors on the right-hand side, press the right side of the
mirror select switch.
The keypad has four arrow keys, pointing up, down,
left, and right. To adjust mirror position, press the
keypad in the direction you want the mirror to move.
10/09/2001
Down View Mirror, Optional
Press up to raise the window; press down to lower the
window. Releasing the switch causes the window to stop.
A down view mirror can be installed on the top of the
passenger door frame to allow the driver a view of
the area adjacent to the right side of the cab. See
Fig. 8.5.
f610522
Fig. 8.6, Power Window Switch
Standard vent (wing) windows do not open. Operating vent windows are optional. To open the operating
vent window, turn the latch on the window and push
the window open. See Fig. 8.7.
8.2
Cab Features
1
2
f670096
10/05/2001
1. Latch
2. Vent Window
Fig. 8.7, Operating Vent Window (optional)
8.3
9
Engine Starting, Operation,
and Shutdown
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Engine Starting, Operation, and Shutdown
Engine Starting
This engine chapter is to serve as a guide for best
practices only. Each make and model engine may
have operating characteristics that are unique to that
particular engine, and will be documented in the engine manufacturer’s literature. Always refer to specific
instructions and recommendations from the engine
manufacturer.
NOTE: Before starting the engine, read Chapter 4 for detailed information on how to read the
instruments and see Chapter 5 for detailed information on how to operate the controls. Read
the operating instructions in the manufacturer’s
engine operation manual before starting the
engine.
07/19/2006
Fig. 9.1, Ignition Switch
During cold conditions, the WAIT TO START
lamp may illuminate on vehicles with Cummins
engines. Wait until the lamp goes out before
turning the ignition key to START.
WARNING
Never pour fuel or other flammable liquid into the
air inlet opening in the air intake in an attempt to
start the vehicle. This could result in a flash fire
causing serious personal injury or property
damage.
NOTE: The length of time the WAIT TO START
lamp remains illuminated depends on the ambient temperature. The lower the ambient temperature, the longer the lamp will be illuminated.
NOTE: The engine electronics supply the correct amount of fuel for starting the engine. Accelerator pedal pressure is unnecessary, and
could interfere with engine starting.
1.
Before engine start-up, complete the engine pretrip and post-trip inspections and maintenance
procedures in Chapter 20 and Chapter 21.
2.
Set the parking brake.
3.
For manual transmissions, place the transmission in neutral and fully depress the clutch pedal.
Do not depress the accelerator pedal.
5.
For automatic transmissions, put the transmission in neutral. Do depress the accelerator pedal.
6.
4.
9.1
Turn the ignition switch to the ON position. See
Fig. 9.1. Electronic gauges on the instrumentation control unit (ICU) will complete a full sweep
of their dials, the warning and indicator lamps will
illuminate, and the buzzer will sound for three
seconds.
Turn the ignition key to the START position. Do
not depress the accelerator pedal.
Release the key the moment the engine starts.
Apply load gradually during the warm-up period.
NOTICE
NOTICE
If the warning lights stay on, or do not come on
momentarily after turning on the ignition, do not
operate the engine. To do so may result in engine
damage.
f610805
Do not rev the engine if the oil pressure gauge
indicates no oil pressure. Shut down the engine
within approximately ten seconds to avoid engine
damage.
7.
Check the oil pressure gauge for any drop in lubricating oil pressure or mechanical malfunction
in the lubricating oil system.
Cold-Weather Starting
See the engine manufacturer’s operation manual for
starting aids that are approved for specific engines.
Engine Starting, Operation, and Shutdown
Starting After Extended Shutdown
Before engine start-up, complete the engine pretrip
and post-trip inspections and maintenance procedures in Chapter 20 and Chapter 21.
NOTICE
Failure to eliminate water-diluted lubricating oil
may lead to serious engine damage at startup.
An engine in storage for an extended period of time
(over winter, for example) may accumulate water in
the oil pan through normal condensation of moisture
on the internal surfaces of the engine. Oil diluted by
water cannot provide adequate bearing protection at
start-up. For this reason, change the engine oil and
filters after extended storage.
Engine Operation
Safety and Environmental
Considerations
All Freightliner diesel engines comply with the requirements of the Federal (U.S.) Clean Air Act. Once
an engine is placed in service, the responsibility for
meeting both state and local regulations is with the
owner/operator.
NOTICE
It is extremely important that the following guidelines be followed for engines that comply with
EPA10 or newer regulations, or damage may
occur to the aftertreatment device, and the warranty may be compromised.
• Use ultralow-sulfur diesel with 15 ppm sul-
fur content or less.
• Do not use fuel blended with used engine
lube oil or kerosene.
• Use only engine lube oil with a sulfated ash
level less than 1.0 wt%; currently referred
to as CJ-4 oil.
Adequate maintenance of the engine and the diesel
particulate filter (DPF) are the responsibility of the
owner/operator, and are essential to keep the emission levels low. Good operating practices, regular
maintenance, and correct adjustments are factors
that will help keep emissions within the regulations.
The driver should be familiar with the vehicle warning
system in order to bring the vehicle to a safe stop if
the engine malfunctions. If the driver doesn’t understand how the warning system works, an engine
shutdown could occur, causing a safety hazard. See
Chapter 10 for more information.
Engine Break-In
Each engine must pass a full-load operating test on
a dynamometer before shipment, thereby eliminating
the need for a break-in. Before running the engine
for the first time, follow the instructions in the engine
manufacturer’s operation manual specific to your
engine.
Normal Operation
WARNING
Do not operate the engine in an area where flammable vapors such as gasoline or diesel fumes
are present. Shut off the engine when in an area
where flammable liquids or gases are being
handled. Failure to observe these precautions
could result in serious injury or death.
Every engine has an operating range in which it performs most efficiently. The operating range extends
from maximum torque rpm at the low end, to engine
rated speed at the high end. Most engines deliver
best fuel economy when operated in the low- and
mid-speed segments of the efficiency range and produce maximum horsepower at rated speed, which is
also the recommended maximum speed of the engine. For further engine-specific information, refer to
the engine manufacturer’s operation manual.
Prolonged idling of engines is not recommended, and
is illegal in some states. Idling produces sulfuric acid,
that is absorbed by the lubricating oil, and eats into
bearings, rings, valve stems, and engine surfaces. If
you must idle the engine for cab heat or cooling, use
the high idle function of the cruise control switches.
An idle speed of 900 rpm should be enough to provide cab heat in above freezing ambient temperatures.
If the engine is programmed with the idle shutdown
timer, ninety seconds before the preset shutdown
time, the CHECK ENGINE light will begin to flash at
a rapid rate. If the position of the clutch pedal or service brake changes during this final ninety seconds
the idle shutdown timer will be disabled until reset.
9.2
Engine Starting, Operation, and Shutdown
Cold-Weather Operation
Satisfactory performance of a diesel engine operating
in low ambient temperatures requires modification of
the engine, surrounding equipment, operating practices, and maintenance procedures. The lower the
temperature, the greater the amount of modification
required. For service products approved for use in
cold weather for your engine, see the engine manufacturer’s engine operation manual, supplied in the
vehicle documentation package.
If satisfactory engine temperature is not maintained,
maintenance costs will increase due to greater engine wear. If the engine coolant temperature becomes too low, raw fuel will wash the lubricating oil
off the cylinder walls and dilute the crankcase oil,
causing all moving parts of the engine to suffer from
poor lubrication.
If the engine is in good mechanical condition and the
precautions necessary for cold-weather operation are
taken, ordinary cold weather will not cause difficulty
in starting or loss of efficiency.
The following points are important to observe when
operating in cold weather:
• Check for cracks in the batteries, for corrosion
of the terminals, and for tightness of the cable
clamps at the terminals.
when the ambient temperature remains below 10°F
(-12°C).
Engine Shutdown
1.
NOTICE
Idle the engine one to two minutes before shutting it down. After hard operation, shutting down
the engine without idling may cause damage to
the turbocharger.
2.
NOTICE
any battery that is damaged.
after the engine is shut down, to prevent battery discharge.
• Have the alternator output checked at an au-
thorized service provider.
• Check the condition and tension of the drive
belts.
• Refer to the engine manufacturer’s engine op-
eration manual for recommended heaters, lowviscosity lubricating oils, wintergrade fuels, and
approved coolants.
A winterfront may be used to improve cab heating
while idling. If a winterfront is used, at least 25% of
the grille opening should remain open in sectioned
stripes that run perpendicular to the charge air cooler
tube-flow direction. This assures even cooling across
each tube, and reduces header to tube stress, and
possible failure. Winterfronts should only be used
9.3
Allow the engine to idle one to two minutes before shutting it down. This allows the lubricating
oil and the coolant to carry heat away from the
combustion chambers, bearings, shafts, and
seals. The extreme heat may cause bearings to
seize or oil seals to leak.
IMPORTANT: Bearings and seals in the turbocharger are subjected to the high heat of combustion exhaust gases. While the engine is running, this heat is carried away by oil circulation,
but if the engine is stopped suddenly, the turbocharger temperature may rise as much as 115°F
(46°C).
• Charge the batteries to full capacity. Replace
• If equipped, turn off the load disconnect switch
With the vehicle stopped, apply the parking
brake and place the transmission in neutral.
Except in an emergency, do not shut down the
engine when the coolant temperature is above
194°F (90°C). To do so could damage the engine.
3.
Turn off the ignition switch and shut down the
engine.
10
Optional Engine Systems
Engine Protection—Warning and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Braking Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1
10.2
10.2
10.3
10.6
Optional Engine Systems
Engine Protection—Warning
and Shutdown
The driver should be familiar with the vehicle warning
system in order to bring the vehicle to a safe stop if
the engine malfunctions. If the driver doesn’t understand how the warning system works, an engine
shutdown could occur.
The engine will begin a warning and shutdown process if the engine coolant temperature, coolant level,
engine oil pressure, or exhaust aftertreatment system
(ATS) reach preset levels. On some engines, the engine will also begin the warning and shutdown process when the engine oil temperature or the intake
air temperature reach preset levels. Detroit Diesel
engines will also begin the warning and shutdown
process if water is detected in the fuel.
See the engine manufacturer’s operation manual for
specific details for your vehicle.
See Chapter 11 in this manual for the warning and
shutdown modes associated with the ATS.
Electronic engine protection is programmable as an
option, and can be specified as the following: DERATE and SHUTDOWN mode (factory default),
WARNING mode, or OFF mode.
WARNING
When the red STOP engine or engine protection
light illuminates, most engines are programmed
to shut down automatically within 30 seconds.
The driver must immediately move the vehicle to
a safe location at the side of the road to prevent
causing a hazardous situation that could cause
bodily injury, property damage, or severe damage
to the engine.
In the DERATE and SHUTDOWN mode, the red
STOP engine lamp will illuminate when the problem
is serious enough to reduce power or speed. See
Fig. 10.1. Engine power will ramp down, then the
engine will shut down if the problem continues. The
driver has 30 seconds or 60 seconds (depending on
the critical fault type) after the STOP engine lamp
illuminates to move the vehicle safely off the road. If
the vehicle cannot be moved to a safe location within
that time, the engine can be restarted by turning the
ignition switch to the OFF position for at least five
seconds, then back ON. Repeat this action until the
vehicle is safely off the road.
10.1
CHECK
07/09/2009
1
1. Malfunction Indicator
Lamp (MIL)
STOP
2
3
f611036
2. CHECK Engine Lamp
3. STOP Engine Lamp
Fig. 10.1, Engine Warning Lights
Some vehicles may have a shutdown-override
switch, which may be used to momentarily override
the shutdown sequence. See Fig. 10.2. This switch
resets the shutdown timer, restoring power to the
level before the derate for another 30 or 60 seconds
(depending on the critical fault type). The switch
must be pressed again after 5 seconds to obtain a
subsequent override. It can be used to move the vehicle to a safe stopping area. Do not operate the vehicle further until the problem has been corrected.
If the engine protection parameters are set to
WARNING mode, the amber CHECK engine lamp
will flash and a buzzer will sound. The engine electronics log the event for diagnostic purposes. The
CHECK engine lamp will go out if the problem stops.
If the engine protection parameters are set to OFF
mode, the individual sensor indicator lamps will illuminate if a problem exists, but no shutdown action
will be started and the event will not be recorded.
f611040
08/13/2009
Fig. 10.2, Shutdown Override Switch
Optional Engine Systems
Engine Idle Limiting
Cruise Control
Idle Shutdown Timer
This feature is an optional 1- to 100-minute idle shutdown system. Its purpose is to conserve fuel by
eliminating excessive idling and allowing a turbocharger cool-down period. Idle shutdown timing and
parameters are programmable. See the engine
manufacturer’s operation manual for specific details
for your vehicle.
California Engine Idle Limiting
In order to meet the California Air Resources Board
(CARB) engine idle limiting standard, an engine idle
shutdown feature has been included in engine control strategy. When the CARB engine idle limiting feature is enabled, the engine will generally shut down
after five minutes of continuous idling when the
transmission is in neutral or park and the parking
brake is set. It will also shut down after fifteen minutes when the transmission is in neutral or park, with
the parking brake off. See the engine manufacturer’s
operation manual for specific details for your vehicle.
WARNING
Do not use the cruise control system when driving conditions do not permit maintaining a constant speed, such as in heavy traffic or on roads
that are winding, icy, snow-covered, slippery, or
roads with a loose driving surface. Failure to follow this precaution could cause a collision or
loss of vehicle control, possibly resulting in personal injury or property damage.
NOTICE
When the cruise control is engaged, do not attempt to shift gears without using the clutch
pedal. Failure to follow this precaution will result
in a temporarily uncontrolled increase in engine
speed. Transmission damage and gear stripping
could result.
Cruise control is activated by two dash-mounted
switches (Fig. 10.3).
After an automatic shutdown, the engine may be restarted and operated normally.
• On/Off Switch—this two-position rocker is la-
Activating or momentarily changing the position of
the brake pedal, clutch pedal, accelerator pedal,
stop-engine override switch, or parking brake during
the final thirty seconds will cause the shutdown timer
to reset, and will prevent the engine from shutting
down.
• Set/Resume Switch—this three-position paddle
The automatic shutdown feature is required on all
California-certified engines (with the exception of engines used in specific vehicle types that the state of
California has determined to be exempt from the requirement). Owners that wish to have the shutdown
feature disabled on vehicles operating in California
should consult with California authorities to determine
if their vehicle qualifies for the exemption.
beled SPD CNTL on the lower half of the
switch. When cruise control is on, an amber
light illuminates the top part of the switch.
switch is labeled RES/ACC above the paddle
and SET/CST below the paddle.
1.
2.
The automatic shutdown feature is generally disabled
on engines certified by the U.S. EPA for use outside
of California.
To cruise at a particular speed:
1.1
Press the upper half of the On/Off switch.
1.2
Hold the accelerator pedal down until the
speedometer reaches the desired speed.
1.3
Momentarily lower the paddle of the Set/
Resume switch to SET/CST.
To disengage the cruise control:
2.1
Depress the brake pedal (on an automatic
or manual transmission) or
Depress the clutch pedal (on a manual
transmission only).
2.2
3.
Press the lower half of the On/Off switch.
To resume a preselected cruise speed:
3.1
Ensure the On/Off switch is on.
10.2
Optional Engine Systems
until the vehicle accelerates to the desired
speed.
5.
1
To decrease cruise speed, lower and the paddle
of the Set/Resume switch to SET/CST until the
vehicle decelerates to the desired speed.
Auxiliary Braking Applications
Engine Brake
Each engine manufacturer uses a specific engine
brake for their engine. Regardless of the manufacturer, the engine brake is operated with the principles
outlined in this chapter. Refer to the engine manufacturer’s operation manual for details of their particular
engine brake product.
2
WARNING
f610510
09/13/2001
To turn cruise control on, press the upper half of the On/
Off switch. To turn cruise control off, press the lower half
of the On/Off switch.
To increase cruise speed, raise and hold the paddle of
the Set/Resume switch to RES/ACC until the vehicle
accelerates to the desired speed. To decrease cruise
speed, lower and the paddle of the Set/Resume switch to
SET/CST until the vehicle decelerates to the desired
speed.
1. Cruise Control On/Off Switch
2. Cruise Control Set/Resume Switch
Fig. 10.3, Cruise Control Switches
3.2
Momentarily raise the paddle of the Set/
Resume switch to RES/ACC. Cruise will
return to the last speed selected.
NOTE: When the vehicle speed drops below
the minimum cruise control speed, cruise
control will disengage. To resume to the preselected cruise speed, increase vehicle
speed to above minimum cruise control
speed and momentarily raise the paddled of
the Set/Resume switch to RES/ACC.
NOTE: The speed memory is lost whenever the
ignition is turned off or the cruise control switch
is toggled to Off.
4.
10.3
To increase cruise speed, raise and hold the
paddle of the Set/Resume switch to RES/ACC
To avoid injury from loss of vehicle control, do
not activate the engine brake system under the
following conditions:
• on wet or slippery pavement, unless the
vehicle is equipped with antilock braking
system (ABS) and you have had prior experience driving under these conditions;
• when driving without a trailer or pulling an
empty trailer;
• if the tractor drive wheels begin to lock, or
there is fishtail motion after the engine
brake is activated.
Whenever vehicle braking is required on good road
conditions, the engine brake may be used in conjunction with the service brakes. There is no time
limit for operation of the engine brake. However, an
engine brake does not provide the precise control of,
and is not a substitute for, service brakes.
WARNING
Usage of the engine brake as the primary braking
system can cause unpredictable stopping distances, that could result in personal injury or
property damage. Service brakes are the primary
vehicle braking system.
Two dash-mounted switches control the engine
brake:
Optional Engine Systems
• The On/Off switch (ENG BRK), is used to turn
the engine brake on and off. See Fig. 10.4.
When the engine brake is on, an amber light
will illuminate behind the switch.
• The engine brake intensity switch (HI/MED/LO
or, in some cases, HI/LO) controls the amount
of engine braking. When the panel lights are
on, the ENG BRK legend is backlit in green.
1
2
For slower descent, select a lower gear, being careful not to overspeed the engine. Occasional deactivation of the engine brake may be necessary to maintain the designated road speed under these
conditions.
If the engine is equipped with both cruise control and
an engine brake, the engine brake can operate automatically while in cruise control mode. If the cruise
control/engine brake function is turned on in the
DDEC VI system programming, the engine brake will
come on low when the set road speed increases a
few miles-per-hour (kilometers-per-hour) above the
cruise set speed. The maximum amount of braking is
selected with the dash switches. When the vehicle
returns to the set cruise speed, the engine brake will
turn off.
The engine brake will only operate when the accelerator pedal is fully released. Depressing the clutch
will also prevent the engine brake from operating.
f610588
10/17/2001
1. Engine Brake On/Off
2. Engine Brake Intensity Switch
Fig. 10.4, Engine Brake Switches
Since the engine brake is most effective at rated engine speed, gear selection is very important. Gearing
down the vehicle within the limits of the rated engine
speed makes the engine brake more effective. Recommended engine braking speed is above 1800 rpm
and below the rated speed.
WARNING
The engine brake must be disengaged when
shifting gears using the clutch pedal. If the engine brake is engaged when the transmission is
in neutral, the braking power of the engine brake
can stall the engine, which could result in loss of
vehicle control, possibly causing personal injury
and property damage.
"Control speed" is the speed at which the engine
brake performs 100 percent of the required downhill
braking, resulting in a constant speed of descent.
The control speed varies, depending on vehicle
weight and the downhill grade.
For faster descent, select a higher gear than that
used for control speed. Service brakes must then be
used intermittently to prevent engine overspeed and
to maintain desired vehicle speed.
Vehicles equipped with ABS have the ability to turn
the engine brake off if wheel slip is detected. The
engine brake will automatically turn back on once
wheel slip is no longer detected.
The DDEC VI system will deactivate the engine
brake when the engine speed falls below 1000 rpm
or when the vehicle slows down to a preset speed,
depending on DDEC programming. This prevents
stalling the engine.
Engine Brake Operation
Depending on the brake type, the engine brake may
be disabled when engine temperature falls below a
set level.
NOTICE
Do not allow the engine to exceed 2500 rpm. Serious engine damage could result.
To activate the engine brake after the engine is
warmed up and the vehicle is in motion:
1.
Remove your feet from both the clutch and
throttle pedals.
2.
Press the On/Off switch to toggle the engine
brake on. See Fig. 10.4. The engine brake will
engage at the rate last set on the brake intensity
switch.
3.
Move the intensity switch to the desired intensity.
10.4
Optional Engine Systems
On vehicles with a HI/MED/LO intensity switch,
LO will provide 1/3 of the full braking capacity of
the engine, MED will provide 2/3 of the full braking capacity, and HI will provide maximum engine
braking. On vehicles with a HI/LO intensity
switch, LO will provide ½ of the full braking capacity of the engine; HI will provide maximum
engine braking.
4.
Use the intensity switch set at the LO position
when driving on flat, open stretches of road. If
the service brakes are still required to slow down
on a grade, switch to a higher setting on the
dash switch until there is no need for the service
brakes. Grade descent speed should be such
that the service brakes are used infrequently and
remain cool, thus retaining their effectiveness.
5.
For maximum retarding, maintain the top governed speed of the engine through the appropriate selection of gears. When shifting gears, the
engine brake will disengage when the clutch
pedal is depressed, then engage when the clutch
pedal is released.
6.
To cancel the engine brake application, toggle
the On/Off to off.
Exhaust Brake, Cummins Engines
An exhaust brake is an optional auxiliary braking system that assists but does not replace the service
brake system. The exhaust brake may be used in
conjunction with the service brakes in off-highway
and mountain driving as well as in traffic or highspeed highway driving. Exhaust brakes are not intended for use as the primary braking system during
vehicle operation.
The exhaust brake is controlled by a dash-mounted
rocker switch. See Fig. 10.5 or Fig. 10.6.
To turn the exhaust brake on, press the upper part of
the rocker. When the exhaust brake is on, an amber
light illuminates behind the switch. When the panel
lights are on, the EXHST BRK legend is backlit in
green.
The exhaust brake turns itself off automatically. In
addition, depressing the accelerator or clutch pedal
deactivates the exhaust brake. The ABS, when active, also deactivates the exhaust brake.
10.5
11/28/2001
f610589
Fig. 10.5, Exhaust Brake Switch
03/31/2009
f610589a
Fig. 10.6, Exhaust Brake Switch
Exhaust Brake Operation
WARNING
Do not use the exhaust brake when driving on
slippery or low-traction road surfaces. Failure to
follow this precaution could result in a loss of
vehicle control and possible personal injury or
property damage.
1.
Before starting the engine, make sure that the
exhaust brake is off. Wait until the engine has
reached normal operating temperature to turn on
the exhaust brake.
2.
When approaching a downhill grade, press the
upper half of the exhaust brake switch to turn the
exhaust brake on. When the exhaust brake is on,
an amber light will illuminate behind the switch.
3.
Remove your feet from the accelerator and
clutch pedals.
Optional Engine Systems
NOTICE
Power Takeoff (PTO) Governor
NOTE: The exhaust brake is only active when
engine speed is between 1100 and 2700 rpm.
Engine power takeoffs (PTO) are devices used to tap
into engine power to run auxiliary devices, such as
hydraulic pumps that power additional equipment.
The following instructions are general guidelines for
operating a PTO.
4.
1.
Set the parking brake and put the transmission in
neutral.
2.
Press the dash-mounted PTO switch. Release
the switch when the amber light behind the
switch begins to blink.
Do not allow the engine to exceed its governed
speed, or serious engine damage could result.
While going down the grade, use a low enough
gear to safely descend with a minimum application of the service brakes. As a general guideline, use the same gear as you would to ascend
the hill.
The following conditions should exist if the brake
is operating properly:
When the light is steadily illuminated, the PTO is
engaged and ready to operate. In stationary
mode, the vehicle must remain in neutral with the
parking brake set.
• A slight change in the sound of the engine
may be noticed when the exhaust brake is
applied.
3.
To activate the mobile mode, shift from neutral to
reverse, 1st, or 2nd gear. The clutch will open
and the PTO will disengage for a moment.
4.
Touch the throttle pedal to close the clutch and
engage the PTO in mobile mode. The PTO may
be operated with the transmission in reverse,
neutral, 1st, or 2nd gears only.
• Exhaust smoke should appear normal.
• Engine temperature should remain in the
normal operating range.
• Road speed usually decreases when the
exhaust brake is applied during a descent.
When the vehicle is carrying a heavy load
or the grade is extremely steep, you may
need to apply the service brakes occasionally.
• Do not expect a retarding effect similar to
sudden hard application of the service
brakes. The exhaust brake retards the vehicle with a smooth braking effect.
NOTE: Do not attempt to change gears while
the vehicle is moving. The transmission will ignore the request.
5.
To end the mobile mode, bring the vehicle to a
stop. The clutch will open and shut down power
to the PTO.
6.
To resume stationary mode, shift to neutral. The
PTO will engage.
7.
To end stationary mode, press the dash switch.
When the light in the switch goes out, power to
the PTO is shut off.
• During a descent, the tachometer usually
shows a drop in rpm, depending on the
grade and the vehicle load.
• Depending on the grade and vehicle load,
you may or may not feel the retarding force
acting against your body when the brake is
applied. The retarding force of the brake
may not always be noticed, but it is actually preventing the vehicle from going
much faster.
5.
Apply the service brakes to reduce the engine
rpm or make a slower descent by using a lower
gear.
6.
Make sure the exhaust brake is turned off before
shutting down the engine.
10.6
11
Emissions and Fuel
Efficiency
Greenhouse Gas Emissions and Fuel Consumption Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
EPA-Regulated Emissions Aftertreatment System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Diesel Exhaust Fluid and Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Emissions and Fuel Efficiency
Greenhouse Gas Emissions
and Fuel Consumption
Standards
example, using CJ-4+ oil with 1.3% sulfated ash
(30% more ash content) may result in the need
for DPF cleaning or replacement 20 to 30%
sooner than would normally be required.
Vehicles and/or engines manufactured after December 31, 2006 and domiciled in the U.S. or Canada
are required to meet all EPA and NHTSA regulations
effective as of the vehicle build date. Engines manufactured between January 1, 2010 and December 31,
2012 meet EPA10 requirements. Engines manufactured from January 1, 2013 meet NHTSA and EPA
2014 fuel efficiency and greenhouse gas emission
standards (GHG14) requirements.
IMPORTANT: See the engine manufacturer’s
operation manual for complete details and operation of the ATS.
Model year 2013 and later vehicles meet additional
requirements as specified by GHG14 requirements.
These vehicles are equipped with components that
increase fuel efficiency and reduce GHG emissions.
Components may include, but are not limited to, lowrolling resistance tires; aerodynamic devices such as
hood, cab/sleeper extenders, and fuel tank fairings;
vehicle speed limiter; and idle shutdown timer. If replacement of any drag-reducing component is required, the replacement component must meet or
exceed the drag reduction performance of the originally installed component in order to maintain compliance with GHG14 requirements.
EPA-Regulated Emissions
Aftertreatment System
NOTICE
It is extremely important that the guidelines
below are followed for engines that comply with
EPA10 and newer regulations, or damage may
occur to the aftertreatment device, and the warranty may be compromised.
• Use ultralow-sulfur diesel with 15 ppm sul-
fur content or less.
• Do not use fuel blended with used engine
lube oil or kerosene.
• Use only engine lube oil with a sulfated ash
level less than 1.0 wt%; currently referred
to as CJ-4 oil.
IMPORTANT: Using non-specification fuels or
oils can lead to shortened diesel particulate filter
(DPF) cleaning or replacement intervals. For
11.1
The EPA mandates that all engines built after December 31, 2009 must reduce the level of emissions
exhausted 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 compliant
with EPA10 and newer regulations use technology
known as selective catalytic reduction (SCR) in the
exhaust aftertreatment system (ATS). The ATS includes an aftertreatment device (ATD), with the addition of SCR to reduce NOx downstream of the engine. The SCR process requires the introduction of
diesel exhaust fluid (DEF) into the exhaust stream.
After exhaust gases leave the engine, they flow into
the ATS. First they flow into a two-part ATD, comprised of a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). The DPF traps soot particles, then exhaust heat converts the soot to ash, in
a process called regeneration (regen). After exhaust
gases leave the DPF, a controlled quantity of diesel
exhaust fluid (DEF) is injected into the exhaust
stream. In the presence of heat, DEF is converted to
ammonia gas, which reacts with NOx in the selective
catalyst chamber to yield nitrogen and water vapor,
which exit through the tailpipe.
Regeneration
The harder an engine works, the better it disposes of
soot. If the exhaust temperature is high enough, a
process called passive regeneration (regen) occurs
as the vehicle is driven normally. However, if the engine isn’t running hot enough, the electronic controls
may initiate an active regen, whereby extra fuel is
injected into the exhaust stream to superheat and
reduce the soot trapped in the DPF to ash. Active
regen happens only when the vehicle is moving
above a certain speed, determined by the engine
manufacturer. See your engine operation manual for
complete details. Both active and passive regen happen automatically, without driver input.
Emissions and Fuel Efficiency
WARNING
Active regeneration can occur automatically anytime the vehicle is moving. The exhaust gas temperature could reach 1500°F (800°C), which is hot
enough to cause a fire, heat damage to objects
or materials, or personal injury to persons near
the exhaust outlet. The exhaust temperature can
remain high even after the vehicle has stopped.
When stopping the vehicle shortly after an automatic regen, ensure the exhaust outlets are directed away from structures, trees, vegetation,
flammable materials, and anything else that may
be damaged or injured by exposure to high heat.
RGEN
f610848
03/09/2012
Fig. 11.1, Regen Request Switch
See Regen Switches, below, for instructions on
preventing automatic regen if necessary.
When operating conditions do not allow for ATD filter
cleaning by active or passive regen, the vehicle may
require a driver-activated parked regen. When this
occurs, the DPF lamp illuminates, indicating that a
regen is required. The driver must either bring the
vehicle up to highway speed to increase the load
(thus starting an active regen), or park the vehicle
and initiate a parked regen. See Regen Switches,
below, for instructions on initiating a parked regen.
07/30/2009
Regen Switches
The regen request switch, located on the dash, is
used to initiate a parked regen. See Fig. 11.1. The
function of the switch varies by the engine make and
model in the vehicle. See the engine operation
manual for switch operation details.
Some vehicles may be equipped with a regen
request/inhibit switch. See Fig. 11.2. To stop a regen
in progress or prevent the start of a regen, press the
lower half of the switch. Regen is then delayed until
the switch is no longer active.
NOTE: The regen switch can initiate a parked
regen only when the DPF lamp is illuminated.
Fig. 11.2, Regen Request/Inhibit Switch
structures, trees, vegetation, flammable materials, and anything else that may be damaged or
injured by prolonged exposure to high heat.
To initiate a parked regen, perform the following
steps.
1.
Park the vehicle away from all flammable materials, put the transmission in neutral, and set the
parking brake.
2.
Start and warm the engine until the coolant temperature is at least 150°F (66°C).
3.
Lift the regen request switch guard and press
and hold the yellow button for five seconds. As
the regen process is initiated, engine rpm increases and the HEST lamp illuminates to indicate extremely high exhaust temperatures.
WARNING
During parked regen, exhaust temperatures are
very high and could cause a fire, heat damage to
objects or materials, or personal injury to persons near the exhaust outlet.
Before initiating a parked regeneration, make certain the exhaust outlets are directed away from
f610944
IMPORTANT: The driver must remain with the
vehicle during the entire regen cycle.
4.
The regen cycle will finish after 20 to 60 minutes,
at which time engine idle speed drops to normal
11.2
Emissions and Fuel Efficiency
and the vehicle can be driven normally. The
HEST lamp is extinguished when vehicle speed
exceeds 5 mph (8 km/h) or the system has
cooled to normal operating temperature.
5.
To stop a parked regen at any time during the
process:
• depress the clutch pedal, brake pedal, or
accelerator pedal;
• press and hold the regen inhibit switch until
idle returns to normal;
• shut down the engine.
ATS Warning Lamps
There are three warning lamps that alert the driver of
high exhaust temperature, the need to perform a
parked regen or service the DPF, or of an engine
fault that affects emissions. A decal attached to the
driver’s sun visor explains the ATS warning lamps.
Fig. 11.3.
See Fig. 11.4 for an explanation of the ATS warnings, and actions required to avoid engine protection
sequences.
Malfunction Indicator Lamp (MIL)
A steadily illuminated yellow malfunction indicator
lamp (MIL) indicates an engine fault that affects
emissions. See Fig. 11.5.
DPF Status Lamp
When soot accumulates in the DPF and the DPF status lamp illuminates, see Fig. 11.6, perform a parked
regen or bring the vehicle up to highway speed to
increase the load (thus starting an active regen).
If the DPF status lamp blinks while the CHECK engine lamp is illuminated, initiate a parked regen immediately in order to prevent an engine derate.
If the red STOP engine lamp illuminates with the
blinking DPF lamp and the CHECK engine lamp,
begin a parked regen in order to prevent an engine
shutdown. Park the vehicle and perform a parked
regen.
High Exhaust System Temperature
(HEST) Lamp
Slow (10-second) flashing of the high exhaust system temperature (HEST) lamp indicates that a
11.3
parked regen is in progress, and the engine’s high
idle speed is being controlled by the engine software,
not the vehicle driver.
Steady illumination of the HEST lamp alerts the
driver of high exhaust temperature during the regen
process if the vehicle speed is below 5 mph (8 km/
h), or during a parked regen. See Fig. 11.7.
DPF Maintenance
Eventually ash will accumulate in the DPF and the
filter will require servicing. DPF servicing must be
performed by an authorized technician, following the
engine manufacturer’s instructions. A record must be
maintained for warranty purposes, that includes:
• date of cleaning or replacement;
• vehicle mileage;
• particulate filter part number and serial number.
Diesel Exhaust Fluid and Tank
Diesel Exhaust Fluid
Diesel exhaust fluid (DEF) is used in the ATS to
lower NOx in the exhaust stream. DEF is colorless
and close to odorless (it may have a slightly pungent
odor similar to ammonia). It is nontoxic, nonflammable, and biodegradable. It is mildly corrosive to
aluminum, but does not affect the strength or structure of the aluminum.
White crystals may be noticeable around components that come into contact with DEF. The crystals
are easily removed with water.
DEF consumption varies depending on ambient conditions and vehicle application.
Freezing Conditions
DEF freezes to slush at around 12°F (-11°C). It is not
damaged or destroyed if frozen, and is fully usable
when thawed. The DEF in the tank is allowed to
freeze while a vehicle is non-operational. At start-up,
normal operation of the vehicle is not inhibited if the
DEF is frozen; an immersion heater with engine coolant flowing through it warms the DEF once the engine is running, allowing the SCR system to operate.
Pre-2013 DEF supply lines are electrically-heated
and are purged when the engine is shut down; complete purging of the DEF lines requires approximately
five minutes after the engine is shut down.
Emissions and Fuel Efficiency
IMPORTANT
DPF Regen Needed
1
2
Diesel Particulate Filter (DPF)
regeneration is needed.
If flashing, regenerate as soon as
possible. Engine derate possible.
Hot exhaust can cause fire.
Hot Exhaust
Keep flammables and people away
from exhaust.
3
DEF Refill Needed
DEF
Diesel Exhaust Fluid (DEF) level is
low. Engine derate likely.
Refill tank with certified DEF.
See operator’s manual for complete instructions.
11/30/2010
24−01656−000
f080161
Fig. 11.3, Warning Lamp Decal, Sun Visor
DEF supply lines with engine model year 2013 and
newer are designed to survive freezing conditions
while containing DEF, so purging is not required.
DEF Tank
Engines that are compliant with EPA10 and newer
regulations are equipped with a DEF tank located on
the driver’s side of the vehicle behind the battery box
or forward of the fuel tank. See Fig. 11.8 and
Fig. 11.9. The DEF tank has a 19 mm filler neck inlet
that prevents the hose from a diesel outlet from
being inserted, and has a blue cap for easy
identification.
Fuel/DEF Gauge
The diesel fuel and DEF levels are measured in a
dual-purpose gauge. See Fig. 11.10.
Fuel level is indicated at the top of the gauge. Below
the fuel level, a low fuel warning lamp illuminates
amber when the fuel level drops below 1/8th of the
capacity.
The lower portion of the gauge has a DEF warning
lamp that illuminates amber when the DEF tank is
near empty, and a lightbar that indicates the level of
DEF in the tank. The DEF light bar illuminates as follows:
• Four bars illuminated green—Between 75%
and 100% full
• 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
11.4
Emissions and Fuel Efficiency
EXHAUST AFTERTREATMENT SYSTEM INFORMATION
WARNING
INDICATOR
LAMP(S)
CHECK
(Solid)
(Flashing)
Level 1
Level 2
(Flashing)
CHECK
STOP
(Flashing)
Level 3
Level 4
Indicator Lamp
Message(s)
Filter Regeneration
Recommended
Filter Regeneration
Necessary
Parked Regeneration
Required − Engine
Derate
Parked Regeneration Required −
Engine Shut Down
Diesel Particulate
Filter Condition
Filter is reaching
capacity.
Filter is now
reaching maximum
capacity.
Switch.
Filter has reached
maximum capacity.
Filter has exceeded
maximum capacity.
Required Action
Bring vehicle to
highway speeds to
allow for an Automatic
Regeneration or
perform a Parked
Regeneration.
To avoid engine
derate bring vehicle
to highway speeds
to allow for an
Automatic
Regeneration or
perform a Parked
Regeneration as
soon as possible.
Vehicle must be
parked and a Parked
Regeneration must
be performed −
engine will begin
derate.
Vehicle must be parked and a
Parked Regeneration or Service
Regeneration must be performed.
Check engine operator’s manual
for details −engine will shut down.
HEST (High Exhaust
System Temperature)
Flashing
A regeneration is in
progress.
Solid
Exhaust Components
and exhaust gas are
at high temperature.
When stationary, keep
away from people and
flammable materials
or vapors.
For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.
See Engine Operator’s Manual for complete Regeneration Instructions.
24−01583−000B
06/29/2009
f080147
Fig. 11.4, ATS Warning Lamps
09/25/2006
f610814a
Fig. 11.5, Malfunction Indicator Lamp (MIL)
DEF Warnings and Engine Limits
IMPORTANT: Ignoring the DEF warning lights
results in limited engine power, with the application of a 5 mph (8 km/h) speed limit after the
engine is shut down and started again.
DEF Level Low—Initial Warning
When the DEF level is low, the following lamps notify
the driver. See Fig. 11.11. Refill the DEF tank in
order to cancel the warning sequence.
11.5
09/25/2006
f610815a
Fig. 11.6, DPF Status Lamp
• One bar of the DEF level indicator illuminates
amber—DEF very low, refill DEF
• The DEF warning lamp illuminates solid amber
DEF Empty
When the DEF level reads empty, the following
lamps notify the drive. See Fig. 11.12.
• One bar of the DEF level indicator flashes
red—DEF empty, refill DEF
• The DEF warning lamp flashes amber
Emissions and Fuel Efficiency
09/25/2006
f610816a
Fig. 11.7, HEST Lamp
1
2
f470541
07/24/2009
1. DEF Tank
2. Fuel Tank
Fig. 11.9, DEF Tank Located Forward of the Fuel Tank
If the DEF is not refilled, a 5 mph (8 km/h) speed
limit is applied after the next engine shutdown or if a
fuel refill is detected.
DEF Contamination or SCR Tampering
NOTICE
1
2
f470542
07/24/2009
1. Batteries
2. DEF Tank
Fig. 11.8, DEF Tank Located Behind the Battery Box
• The MIL lamp illuminates
Pre-2013 Detroit engines: Power is limited, with a 55
mph (90 km/h) speed limit.
Cummins and 2013 Detroit engines: Power is limited
with progressively harsher engine power limits
applied.
DEF Tank Empty and Ignored
If the empty warning is ignored and the DEF tank is
not refilled, the red STOP engine lamp illuminates in
addition to the MIL lamp and CHECK engine lamp
(on vehicles with a Cummins ISB or ISC/L engine).
See Fig. 11.13.
Once contaminated DEF or tampering has been
detected, the vehicle must be taken to an authorized service facility to check the SCR system for
damage and to deactivate the warning lights and
engine limits.
If contaminated DEF or tampering with the ATS is
detected, the DEF warning light flashes and the MIL
lamp illuminates to warn the driver. The CHECK engine lamp also illuminates on vehicles with a Cummins ISB or ISC/L engine. See Fig. 11.13.
• Detroit engines: Engine power is limited with
progressively harsher limits applied. If the fault
is not corrected, the STOP engine light illuminates and a 5 mph (8 km/h) speed limit is applied after the next engine shutdown, while
parked and idling, or if a fuel refill is detected.
• Cummins engines: Engine power is limited with
progressively harsher limits applied. If the fault
is not corrected, the STOP engine light illuminates and a 5 mph (8 km/h) speed limit is applied after the next engine shutdown, or while
parked and idling.
11.6
Emissions and Fuel Efficiency
1/2
1/2
1/2
ULTRA LOW SULFUR
DIESEL FUEL ONLY
ULTRA LOW SULFUR
DIESEL FUEL ONLY
ULTRA LOW SULFUR
DIESEL FUEL ONLY
E
F
E
DEF
E
1
F
E
DEF
F
E
2
A
F
DEF
F
E
B
F
C
11/08/2010
f611037
A. Green bars—DEF level indicators
B. One bar illuminated amber—DEF very low, refill DEF
1. Low Fuel Warning Lamp
C. One bar flashing red—DEF empty, refill DEF
2. DEF Warning Lamp
Fig. 11.10, Fuel/DEF Gauge
A
A
B
B
07/09/2009
A. DEF Warning Lamp (illuminated)
B. DEF Lightbar (one bar amber)
Fig. 11.11, DEF Level Low Initial Warning
f470537
11/08/2010
f470539a
NOTE: MIL illuminates. CHECK engine lamp illuminates
if Cummins ISB or ISC/L engine. Engine power is limited.
A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)
Fig. 11.12, DEF Empty Warning
11.7
Emissions and Fuel Efficiency
A
B
11/08/2010
f470540a
NOTE: STOP engine light and MIL illuminate, engine
power is limited, speed limit of 5 mph (8 km/h)
A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)
Fig. 11.13, DEF Empty and Ignored Warning
11.8
12
Brake Systems
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meritor WABCO® Antilock Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enhanced Stability Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Roll Stability Advisor/Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1
12.3
12.4
12.5
Brake Systems
Air Brake System
Brake System General Information
A dual air brake system consists of two independent
air systems that use a single set of brake controls.
Each system has its own reservoirs, plumbing, and
brake chambers. The primary system operates the
service brakes on the rear axle; the secondary system operates the service brakes on the front axle.
Service brake signals from both systems are sent to
the trailer.
WARNING
Do not operate the vehicle with the front brakes
backed off or disconnected. Backing off or disconnecting the front brakes will not improve vehicle handling and may lead to loss of vehicle
control, resulting in property damage or personal
injury.
Brake System Conditions
The warning light and buzzer come on if air pressure
drops below 64 to 76 psi (441 to 524 kPa) in either
system. If this happens, check the dual system air
pressure gauge to determine which system has low
air pressure. Although the vehicle’s speed can be
reduced using the foot brake control pedal, either the
front or rear service brakes will not be operating at
full capacity, causing a longer stopping distance.
Bring the vehicle to a safe stop and have the air system repaired before continuing.
IMPORTANT: In the event of a total loss of service brakes with full system air pressure, use
the parking brake control valve (yellow knob) to
bring the vehicle to a complete stop in the safest location possible.
Before a vehicle with insufficient system air pressure
can be moved, the spring parking brakes must be
released by applying an external air source at the
gladhands, or by manually caging the parking brake
springs.
WARNING
Do not release the spring parking brakes and
then drive the vehicle. There would be no means
of stopping the vehicle, which could result in serious personal injury or vehicle damage. Before
12.1
releasing the spring parking brakes, make the
connection to a towing vehicle or chock the tires.
After correcting the brake system problem, uncage
the spring parking brakes before resuming normal
vehicle operation.
Primary Air Brake System
Loss of air pressure in the primary air system causes
the rear service brakes to become inoperative. The
secondary air system will continue to operate the
front brakes and the trailer brakes (if equipped).
Secondary Air System
Loss of air pressure in the secondary air system
causes the front axle brakes to become inoperative.
The primary air system will continue to operate the
rear service brakes and the trailer brakes (if
equipped).
Brake System Operation
Before driving your vehicle, allow time for the air
compressor to build up a minimum of 100 psi (689
kPa) pressure in both the primary and secondary
systems. Monitor the air pressure system by observing the dual system air pressure gauge and the lowair-pressure warning light and buzzer. The warning
light and buzzer shut off when air pressure in both
systems reaches 64 to 76 psi (441 to 524 kPa).
IMPORTANT: Before driving the vehicle, secure all
loose items in the cab so that they will not fly forward
during a full brake application. Make sure all passengers are wearing seat belts.
During normal brake stops, depress the foot brake
control pedal until braking action slows down the vehicle. Increase or decrease the pressure on the
pedal so that the vehicle comes to a smooth, safe
stop. Apply the spring parking brakes if the vehicle is
to be parked.
IMPORTANT: An air brake proportioning system
may be used in tractor air brake systems when
the vehicle is not equipped with antilock braking
system (ABS). When operating in bobtail mode,
the rear brake chambers (on which the axle
load has been greatly reduced) receive reduced
(proportional) air pressure, while the front axle
brake chambers receive full (normal) air pressure. This results in a different brake pedal
"feel," as the pedal seems to require more travel
Brake Systems
and/or effort to slow or stop the vehicle. However, the air brake proportioning system actually
improves vehicle control when the tractor is in
bobtail mode. When the tractor is towing a
trailer, the rear brake chambers will receive full
(normal) application air pressure.
When parking a vehicle attached to a trailer that
does not have spring parking brakes, apply the tractor parking brakes. Chock the trailer tires before disconnecting the vehicle from the trailer.
WARNING
If a trailer or combination vehicle is not equipped
with spring parking brakes, do not park it by pulling 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,
the trailer brakes would release, possibly causing
an unattended runaway vehicle.
NOTICE
Never apply the service and spring parking
brakes simultaneously. To do so transmits excessive input force to the brake components, which
could damage or cause eventual failure of brake
actuating components.
Brake Controls
f610591
10/17/2001
Fig. 12.1, Trailer Brake Lever
The red octagonal-shaped knob in the control panel
actuates the trailer air supply valve. See Fig. 12.2.
After the vehicle’s air hoses are connected to a
trailer and the pressure in both air systems is at least
65 psi (448 kPa), the trailer air supply valve must be
pushed in. It should stay in to charge the trailer air
supply system and to release the trailer spring parking brakes.
Pull the trailer air supply valve out before disconnecting a trailer or when operating a vehicle without a
trailer. If pressure in both air systems drops to 35 to
45 psi (242 to 310 kPa), the trailer air supply valve
automatically pops out, exhausting the trailer air supply, and applying the trailer service or spring parking
brakes.
The trailer brake lever (hand control valve) is used
for applying the trailer brakes without applying the
truck or tractor service brakes. It is usually mounted
on the right-hand control panel. See Fig. 12.1. The
valve can be partially or fully applied, but in any partially on position it will be overridden by a full application of the service brake pedal. Moving the lever
down applies the trailer brakes, while moving it up
releases the trailer brakes. The lever will automatically return to the up position when it is released.
1
f610291
03/10/99
WARNING
Do not use the trailer service brakes for parking;
they are not designed for this purpose. If air
bleeds out of the trailer air tank during parking,
the vehicle could roll, causing serious personal
injury or property damage.
2
1. Trailer Air-Supply-Valve Knob
2. Parking-Brake-Valve Knob
Fig. 12.2, Brake Valve Knobs
The yellow diamond-shaped knob in the control
panel actuates the parking brake valve. See
Fig. 12.2. Pulling out the parking brake valve applies
both the tractor and trailer spring parking brakes and
12.2
Brake Systems
automatically causes the trailer air supply valve to
pop out.
NOTICE
Do not use the spring parking brakes if the service brakes are hot, such as after descending a
steep grade. To do so could damage the brakes.
Allow hot brakes to cool before using the spring
parking brakes.
Do not use the spring parking brakes during
freezing temperatures if the service brakes are
wet. To do so could cause them to freeze. If the
brakes are wet, drive the vehicle in low gear and
lightly apply the brakes to heat and dry them.
If the trailer is not equipped with spring parking
brakes, pulling out the parking brake valve applies
the tractor spring parking brakes and the trailer service brakes. When the tractor and trailer parking
brakes (or trailer service brakes) are both applied,
the trailer brakes are released by pushing in the
trailer air supply valve, leaving the tractor parking
brakes applied. Air pressure in the primary or secondary reservoir must be at least 65 psi (447 kPa)
before the tractor spring parking brakes, or the trailer
service or spring parking brakes, can be released.
Automatic Slack Adjusters
Automatic slack adjusters should never be manually
adjusted except during routine maintenance of the
foundation brakes (e.g., replacing shoes), during
slack adjuster installation, or in an emergency situation.
When the brake pushrod stroke exceeds the legal
brake adjustment limit on a vehicle, there is likely a
mechanical problem with the foundation brake components or the adjuster is improperly installed.
Visit a repair facility as soon as possible when
brakes equipped with automatic slack adjusters are
determined to be out of adjustment.
NOTICE
Manually adjusting an automatic slack adjuster to
bring the pushrod stroke within legal limits is not
repairing. In fact, continual adjustment of automatic slack adjusters may result in premature
wear of the adjuster itself. Further, the improper
adjustment of some automatic slack adjusters
12.3
may cause internal damage to the adjuster,
thereby preventing it from properly functioning.
Meritor WABCO® Antilock
Braking System
The Meritor WABCO Antilock Braking System (ABS)
is an electronic wheel speed monitoring and control
system that works with the standard air brake system. ABS passively monitors vehicle wheel speed at
all times, and controls wheel speed during emergency stops or wheel lock situations.
IMPORTANT: For proper ABS system operation,
do not change tire sizes. The sizes of the tires
installed during production are programmed into
the electronic control unit. Installing differentsized tires could result in a reduced braking
force, leading to longer stopping distances.
ABS includes signal-generating tone wheels and sensors located in the wheel hubs of each sensed
wheel. The sensors transmit vehicle wheel speed
information to an electronic control unit (located behind the center dash). The control unit’s main circuit
interprets the speed sensor signals and calculates
wheel speed, wheel retardation, and a vehicle reference speed. If the calculations indicate wheel lockup,
the main circuit signals the appropriate modulator
valve to reduce braking pressure. During emergency
braking, the modulator valve alternately reduces, increases, or maintains air pressure supply in the
brake chamber to prevent front and rear wheel
lockup.
The electronic control unit also has a safety circuit
that constantly monitors the wheel sensors, traction
control valve (if equipped), modulator valves, and the
electrical circuitry.
The Meritor WABCO ABS combines one front-axle
control channel with one rear-axle control channel to
form one control circuit. For example, the sensor and
modulator valve on the left-front axle form a control
circuit with the sensor and modulator valve on the
right-rear axle. If, during vehicle operation, the safety
circuit senses a failure in any part of the ABS, the
tractor warning lamp (TRACTOR ABS) illuminates
and the control circuit where the failure occurred is
switched to normal braking action. The remaining
control circuit will retain the ABS effect. Even if the
ABS is completely inoperative, normal braking ability
is maintained. An exception would be if a modulator
Brake Systems
valve (or combination modulator valve) is damaged
and inoperative. As these components are an integral
part of the air brake system, normal braking may be
impaired or inoperative.
During emergency or reduced-traction stops, fully
depress the brake pedal until the vehicle comes to a
safe stop. Do not pump the brake pedal. With the
brake pedal fully depressed, the ABS will control all
wheels to provide steering control and a reduced
braking distance.
Although the ABS improves vehicle control during
emergency braking situations, the driver still has the
responsibility to change driving styles depending on
existing traffic and road conditions. For example, the
ABS cannot prevent an accident if the driver is
speeding or following too closely.
Trailer ABS Compatibility
The Meritor WABCO ABS is designed to communicate with a trailer ABS, if they are compatible. Compatibility will result in the illumination of the TRAILER
ABS lamp during vehicle start-up and fault detection.
The TRAILER ABS lamp will not illuminate unless a
compatible trailer is connected to the tractor. The
dash-mounted lamp will operate as follows when a
compatible trailer is properly connected to the tractor:
• When the ignition key is turned to the ON posi-
tion, the TRAILER ABS lamp will illuminate momentarily, then turn off.
• If the lamp illuminates momentarily during ve-
hicle operation, then shuts off, a fault was detected and corrected.
• If the lamp illuminates and stays on during ve-
hicle operation, there is a fault with the trailer
ABS. Repair the trailer ABS system immediately to ensure full antilock braking capability.
An additional solenoid valve is installed. During
reduced-traction situations, the ATC solenoid valve
controls air pressure to the modulator valves and
they in turn increase, hold, or reduce pressure to the
appropriate brake chambers to provide better traction
whenever wheel spin occurs.
When the ATC system is in the NORMAL mode, it
will apply gentle braking to the spinning wheel, to
feed power to the wheel(s) with better traction. If
both wheels are spinning, the system will signal the
engine to reduce power.
ATC includes a deep snow and mud option to increase available traction on extra soft surfaces like
snow, mud, or gravel. A momentary contact rocker
switch labeled ATC will be located on the dash.
Pressing the switch will temporarily allow more drive
wheel spin. The activation of the deep snow and
mud option is indicated by a flashing WHEEL SPIN
lamp. Pressing the switch again will cycle the system
back to normal operation.
NOTICE
The deep snow and mud option is intended to be
used under specific slippery conditions that require momentary increased wheel spin. Using
this option for an extended period of time may
damage the vehicle brake system.
After the ignition switch is turned on, the TRACTOR
ABS lamp and the WHEEL SPIN indicator lamp
come on for about three seconds. After three seconds, the warning lights go out if all of the tractor’s
ABS components are working.
IMPORTANT: If any of the ABS warning lights
do not work as described above, or come on
while driving, repair the ABS immediately to ensure full antilock braking capability.
IMPORTANT: If a compatible trailer is connected, and the lamp is not illuminating momentarily when the ignition key is turned to the ON
position, it is possible that the lamp is burnt out.
Enhanced Stability Control
Automatic Traction Control
The Enhanced Stability Control system is intended only as an aid for a conscientious and
alert driver and is not a substitute for safe driving procedures. Failure to drive safely, and use
the system properly, could result in personal injury and/or death and property damage.
Vehicles with electronic engines and ABS may have
Automatic Traction Control (ATC). On these vehicles,
the ATC system automatically limits wheel spin during reduced-traction situations. In normal braking applications, the standard air brake system is in effect.
WARNING
12.4
Brake Systems
The Enhanced Stability Control (ESC) system offers
the capability of complete directional stability (yaw
control) in oversteer and understeer conditions to
reduce the likelihood of drift-out or jackknife. The
system determines where the driver is attempting to
steer the vehicle and how much brake demand is
required in order to more precisely control the vehicle
in an emergency situation.
ESC works by constantly comparing the driver’s intention with the vehicles’ actual behavior. The system
does this by monitoring systems such as wheel
speed, steering angle, yaw rate, lateral acceleration,
throttle position, and brake application. A central microcomputer analyzes the collected data and triggers
a response to keep the vehicle on course when an
unstable condition is detected.
When the system detects that the vehicle is at risk of
rolling over, it applies individual tractor wheel end
brakes and trailer brakes, activates the engine retarder (if equipped), and/or cuts engine power, depending on the severity. As a result, the driver has
full control over the vehicle until the system detects a
potential rollover and intervenes accordingly. ESC
operates automatically; the driver does not monitor or
activate the system.
Roll Stability Advisor/Control
The enhanced stability system may include the roll
stability advisor (RSA) only, or it may also include the
roll stability control (RSC).
A decal (Fig. 12.3) on the auxiliary dash panel, and
an amber-colored dash indicator light (Fig. 12.4), indicate that the vehicle is equipped with roll stability
system components. On these vehicles, the roll stability indicator light replaces the wheel spin indicator
light.
06/26/2003
f602128
Fig. 12.4, Roll Stability Indicator Lamp
Roll Stability Advisor
IMPORTANT: This is not an advance warning
system. The roll stability advisor displays a message only after the driving maneuver is completed.
The roll stability system uses a lateral-acceleration
sensor that monitors rollover risk. Shortly after a
curve, lane change, or other driving maneuver that
results in a rollover-risk detection, a dash warning
light illuminates, an audible tone sounds, and a driver
advisory message is displayed in the driver message
center. The purpose is to advise the driver that the
previous maneuver produced a rollover risk.
The roll stability advisor displays different text messages depending on the severity of the risk of each
occurrence of risky driving. From the highest risk
level to the lowest risk level, the system will sound
an audible alert, and display a message, as shown in
Fig. 12.5.
NOTE: The system will calculate and recommend a speed reduction value. It may be different than the values shown here.
Bring the vehicle to an authorized service facility if a
system failure message is displayed.
SAFETY INSTRUCTIONS
Roll Stability Control
lamp indicates traction
OR roll control event.
Follow instructions in
driver’s manual.
WARNING
24−01204−000
07/11/2003
f080125
Fig. 12.3, Roll Stability Decal
12.5
The Roll Stability Control system is intended only
as an aid for a conscientious and alert driver.
Carefully read the information in this manual to
understand this system and its limitations. The
Roll Stability Control system is not a substitute
for safe driving procedures. Failure to drive
Brake Systems
MSG
Message
Message to Display
No.
1
System Fault
WARNING
Display Buzzer
Time:
Time:
Seconds Seconds
4
1
4
None
19.6
10
RAC SYSTEM FAIL
2
RSC
ACTIVE SLOWING
ROLLOVER RISK
3
RSA Level 3
VERY HIGH RISK OF
ROLLOVER DETECTED
AT LEAST 7 MPH
or in metric
REDUCE SPEED
AT LEAST 11 KPH
RSA Level 2
HIGH RISK OF
14
5
ROLLOVER DETECTED
REDUCE SPEED
AT LEAST 7 MPH
or in metric
REDUCE SPEED
AT LEAST 11 KPH
5
RSA Level 1
ROLLOVER RISK
8.4
2
DETECTED
AT LEAST 7 MPH
or in metric
REDUCE SPEED
AT LEAST 11 KPH
HBED Level 3
HARD BRAKING WITH
14
0.5
ABS ACTIVATED
LOOK AHEAD
BRAKE SOONER
7
HBED Level 2
HARD BRAKING
14
0.5
14
0.5
DETECTED
LOOK AHEAD
BRAKE SOONER
8
HBED Level 1
LOSS OF TRACTION
ABS ACTIVATED
ROAD SURFACE
MAY BE POOR
07/25/2008
The hard-braking advisor uses the information from
the ABS wheel speed sensors to determine when
braking is severe enough to produce lockup at one
or more wheels on the tractor, and/or very rapid vehicle deceleration. Shortly after a hard-braking event
occurs, an advisory message is displayed in the
driver message center, indicating that the braking
behavior was too aggressive for the current road surface conditions. This system is not a replacement for
a driver’s good judgment. Sometimes it is necessary
to brake hard.
From the highest risk level to the lowest risk level,
the system will sound an audible alert, and display a
message, as shown in Fig. 12.5.
Trip/Leg Totals
REDUCE SPEED
6
The dash indicator light illuminates whenever the roll
stability control system intervenes.
Hard-Braking Advisor
REDUCE SPEED
4
The roll stability control system automatically reduces
engine power, applies the engine brake, and/or applies the tractor and trailer brakes when the acceleration sensor detects that the vehicle is at risk of rolling
over. The control can intervene even before an advisory message is displayed.
f040769
Fig. 12.5, Roll Stability and Hard-Braking Warnings
The driver message center records the number of
messages received, and displays the number of
messages as counts. Roll stability advisor (RSA) and
hard-braking event data (HBED) counts can be
viewed in the trip advisory screen, and the leg advisory screen.
Counts can be reset using the + key on the steering
wheel. Clearing RSA and HBED leg counts will also
reset the leg miles and leg hours. Clearing RSA and
HBED trip counts will also reset trip miles, trip hours,
leg miles, leg hours, and leg advisory counts. In addition, resetting leg miles will clear leg counts. Clearing trip miles will reset miles, hours, and counts in
both the leg and trip screens.
The TRIP and LEG advisor screens count both the
roll stability advisories (ROLL) and hard-braking
events (BRK). For example, if during a TRIP, the
driver message center recorded the events in
Table 12.1, the message center would display as
shown in Fig. 12.6.
safely, and use the system properly, could result
in personal injury and/or death and property
damage.
12.6
Brake Systems
TRIP ADVISORIES
237 ROLL
A B C
518 BRK
D
E
F
07/25/2008
f040770
A. RSA lev. 3 Count (2)
B. RSA lev. 2 Count (3)
C. RSA lev. 1 Count (7)
D. HBED lev. 3 Count (5)
E. HBED lev. 2 Count (1)
F. HBED lev. 1 Count (8)
Fig. 12.6, Trip Advisor Message Screen
RSA/HBED Count
Message Received
Message Counts
RSA Level 3
2
RSA Level 2
3
RSA Level 1
7
HBED Level 3
5
HBED Level 2
1
HBED Level 1
8
Table 12.1, RSA/HBED Count
If the count reaches more than 9 occurrences an uparrow symbol will appear, to indicate to the driver
that the count has exceeded 9 counts. See
Fig. 12.7.
TRIP ADVISORIES
23 ROLL
518 BRK
A
07/25/2008
f040771
A. RSA Lev. 1 has more than 9 counts.
Fig. 12.7, Trip Advisor Message Screen (more than 9
counts)
12.7
13
Manual Transmissions and
Clutch
Eaton Fuller 13-Speed and 18-Speed Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . 13.1
Eaton Fuller 10-Speed Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Manual Transmissions and Clutch
Eaton Fuller 13-Speed and 18Speed Splitter and Range-Shift
Transmissions
IMPORTANT: Always preselect splitter shifts.
Preselection requires that the splitter-control
button be moved to the necessary position before starting to shift.
For complete information on Eaton transmissions, go
to the Eaton website, www.roadranger.com.
Preselecting splitter shifts allows for smoother and
faster shifting. However, do not delay: complete the
shift immediately after preselecting the split to avoid
unnecessary wear on transmission components.
General Information, Eaton Fuller
Splitter and Range-Shift
Transmissions
Combination splitter and range-shift transmissions
allow the choice of two splitter ratios in each shift
knob position, as well as the additional ratios provided by a low range and a high range.
IMPORTANT: Not all ratios are used in each
range, and the shift patterns vary between
transmissions. Read the shift pattern decal on
the dash for the operating instructions for the
transmission installed in your vehicle.
IMPORTANT: Never make a splitter shift while
moving in reverse.
13-Speed RTLO Models
Eaton Fuller 13-speed transmissions have thirteen
forward speeds and two reverse speeds. Each transmission consists of a 5-speed front section and a
3-speed auxiliary section. The auxiliary section contains low- and high-range ratios, plus a splitter gear.
See Fig. 13.1 for the shift pattern.
Hi
R
Lo
Range-Shift
The range-preselection lever selects the low or high
range for each transmission ratio. It is used once
during an upshift sequence and once during a downshift sequence.
The range-preselection lever is down when in the low
range, and up when in the high range.
IMPORTANT: Always preselect range shifts
when upshifting or downshifting. Preselection
requires that the range lever be moved to the
necessary position before starting to shift.
When correctly preselected, range shifts are completed automatically as the lever is moved through
neutral and into the next gear. Preselecting range
shifts prevents damage to the transmission and provides for smoother shifts.
IMPORTANT: Never make a range shift while
moving in reverse.
Splitter Control
Dependent on the transmission model, some ratios
can be split using the splitter-control button (located
on the side of the shift knob).
13.1
5 5
Dir OD
7 7
Dir OD
1
3
1
A
N
B
LOW
6 6
Dir OD
8 8
Dir OD
2
4
03/13/96
A. High Range
B. Low Range
1. Splitter Control Button
C
D
f260044a
C. High (forward)
D. Low (rearward)
Fig. 13.1, Eaton Fuller 13-Speed Transmission Shift
Pattern
All thirteen speeds are controlled with one shift knob.
LOW gear in the front section is used only as a starting gear; it is never used when the transmission is in
high range. The other four ratios are used once in
the low range and once again in the high range.
When in the high range, the gear ratios can be split
by using the splitter-control button with the underdrive ratio (RT models), or overdrive ratio (RTO
models). When in the low range, the gear ratios cannot be split.
IMPORTANT: The shift knob has an interlock
feature that prevents the splitter-control button
Manual Transmissions and Clutch
• Never push the range-preselection lever down
from being activated when the rangepreselection lever is down (in low range). When
in high range with the splitter-control button activated, the range-preselection lever cannot be
moved down.
into low range while operating in high range,
except when downshifting from 5th gear to 4th
gear.
• Do not shift from high range to low range at
high vehicle speeds.
18-Speed RTLO Splitter and Range-Shift
Models
• Preselect all range and splitter shifts. Move the
Eaton Fuller 18-speed transmissions have eighteen
forward speeds and four reverse speeds. Each transmission consists of a 5-speed front section and a
4-speed auxiliary section. The auxiliary section contains low- and high-range ratios, plus a splitter gear.
• Never make a range shift or a splitter shift
range-preselection lever and/or splitter-control
button to the needed position before starting to
shift.
while the vehicle is in reverse.
• Never move the range-preselection lever with
All eighteen speeds are controlled with one shift
knob. All nine ratios in both the low and high ranges
can be split.
the shift knob in neutral while the vehicle is
moving.
• Skip ratios while shifting only when operating
LOW gear in the front section is used only as a starting gear; it is never used when the transmission is in
high range. LOW gear can be split, to provide both a
direct and an overdrive ratio.
Operation Tips, Eaton Fuller Splitter
and Range-Shift Transmissions
The following tips highlight important operation principles.
• For all conditions, use the highest gear that is
still low enough to start the vehicle moving with
the engine at or near idle speed, and without
slipping the clutch excessively.
conditions permit, depending on the load,
grade, and road speed.
• Never coast with the shift knob in the neutral
position.
Upshifting
1.
Position the gear shift knob in neutral. Start the
engine and bring the air system pressure up to
100 to 120 psi (689 to 827 kPa).
2.
Position the range-preselection lever down, in
low range. See Fig. 13.2.
1
When operating on-highway with no load or
under ideal conditions, use 1st gear to start the
vehicle moving forward.
R
When operating off-road or under adverse conditions, use LOW gear to start the vehicle moving forward.
• Partially disengage the clutch to break engine
LOW LOW
Dir OD
6
Dir
2
Dir
6
OD
2
OD
7
Dir
3
Dir
7
OD
3
OD
A
8
Dir
4
Dir
8
OD
4
OD
B
C
03/13/96
A. High Range
B. Low Range
1. Splitter Control Button
torque during normal gear shifts.
D
f260157a
C. Overdrive (forward)
D. Direct Drive (rearward)
Fig. 13.2, Eaton Fuller 18-Speed Transmission Shift
Pattern
• Double-clutch between all upshifts and down-
shifts that require movement of the shift knob.
Splitting of gears does not require movement
of the shift knob.
5
OD
1
OD
N
• Use the clutch brake to stop gear rotation
when shifting into LOW or reverse while the
vehicle is stationary. The clutch brake is actuated by depressing the clutch pedal all the way
to the floor.
5
Dir
1
Dir
3.
Make sure the splitter-control button is in the low
(rearward) position. See Fig. 13.2.
13.2
Manual Transmissions and Clutch
4.
pedal. After releasing the clutch, accelerate
again.
For 13-speed transmissions:
To start the vehicle moving, press the clutch
pedal to the floor, shift into LOW or 1st gear,
then engage the clutch with the engine at or near
idle speed. Accelerate to 80 percent of engine
governed speed.
For 18-speed transmissions:
To start the vehicle moving, press the clutch
pedal to the floor, shift into LOW, then engage
the clutch with the engine at or near idle speed.
To shift from LOW direct to LOW overdrive,
move the splitter-control button into the overdrive
(forward) position, then immediately release the
accelerator. Press and release the clutch pedal.
After releasing the clutch pedal, accelerate
again.
5.
Continue upshifting through the shift pattern.
Double-clutch during knob shifts (6th to 7th, etc.);
single-clutch during split shifts (6th direct to 6th
overdrive, etc.).
Downshifting
IMPORTANT: Never use the clutch brake when
downshifting, or as a brake to slow the vehicle.
1.
To downshift from 8th overdrive to 8th direct (or
8th direct to 8th underdrive on RT model transmissions), move the splitter-control button to the
low (rearward) position, then immediately release
the accelerator. Press and release the clutch
pedal, then accelerate the engine once the transmission has shifted.
2.
Start the downshift from 8th direct to 7th overdrive by moving the splitter-control button to the
high (forward) position, then immediately doubleclutch through neutral, moving the shift knob
from 8th gear to 7th gear.
3.
Downshift progressively through each of the high
range gears, alternating the procedures in steps
1 and 2 above until reaching 5th direct.
4.
When in 5th direct and ready for the downshift to
4th (13-speed transmissions) or 4th overdrive
(18-speed transmissions), push the rangepreselection lever down and move the splittercontrol button to the high (forward) position.
Double-clutch through neutral and into 4th gear,
engage the clutch, and accelerate the engine.
5.
Continue downshifting from 4th gear to 1st gear.
For 13-speed transmissions:
Upshift from LOW (or 1st gear) through 4th gear,
double-clutching during knob shifts, and accelerating to 80 percent of engine governed speed.
See Fig. 13.1.
For 18-speed transmissions:
Upshift from LOW overdrive to 1st direct by first
moving the splitter-control button into the direct
drive (rearward) position (Fig. 13.2). Doubleclutch and move the shift knob through neutral to
the 1st gear position.
Continue upshifting through the shift pattern.
Double-clutch during knob shifts (1st to 2nd to
3rd to 4th); single-clutch during split shifts (1st
direct to 1st overdrive, etc.).
6.
When in 4th gear (13-speed transmissions) or
4th overdrive (18-speed transmissions), use the
range-preselection lever and the splitter-control
button to upshift to 5th gear.
While in 4th gear, pull the range-preselection
lever up into high range and move the splittercontrol button to the low (rearward) position.
Double-clutch through neutral and into 5th gear,
engage the clutch, and accelerate the engine.
7.
Upshift progressively through the high range
gears.
To shift from 5th direct to 5th overdrive (or 5th
underdrive to 5th direct on RT model transmissions), move the splitter-control button to the
high (forward) position, then immediately release
the accelerator. Press and release the clutch
13.3
For 13-speed transmissions:
Downshift through the low range gears as conditions require.
For 18-speed transmissions:
Continue downshifting from 4th overdrive to 4th
direct, then 4th direct to 3rd overdrive, etc.
Double-clutch during knob shifts (4th to 3th, etc.);
single-clutch during split shifts (4th direct to 3rd
overdrive, etc.).
Manual Transmissions and Clutch
Eaton Fuller 10-Speed RangeShift Transmissions
For complete information on Eaton transmissions, go
to the Eaton website, www.roadranger.com.
IMPORTANT: Shift patterns vary between transmissions. Be sure to read the shift pattern decal
on the dash for the operating instructions for the
transmission installed in your vehicle.
General Information, 10-Speed
Range-Shift Transmissions
Eaton Fuller 10-speed transmissions have ten forward speeds and two reverse speeds. Each transmission has a 5-speed front section and a 2-speed
auxiliary section.
A range-shift transmission allows for additional ratios
provided by a low range and a high range. The ten
forward speeds are obtained by twice using a
5-speed shift pattern: first in the low range, then in
the high range. See Fig. 13.3 for the shift patterns.
HI
R
LO
7
2
9
4
The following tips highlight important operation principles.
• Use the clutch brake to stop gear rotation
10
5
when shifting into LOW or reverse while the
vehicle is stationary. The clutch brake is actuated by depressing the clutch pedal all the way
to the floor.
B
f261053
12/15/1999
A. High Range
Operation Tips, Eaton Fuller RangeShift Transmissions
still low enough to start the vehicle moving with
the engine at or near idle speed, and without
slipping the clutch excessively.
A
8
3
NOTE: The 4th/9th and the 5th/10th shift positions in the RT (direct ratio) and RTX (overdrive
ratio) transmissions are directly opposite in the
RTO (overdrive ratio) transmissions.
• For all conditions, use the highest gear that is
N
6
1
To operate a range-shift transmission, move the shift
knob through all the low-range gear positions and
then pull the range-preselection lever up to move into
the high-range ratios. Use the same shift knob positions in both the low and high ranges.
B. Low Range
• Partially disengage the clutch to break engine
torque during normal gear shifts.
Fig. 13.3, Eaton Fuller 10-Speed Transmission Shift
Patterns
• Double-clutch between all upshifts and down-
The range-preselection lever selects the low or high
range for each ratio. It is used once during an upshift
sequence and once during a downshift sequence.
The range-preselection lever is down when in the low
range, and up when in the high range.
• Never push the range-preselection lever down
IMPORTANT: Always preselect range shifts
when upshifting or downshifting. Preselection
requires that the range lever be moved to the
necessary position before starting to shift.
When correctly preselected, range shifts are completed automatically as the lever is moved through
neutral and into the next gear. Preselecting range
shifts prevents damage to the transmission and provides for smoother shifts.
shifts.
into low range while operating in high range,
except when downshifting from 5th gear to 4th
gear.
• Do not shift from high range to low range at
high vehicle speeds.
• Preselect all range shifts. Move the range-
preselection lever to the needed position before starting to shift.
• Never make a range shift while the vehicle is
in reverse.
13.4
Manual Transmissions and Clutch
• Never move the range-preselection lever with
6.
the shift knob in neutral while the vehicle is
moving.
• Skip ratios while shifting only when operating
conditions permit, depending on the load,
grade, and road speed.
Downshifting
• Never coast with the shift knob in the neutral
position.
Upshifting
1.
Position the gear shift knob in neutral. Start the
engine and bring the air system pressure up to
100 to 120 psi (689 to 827 kPa).
2.
Position the range-preselection lever down, in
low range. See Fig. 13.2.
3.
To start the vehicle moving, press the clutch
pedal to the floor; shift into 1st gear (Table 13.1),
then engage the clutch with the engine at or near
idle speed. Accelerate to 80 percent of engine
governed speed.
Eaton Fuller Shift Progressions
TRANS. MODEL
LOW RANGE
HIGH RANGE
10-Speed Direct
or Overdrive (RT
or RTX)
R
2
1
3
4
5
f260329
R
6
7
9
10
8
f260330
Table 13.1, Eaton Fuller Range-Shift Shift
Progressions
4.
5.
Upshift progressively from 1st gear through 5th
gear (Table 13.1), double-clutching between
shifts, and accelerating to 80 percent of engine
governed speed.
When in 5th gear and ready to move to 6th gear,
pull the range-preselection lever up into the high
range. Double-clutch through neutral and into 6th
gear, engage the clutch, and accelerate the engine.
NOTE: If after attempting to shift into the high
range the transmission remains in neutral with
the shift knob in gear, the range synchronizer
protection device may be activated. Move the
shift knob into neutral to allow the range shift to
complete, then move the shift knob back into
gear.
13.5
Upshift progressively through the high range
gears (Table 13.1), double-clutching between
shifts and accelerating to 80 percent of engine
governed speed.
IMPORTANT: Never use the clutch brake when
downshifting, or as a brake to slow the vehicle.
1.
Downshift progressively through each of the high
range gears, double-clutching between shifts.
2.
When in 5th gear and ready to move to 4th gear,
push the range-preselection lever down into the
low range. Double-clutch through neutral and into
4th gear, engage the clutch, and accelerate the
engine.
NOTE: If after attempting to shift into the high
range the transmission remains in neutral with
the shift knob in gear, the range synchronizer
protection device may be activated. Move the
shift knob into neutral to allow the range shift to
complete, then move the shift knob back into
gear.
3.
Downshift progressively through the low range
gears, double-clutching between shifts, as conditions require.
Clutch
Clutch General Information
To ensure long service life of the clutch, start in the
right gear, be alert to clutch malfunctions, and know
when to adjust the clutch.
Typical operation will not break down the clutch friction surfaces. Heat and wear are almost nonexistent
when a clutch is fully engaged. However, during the
moment of engagement, when the clutch is picking
up the load, considerable heat is generated. If a
clutch slips excessively, high temperatures develop
quickly between the flywheel, driven discs, and pressure plates. An improperly adjusted or slipping clutch
can generate temperatures high enough to cause the
friction-facing material to char and burn, destroying
the clutch.
Manual Transmissions and Clutch
Clutch Operation
Vehicle Loading
Clutch Break-In
Clutches are designed for specific vehicle applications and loads. Do not exceed these weight limitations.
The clutch may slip for a short time while the friction
surfaces break-in on a new or newly-installed clutch.
However, allowing the clutch to slip for more than
two seconds can severely damage the clutch disc,
pressure plate, and the flywheel.
NOTICE
Do not allow sustained slippage of the clutch;
which will severely damage the clutch disc, pressure plate, or flywheel. Damage caused by clutch
slippage due to improper break-in is not warrantable.
During initial operation of a new vehicle or a vehicle
with a new clutch, check for clutch slippage during
acceleration. If the clutch slips, decelerate until the
clutch does not slip. Allow the clutch to cool 15 to 30
seconds, then gradually accelerate again. If the
clutch continues to slip, repeat the procedure as
many as five times. If the clutch slips after five attempts, stop the vehicle and allow the clutch to cool
for at least one hour. Notify your Freightliner dealer
of the problem.
Moving the Vehicle in the Proper Gear
An empty vehicle can be started in a higher transmission gear than can a partially- or fully-loaded vehicle. Select the gear combination that allows the
vehicle to start moving with an idling engine or, if
necessary, just enough throttle to prevent stalling the
engine. After the clutch is fully engaged, the engine
can be accelerated to the correct rpm for the upshift
into a higher gear.
Gear Shifting Techniques
Upshift into a higher gear when the vehicle speed
allows the transmission input shaft speed to match
the flywheel speed when engaging the clutch. This
technique results in the smallest speed difference
between the clutch disc and the flywheel, and causes
the least heat and wear on the clutch assembly.
When downshifting, increase the input shaft speed to
match the flywheel by slightly revving the engine. For
transmission operating instructions, refer to the transmission headings in this chapter.
NOTICE
Exceeding vehicle load limits can result in damage to the clutch and the entire powertrain.
Clutch Brake
Apply the clutch brake by depressing the clutch
pedal all the way to the floor plate. The last part of
the clutch pedal travel will compress the clutch brake
plates together, stopping the transmission input shaft.
The clutch brake stops the transmission gears from
rotating in order to quickly engage a transmission
gear after idling in neutral.
NOTICE
Never apply the clutch brake when the vehicle is
moving. If the clutch brake is applied when the
vehicle is moving, the clutch brake will try to
stop or decelerate the vehicle, causing rapid
wear of the clutch brake friction discs. Considerable heat will be generated, causing damage to
the release bearings and the transmission front
bearings.
Using the Clutch
Use the clutch pedal only when starting the engine,
launching the vehicle from a stop, or shifting. To
launch a stationary vehicle, depress the clutch pedal
all the way to the floor plate (see "Using the Clutch
Brake" above) and shift from neutral to a low gear.
Slowly raise your foot until the clutch starts to engage. In this position the clutch is starting to connect
the transmission input shaft to the flywheel and is
causing the most heat and wear. Slightly increase
the engine speed and smoothly allow the clutch
pedal to return to the rest position. Do not allow the
clutch to remain in the partially-engaged position any
longer than necessary to obtain a smooth start.
Double-clutch to shift gears while the vehicle is moving. Depress the clutch pedal most of the way in, but
not all the way to the floor plate. Depressing the
clutch pedal to the floor plate will engage the clutch
brake. Shift the transmission into neutral and fully
13.6
Manual Transmissions and Clutch
release the clutch pedal. When upshifting, wait long
enough for the engine speed to decrease to the road
speed. When downshifting, increase the engine
speed to match the road speed. Again, depress the
clutch pedal part way and then move the shift lever
to the next gear position. Fully release the clutch
pedal after completing the shift.
NOTICE
Riding the clutch while driving is damaging to
the clutch because partial clutch engagement
causes slippage and heat. Resting your foot on
the clutch pedal will also put a constant thrust
load on the release bearing, thinning the bearing
lubricant and increasing the wear on the bearing.
Holding the Vehicle On an Incline
Always use the vehicle service brakes to prevent the
vehicle from rolling backwards while stopped on a
hill. Slipping the clutch on a hill to maintain vehicle
position will quickly damage the clutch assembly.
Clutch Maintenance
Checking the Clutch Adjustment
Report erratic clutch operation as soon as possible to
give maintenance personnel a chance to inspect, lubricate, and adjust the clutch components. Notice
any gradual decrease in the distance the clutch
pedal moves before resistance is felt.
NOTICE
Operating the vehicle with incorrect free pedal
could result in clutch damage.
A correctly adjusted clutch must have about 3/4 inch
(19 mm) of travel at the top of its stroke before a
stronger resistance can be felt. See Fig. 13.4. If the
free pedal travel is less than this distance, have the
clutch adjusted.
Check the clutch free pedal travel daily and note it in
the driver’s report.
Coasting
Coasting with the clutch pedal depressed and the
transmission in a low gear can cause high driven
disc speed. The clutch speed can be much higher
under these conditions than when the engine is driving the clutch. This condition creates a hazardous
situation due to the lack of vehicle control and due to
the high clutch disc speed. Engaging the clutch
under these conditions can cause component damage because of the shock loads to the clutch and
drivetrain.
WARNING
Always shift into the gear that is correct for the
traveling speed of the vehicle and engage the
clutch. Coasting with the clutch disengaged can
prevent engagement of the correct transmission
gear which can cause loss of vehicle control,
possibly resulting in personal injury or property
damage.
High clutch disc speeds while coasting can also
cause the clutch facing to be thrown off the disc.
Flying debris from the clutch can cause injury to
persons in the cab.
02/09/96
f250306
A. Free Pedal
Fig. 13.4, Clutch Free Pedal Travel
Adjusting the Clutch
Clutches have an internal adjustment and external
linkage adjustment. See Group 25 of the 108SD and
13.7
Manual Transmissions and Clutch
114SD Workshop Manual for clutch adjustment procedures and specifications.
Checking the Clutch Brake Operation
Clutch brake operation can be felt as an increased
resistance as the clutch pedal approaches the bottom of its stroke. If the gears grind when shifting into
first or reverse gear from neutral with the clutch
pedal fully depressed, the clutch pedal is out of adjustment or the clutch brake is worn and needs to be
replaced.
Lubricating the Clutch Release Bearing
On vehicles equipped with a greaseable release
bearing, the release bearing should be lubricated at
frequent intervals. See Group 25 of the 108SD and
114SD Maintenance Manual for intervals and procedures.
13.8
14
Automated and Automatic
Transmissions
Freightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Eaton Fuller UltraShift DM Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Eaton Fuller UltraShift PLUS Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
Eaton Fuller AutoShift Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
Allison Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
Automated and Automatic Transmissions
Freightliner SmartShift Shift
Control
5
The SmartShift electronic transmission control is installed with the following transmissions:
1
• Eaton Fuller AutoShift™
It replaces the typical floor-mounted shift lever or
dash-mounted push button control.
SmartShift accepts driver requests for transmission
functions and transmits them through hard wiring to
the transmission control unit (TCU). SmartShift is a
true shift-by-wire system.
SmartShift offers two main advantages over conventional transmission control devices. Without a floormounted shift control, usable cab space is increased.
The SmartShift control is operated by the fingers of
the driver’s right hand, allowing both hands to remain
on the steering wheel.
A two-position driving mode slide switch is mounted
on the body of the control lever just before the
paddle widens out. The slide switch allows the driver
to choose automatic (AUTO) or manual (MAN) mode.
See Fig. 14.1.
In AUTO mode, gears shift automatically without
driver interaction. Manual gearshifts are accomplished by a momentary pull or push on the control in
the plane perpendicular to the steering wheel. Pull
upward (toward the driver) on the control to upshift
and push downward (away from the driver) to downshift. The control is spring-loaded and returns to its
rest position when released after an upshift or downshift.
A four-position (R, N, D, L) gear selector switch is
located at the end of the lever. See Fig. 14.1.
A small neutral lock button is embedded in the gear
selector switch to prevent accidental shifts into gear
from neutral. Any time you shift through neutral,
press down on the neutral lock button to move the
switch from neutral (N) to another gear, such as drive
(D), low (L), or reverse (R). When shifting to neutral,
it is not necessary to press the neutral lock button.
14.1
8
9
2
• Eaton® Fuller® UltraShift™
• Eaton Fuller UltraShift PLUS
7
4
3
General Information, SmartShift
Control
6
10
11
01/24/2003
12
f270120
To upshift manually, pull the lever back (towards the
driver). To downshift manually, push the lever forward
(away from the driver).
1. SmartShift Control Lever
2. Slide Switch (forward driving mode switch)
3. MAN Mode (of slide switch)
4. AUTO Mode (of slide switch)
5. Upshift Direction
6. Reverse Position (of selector switch)
7. Selector Switch
8. Neutral Lock Button
9. Neutral Position (of selector switch)
10. Drive Position (of selector switch)
11. Low Position (of selector switch)
12. Downshift Direction
Fig. 14.1, SmartShift Control (with Eaton Fuller
UltraShift, UltraShift PLUS, and AutoShift)
Eaton Fuller UltraShift DM
Automated Transmissions
General Information, Ultrashift
Transmissions
Eaton Fuller UltraShift is a heavy-duty fully automated transmission. No clutch pedal is required to
operate the vehicle. The UltraShift uses a dry clutch
system which is offered only on this automated transmission system.
The UltraShift transmission uses the four-position
SmartShift control lever on the steering column to
select gears. The current gear is displayed on the
indicator on the right-hand control panel. All forward
shifts can be made either manually or automatically.
Automated and Automatic Transmissions
Operation, UltraShift Transmissions
Automatic and Manual Modes
The SmartShift control lever has a slide switch located on the body of the control lever just before the
paddle widens out. See Fig. 14.2. The slide switch
controls the forward driving mode, automatic (AUTO)
or manual (MAN).
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f610680
NOTE: The gear indicator displays the current gear. In
this example, it displays first gear.
1
2
Fig. 14.3, Gear Indicator: Current Gear
3
01/21/2004
1. Driving Mode Slide
Switch
f270079c
2. Gear Selector Switch
3. Neutral Lock Button
Fig. 14.2, Shift Controls and Indicators, UltraShift and
AutoShift Transmissions
To change mode at any time, move the slide switch
in the desired direction. This allows the driver to respond to a wide range of driving conditions, such as
blind corners, tight curves, and steep hills.
IMPORTANT: In either mode, it is possible to
shift manually by moving the lever up or down
as needed. When the engine speed is within 75
rpm of the load-based shift point for an automatic shift, the TCU will advance the shift.
In either mode, the gear indicator displays the current gear. See Fig. 14.3.
At the start of a shift, the current gear continues to
display until the transmission has been pulled into
neutral. As the transmission is synchronizing for the
new (target) gear, the gear indicator flashes the number of the target gear.
When the shift is complete, the gear indicator displays the new gear, without flashing.
Automatic Mode (AUTO)
In automatic drive mode (AUTO), upshifts and downshifts are made by the transmission without driver
intervention. Press the neutral lock button, move the
gear selector switch to drive (D), and press down on
the throttle pedal. The transmission will shift automatically.
If driving conditions require, it is still possible to request a manual shift. The transmission will make the
shift if the engine speed is within 75 rpm of the loadbased shift point for that gear.
If the driver presses down on the throttle pedal after
a manual downshift in automatic mode, the transmission will upshift again if the TCU requires it.
Manual Mode (MAN)
In manual drive mode (MAN), upshifts and downshifts are made by the driver.
• To upshift, pull the lever up (towards the
driver).
• To downshift, push the lever down (away from
the driver).
The system will hold the current gear until the driver
requests a shift. In downhill situations in particular,
the driver must be alert to vehicle speed by downshifting and/or using the service brakes as needed.
A shift request will be refused if the selected gear
would cause engine overspeed or excessive lugging.
14.2
Automated and Automatic Transmissions
Power Up
4.
1.
With the parking brake set, select neutral (N) by
moving the gear selector switch to the N position.
2.
Turn on the ignition switch. The CHECK TRANS
and TRANS TEMP lamps illuminate and go out
again (bulb check).
The current gear indicator shows the dot display,
arranged in a square pattern. All dots in the pattern should light up, without gaps or spaces. See
Fig. 14.4.
Press the neutral lock button and move the gear
selector switch downward to the D position below
neutral. The gear is displayed on the current
gear indicator.
NOTE: When D is selected, the TCU starts up
in second gear. If desired, the driver can select
to start up in first. No other start gear is available.
5.
On a level grade, release the parking and service brakes and press down on the throttle pedal
to allow the vehicle to move forward. The vehicle
will not move until the pedal is depressed.
WARNING
When starting or stopping on hills and grades,
use extra care to prevent the vehicle from rolling
back. A rollback accident could cause death, serious personal injury, or property damage.
6.
Prevent the vehicle from rolling backwards when
stopped on a hill or grade, or when the vehicle is
starting from a stop on a hill or grade.
6.1
f610678
10/13/2003
Fig. 14.4, Gear Indicator: Power Up Dot Display
3.
To start from a full stop on a hill or grade,
quickly move your foot from the brake
pedal and press firmly on the throttle
pedal.
On steep hills, set the parking brake, and
release it only when there is enough engine power to prevent rollback.
Wait for the current gear indicator to show a solid
N. See Fig. 14.5. When the N is solid (not flashing), the TCU is powered up. Apply the service
brake and start the engine.
6.2
To stop on a hill or grade, press and hold
the brake pedal to keep the vehicle from
moving.
On steep hills, set the parking brake.
When parking, chock the tires, front and/or
rear.
NOTICE
Never hold a hill with the throttle pedal. Operating the vehicle too long between engine idle and
1000 revolutions per minute (rpm) during takeoff
will cause the clutch to overheat.
Power Down
f610679
10/13/2003
Fig. 14.5, Gear Indicator: Neutral
14.3
1.
Apply the service brakes.
Automated and Automatic Transmissions
2.
Move the gear selector switch to the N position.
When the N on the current gear indicator is solid
(not flashing), the TCU is ready to power down.
3.
Set the parking brake.
4.
Turn off the ignition key and shut down the engine.
Selecting Gears
Neutral
IMPORTANT: Always start the engine with the
transmission in neutral (N), the parking brake
set, and the service brakes applied.
N is located directly below R on the four-position
gear selector switch on the SmartShift control lever.
To select N, move the gear selector switch to the position below R. When neutral is selected, the letter N
displays on the current gear indicator. See Fig. 14.5.
WARNING
Do not coast in neutral. Coasting in neutral can
cause an accident, possibly resulting in severe
personal injury or death.
Neutral is always available during operation, whatever the vehicle speed. When in neutral, requests to
upshift or downshift are ignored. If the gear selector
switch is moved from N to D while the vehicle is
moving, the transmission will shift into a gear within
the engine’s operating speed range.
When shifting from neutral, always press on the
brake pedal. If the brake pedal is not pressed, the
transmission will not shift, the current gear display
will flash N, and an audible alert will sound. To reset
the transmission, return the gear selector switch on
the SmartShift lever to N and attempt the shift again,
this time with the brake pedal pressed.
Before shutting down the engine, return the gear selector switch to N. When the ignition is turned off, the
transmission will reset to neutral in a few minutes
regardless of the position of the gear selector switch.
Drive
Drive (D) is located directly below N on the fourposition gear selector switch on the SmartShift control lever. To select D, press in the neutral lock button
and move the gear selector switch to the position
below N. When D is selected, the number of the cur-
rently selected forward gear displays on the gear indicator. See Fig. 14.3.
When in drive, requests to upshift or downshift are
enabled. Either manual or automatic mode can be
selected on the slide switch.
The default starting gear is second, but first can be
selected by the driver, if desired. To change the starting gear, press the brake pedal and select D with the
vehicle stopped. The current gear indicator will display the starting gear. Move the control lever up or
down until the desired starting gear is displayed.
The TCU adapts to the working conditions of each
vehicle and its driver. After power up or a load
change, it needs to learn the new conditions. While
learning, it may hold a gear too long before upshifting. Start the upshift manually. It may take three or
four shifts before UltraShift succeeds in learning the
new load-based shift points, but after that it will
handle the shifting automatically.
Reverse
Reverse (R) is located at the upper end of the fourposition gear selector switch on the SmartShift control lever. To select R, press in the neutral lock button
and move the gear selector switch upward to the position above neutral.
The UltraShift transmission has two reverse gears:
reverse low (RL) and reverse high (RH). To shift
manually between them, use the control lever as described for MAN mode. There is no AUTO mode for
reverse.
When reverse low is selected, the letter R displays
on the current gear indicator. When reverse high is
selected, the letter H displays on the current gear
indicator. See Fig. 14.6.
IMPORTANT: Under normal conditions, do not
select reverse with the vehicle moving forward.
The vehicle must be moving at less than two miles
per hour (3 km/h) before selecting reverse. If reverse
is selected when the vehicle is moving faster, an audible alert will sound and continue sounding at threesecond intervals until the gear selector switch is returned to the D position or the vehicle slows to the
proper speed.
If necessary to rock the vehicle, use the gear selector switch to shift back and forth at low speed between reverse and drive.
14.4
Automated and Automatic Transmissions
If the gear requested is unavailable, a tone will
sound. An unavailable request to upshift is not stored
in memory; the upshift must be requested again.
Downshifting
To request a downshift with the transmission in drive
or low, push the control lever down (away from the
driver). If the gear is available, the transmission will
downshift and the new gear will display on the gear
indicator. Skip shifts are available while downshifting.
For best engine braking, select low while moving. In
low, downshifts are performed at higher rpm than in
drive.
10/14/2003
f610681
Fig. 14.6, Gear Indicator: Reverse Low Gear
Low
Low (L) is located at the lower end of the fourposition gear selector switch on the SmartShift control lever. To select L, press in the neutral lock button
and move the gear selector switch to the position
below D.
When in low, the current gear is maintained. Requests to upshift are not enabled.
IMPORTANT: If the engine is approaching overspeed, the TCU will override the current gear
setting and upshift to prevent engine damage.
To enhance engine braking, downshifts are performed at higher rpm than normal.
If L is selected from neutral while stopped, the vehicle starts up in first gear and stays there until the
engine approaches overspeed.
Upshifting
To request an upshift with the transmission in drive,
pull the control lever up (towards the driver). If the
gear is available, the transmission will upshift and the
new gear will display on the gear indicator. Skip
shifts are not available while upshifting. Upshifts are
not available in low, except to prevent engine overspeed.
If the transmission does not upshift quickly enough
after power up or a load change, begin the shift
manually. The TCU will learn the new load-based
shift conditions after three or four shifts.
14.5
IMPORTANT: If the engine is approaching overspeed, the TCU will override the current gear
setting and upshift to prevent engine damage.
If the gear requested is unavailable, a tone will
sound. An unavailable request to downshift is not
stored in memory; the downshift must be requested
again.
When coasting to a stop, the TCU may not finish the
downshift until the driver presses down on the
throttle pedal again.
IMPORTANT: A downshift request can never
result in a shift into neutral, even if the vehicle is
in the drive position in the lowest possible gear.
Before starting down a hill, slow down. Downshift to
a speed that you can control without hard pressure
on the service brakes.
Before entering a curve, slow down to a safe speed.
Downshift if necessary. This lets you use some
power through the curve to help the vehicle be more
stable on the turn. It also allows you to regain speed
faster as you come out of the curve.
Ultrashift Diagnostics
Clutch Protection Fault
Even though a vehicle with an UltraShift transmission
does not have a clutch pedal, it does have a mechanical clutch. As you slowly increase and decrease
engine rpm from a stop, the mechanical clutch is engaging and disengaging, just like slipping the clutch
with a manual transmission. Excessive clutch slippage creates heat and reduces the life of the clutch.
These are some conditions which can cause clutch
damage:
Automated and Automatic Transmissions
• Using the throttle to hold the vehicle on a hill
Locked In Gear
• Starting the vehicle from a stop in a gear that’s
If the vehicle is shut down in gear, the transmission
may become locked in gear. The transmission will
attempt to get to neutral during the next power up if
the gear selector switch is positioned on N. If neutral
can’t be achieved, a dash (–) will appear on the gear
indicator when the vehicle is restarted.
too high
• Overloading the vehicle
• Using high idle with the vehicle in gear
The TCU is programmed to prevent clutch damage.
When the clutch overheats, the following alerts take
place:
• The TRANS TEMP light comes on
• The current gear indicator displays "C," then
"A"
• A warning tone sounds at one-second intervals
The alerts continue until the clutch cools, the throttle
is released, or the clutch is fully engaged.
NOTE: If the transmission becomes locked in
gear while the vehicle is moving, increased
braking effort may be required to stop the vehicle.
If the current gear indicator displays a dash during
power up with the gear selector switch in neutral,
complete the following steps.
1.
Make sure the parking brake is set.
2.
Turn off the ignition and wait at least two minutes.
In the event of a problem, complete the following
steps.
3.
Depress the brake pedal and release the parking
brake.
1.
Note the driving conditions at the time the problem occurred.
4.
2.
Record the status of the transmission at the time
of the problem (AUTO or MAN mode, gear setting, current gear, engine speed, etc.).
Make sure the gear selector switch is positioned
on N, then turn on the ignition key. Do not attempt to start the engine yet.
5.
3.
Complete the transmission reset procedure.
If necessary to get the transmission to shift into
neutral, release the pressure on the brake pedal
slightly.
6.
Once the TCU reaches neutral, a solid N will appear on the gear indicator and the vehicle will
start. Apply the service brakes and start the engine.
7.
If the current gear indicator continues to display
a dash, contact an authorized Freightliner or
Eaton service facility.
System Problem
Transmission Reset Procedure
In some cases, proper transmission operation can be
restored by resetting the TCU. Use the following procedure to reset the TCU.
1.
When it is safe to do so, stop the vehicle.
2.
Select N by moving the gear selector switch to
N.
3.
Set the parking brake.
4.
Shut down the engine.
5.
Wait at least two minutes.
6.
Restart the engine.
7.
If the problem continues or the transmission
doesn’t achieve neutral after power up, contact
an authorized Freightliner or Eaton service facility.
Eaton Fuller UltraShift PLUS
Automated Transmissions
Eaton Fuller UltraShift PLUS automated transmissions use shift selection software and electric clutch
actuation; a clutch pedal is not needed to operate the
vehicle. These transmissions use the four-position
SmartShift control (see Fig. 14.1) on the steering
column to select mode, direction, neutral, low, and to
make manual shifts. To know what gear the transmission is in, see the current gear indicator on the dash.
Forward shifts can be made either manually or
automatically.
14.6
Automated and Automatic Transmissions
Power Up
NOTE: Engine cranking is delayed until the
transmission power-up is complete and the gear
display shows a solid "N".
1.
With the parking brake set, turn the ignition
switch to the ON position.
2.
Start the engine.
3.
Apply the service brake.
NOTE: If the service brake is not applied while
selecting a starting gear, the initial start gear will
not be found and the driver will need to select
Neutral and press the service brake while selecting the desired mode.
4.
Select the desired mode and starting gear. (Inappropriate start gear selections are ignored to
avoid damaging the transmission.)
5.
Release the parking brake.
6.
Release the service brake and apply the accelerator.
Power Down
1.
Select Neutral on the shift control.
NOTE: If the gear display does not show a solid
"N", neutral has not yet been obtained. Neutral
should always be reached before powering
down an UltraShift PLUS, except in cases of
emergency.
2.
Set the parking brake.
3.
Turn off the ignition, and shut down the engine.
Reverse (R)
NOTE: If attempting to select a non-Neutral
mode without applying the service brakes, the
transmission will not shift into gear. To shift into
gear, select Neutral, apply the service brakes,
and select the desired mode again. Also, the
vehicle will not engage reverse above 2 mph (3
km/h).
Reverse (R) is at the upper end of the four-position
selector switch located at the end of the SmartShift
control. To select R, press in the neutral lock button
14.7
and move the selector switch to the position above
neutral. The default Reverse gear is engaged.
NOTICE
Avoid launching the vehicle in high range.
Launching the vehicle in high range increases
the likelihood of clutch abuse and could be detrimental to clutch life.
Automatic Mode (AUTO)
In automatic drive mode (AUTO), upshifts and downshifts are made by the UltraShift PLUS without driver
intervention. Press in the neutral lock button, move
the selector switch to Drive (D), and press down on
the throttle pedal. The transmission will shift automatically.
NOTE: If attempting to select a non-Neutral
mode without applying the service brakes, the
transmission will not shift into gear. To shift into
gear, select Neutral, apply the service brakes,
and select the desired mode again.
In Drive, the start gear is automatically selected. The
selected start gear can vary depending on several
vehicle inputs such as load, grade, and axle/
transmission ratio. The start gear can be changed
using the SmartShift control, provided the selected
gear would allow the vehicle to launch without damaging the transmission. If the start gear is changed
using the SmartShift control, it will be the default until
the vehicle is powered down or the selection is
changed again manually.
IMPORTANT: Prior to ascending a steep grade,
either reduce the default start gear by one
(using the SmartShift control) or apply full
throttle for the duration of the grade so the vehicle maintains the proper engine and vehicle
speed during the entire grade.
In Drive, the transmission automatically performs upshifts and downshifts. However, when the transmission is near the shift point, the shift can be forced
using the upshift or downshift function of the SmartShift control.
NOTE: The transmission may deny a shift while
ascending or descending a grade if the load of
the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque
Automated and Automatic Transmissions
fall outside of the acceptable range to perform a
shift. If the shift is denied, a tone will sound.
Manual Mode (MAN)
In manual mode (MAN), the driver selects upshifts
and downshifts instead of letting the UltraShift PLUS
select them automatically. Manual shifting may be
helpful when traversing a work site, railroad tracks,
or steep grades, for example. To drive forward, press
in the neutral lock button, move the selector switch to
Drive (D), and press down on the throttle pedal. To
shift up, pull the lever up (towards you); to shift
down, push the lever down (away from you). The
system holds the current gear unless a shift is requested or if the system initiates a manual mode
override.
NOTE: The transmission may deny a shift while
ascending or descending a grade if the load of
the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque
fall outside of the acceptable range to perform a
shift. If the shift is denied, a tone will sound.
NOTE: If attempting to select a non-Neutral
mode without applying the service brakes, the
transmission will not shift into gear. To shift into
gear, select Neutral, apply the service brakes,
and select the desired mode again.
Manual Mode Override
The system is equipped with a manual mode override function. If the vehicle is being "back driven" (for
example, descending a grade and vehicle speed exceeds engine speed) and the engine speed is excessively high, the system will upshift automatically.
Also, if the start gear is changed and it causes the
engine to lug at takeoff, the system will override the
current position and select the best available gear.
Low (L)
Low (L) is at the lower end of the four-position selector switch located at the end of the SmartShift control. Use Low when wanting to maximize engine
braking and minimize the use of the brake pedal—for
example, when driving down long grades or when
coming to a stop. To select Low, press in the neutral
lock button and move the selector switch to the L
position. The lowest available start gear will be selected (the starting gear cannot be changed in Low).
If Low is selected while moving, the transmission will
not upshift (unless the system initiates a Low override). The system will downshift at the earliest opportunity to provide maximum engine braking.
NOTE: If attempting to select a non-Neutral
mode without applying the service brakes, the
transmission will not shift into gear. To shift into
gear, select Neutral, apply the service brakes,
and select the desired mode again.
Low Override
The system is equipped with a Low override function.
If the vehicle is being "back driven" (for example, descending a grade and vehicle speed exceeds engine
speed) and the engine speed is excessively high, the
system will upshift automatically. Also, if the start
gear is changed and it causes the engine to lug at
takeoff, the system will override the current position
and upshift.
Clutch Abuse Protection
Although a vehicle equipped with an UltraShift PLUS
uses an automated clutch, the clutch can still overheat and slip with improper use. The clutch abuse
protection feature helps protect the clutch if the automated clutch starts to overheat. When the clutch
abuse protection feature initiates and sounds a warning tone, full clutch actuation must be completed
quickly. If it is not completed quickly enough, the system will either open the clutch (if the throttle pedal is
not being pressed) or close the clutch (if the throttle
pedal is being pressed). If the abuse continues, the
system will open the clutch and take away throttle
control briefly to allow the clutch to cool down.
To protect the clutch:
• Select the lowest possible start gear for the
application.
• Use Creep Mode when appropriate.
• Use the service brakes and the Hill Start Aid
when launching on a grade.
• Minimize the time it takes to engage the clutch
from rest.
• Do not use the throttle to hold the vehicle on a
grade; use the service brakes.
14.8
Automated and Automatic Transmissions
• Do not use the throttle to stop roll back on an
incline after Hill Start Aid disengages; use the
service brakes, and then relaunch.
• Do not continually start and stop, especially
when loaded; use a lower gear or Creep Mode.
Creep Mode
The Creep Mode function allows the vehicle to maintain a constant speed at engine idle without the
driver holding the throttle pedal position. This mode
is useful for very low-speed maneuvering and applications where steady vehicle speed is required. The
vehicle speed is determined by the selected gear
ratio operating at governed low engine idle speed.
Any available gear may be selected, though the
transmission will downshift or exit Creep Mode to
prevent stalling if the engine lugs due to load conditions.
By default, Creep Mode can be activated while in
Manual Mode or Low. Eaton’s ServiceRanger diagnostic software can be used to enable Creep Mode
in Automatic Mode and/or Reverse.
Engaging Creep Mode
To engage Creep Mode:
1.
Select Low or Manual Mode and the desired
gear (while stopped or moving).
2.
Apply the throttle pedal to accelerate the vehicle
until the clutch is closed (engaged).
3.
Release the throttle pedal. The vehicle will continue moving at governed low engine idle speed.
allow for a controlled launch. A grade sensor is used
to determine when to engage the feature.
HSA is "on" by default. It can be turned off by pressing and releasing the override switch on the dash.
HSA will turn back on after the first successful
launch.
When the vehicle is stopped on a grade greater than
3% and in a forward mode or reverse, depress the
service brakes then release them. The vehicle will
begin to move after 3 seconds, and the clutch will
perform partial engagements to slow the vehicle motion. Either step on the brake or apply the throttle to
continue negotiating the grade.
Engine Overspeed Protection
The system will upshift if necessary to prevent engine overspeed in Drive, Manual, and Low.
Shuttle Shifting
Shuttle shifting from reverse to any forward mode is
only allowed if the vehicle speed is approximately
zero.
Auto Start Gear Selection and
Override
The UltraShift PLUS system uses various inputs to
automatically select the best start gear in Drive and
Manual. This selection can be changed using the
SmartShift control; however, if the selection requested could cause damage or engine lugging, the
request will be denied and a tone will sound.
Exiting Creep Mode
Skip Shifting
To exit Creep Mode, apply the throttle pedal to accelerate temporarily, or select a higher gear in Manual
Mode. (Creep Mode can be resumed in the selected
gear by releasing the throttle pedal.)
When appropriate, the UltraShift PLUS system may
skip shift in Drive. When prevailing conditions like
load and grade allow, skip shifts can be performed in
Manual mode using the SmartShift control.
NOTE: The transmission will exit Creep Mode if
the engine lugs 150 rpm below the governed
low engine idle speed. In this case, a lower gear
should be selected if available.
Auto Neutral
Hill Start Aid
UltraShift PLUS transmissions are equipped with a
Hill Start Aid (HSA) feature to prevent the vehicle
from rolling while on grades steeper than 3% and
14.9
The UltraShift PLUS system will automatically shift to
neutral if the vehicle is left in Drive and the parking
brake is set. "AN" will show on the gear display. To
re-engage the transmission, select Neutral and then
either Drive or Reverse on the shift control (it will reengage regardless of whether the parking brake is
released).
Automated and Automatic Transmissions
Automatic Traction Control
Coasting
The UltraShift PLUS system requires the Automatic
Traction Control (ATC) option to be enabled when
driving in soft soil/sand to prevent wheel slippage
and shifting issues. The ATC system has two modes:
"normal" (for sand and loose road surface) and a
mud/snow setting.
When coasting to a stop on level terrain, the UltraShift PLUS system may not downshift into the lower
gears. It will select a gear after the throttle is applied.
ATC Normal Mode
In normal mode, the system will engage the brakes
on the wheel or side that the wheel slip is occurring
to help the vehicle gain traction. The point at which
the traction control will actuate the braking system
increases with throttle: low throttle allows the system
to brake the wheels earlier; heavy/full throttle raises
the point of the acceptable wheel slip.
Adhere to the following points when driving in ATC
normal mode:
• If using Automatic mode in soft soil and/or
sand, maintain the engine speed between
1000 and 1300 rpm to prevent unnecessary
upshifting.
• If using Manual mode in soft soil and/or sand,
do not attempt an upshift and try to maintain
the current gear.
• If the vehicle comes to a stop in the sand it
may be necessary to back up prior to attempting forward movement.
ATC Mud/Snow Mode
To select the mud/snow mode, depress the ATC
switch. This mode raises the wheel slip speed that is
allowed before the traction control activates. The
point at which the traction control will actuate the
braking system increases with throttle: low throttle
allows the system to brake the wheels earlier; heavy/
full throttle raises the point of the acceptable wheel
slip.
Load-Based Shifting
The UltraShift PLUS system is adaptive and will
change the shift points based on grade, engine RPM,
throttle position, and vehicle load. After changing
loads or powering up, the system needs to relearn
these inputs for the first few shifts to make the
proper adjustments.
Eaton Fuller AutoShift
Automated Transmissions
Refer to the Eaton website for additional information,
www.roadranger.com.
General Information, AutoShift
Transmissions
Eaton Fuller AutoShift transmissions have ten or
eighteen forward speeds and two reverse speeds.
The driver must use the clutch to start and stop the
vehicle. However, the driver does not need to use
the clutch to shift gears. The transmission signals the
engine controller when to break torque and the engine controller automatically increases or decreases
engine speed. When engine speed is correct, the
transmission engages the next gear and signals the
engine controller to resume operation.
Operation, AutoShift Transmissions
Automatic and Manual Modes
The SmartShift control lever has a slide switch located on the body of the control lever just before the
paddle widens out. See Fig. 14.2. The slide switch
controls the forward driving mode, automatic (AUTO)
or manual (MAN).
To change mode at any time, move the slide switch
in the desired direction. This allows the driver to respond to a wide range of driving conditions, such as
blind corners, tight curves, and steep hills.
In either mode, the gear indicator displays the current gear. See Fig. 14.3.
At the start of a shift, the current gear continues to
display until the transmission has been pulled into
neutral. As the transmission is synchronizing for the
new (target) gear, the gear indicator flashes the number of the target gear.
When the shift is complete, the gear indicator displays the new gear, without flashing.
14.10
Automated and Automatic Transmissions
Automatic Mode
In automatic drive mode, upshifts and downshifts require no driver interaction. Press in the neutral lock
button, move the gear selector switch to drive (D),
depress the clutch to engage the gear selected, release the clutch, and press down on the throttle
pedal. The transmission will shift automatically based
on vehicle and transmission conditions.
If the vehicle is stopped while in drive, pull up or
push down on the SmartShift control lever to change
the starting gear.
If driving conditions require, it is possible to request 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.
Manual Mode
In manual drive mode (MAN), upshifts and downshifts are made by the driver. Manual mode should
be used whenever you want to select the shifts instead of letting the transmission shift automatically.
To upshift, pull the lever up (towards the driver). To
downshift, push the lever down (away from the
driver). The system will hold the current gear until the
driver requests a shift. In downhill situations in particular, the driver must be alert to vehicle speed by
downshifting and/or using the service brakes as
needed.
A shift request will be refused if the selected gear
would cause engine overspeed or excessive lugging.
5.
Depress the clutch again and release the parking
and service brakes.
6.
Select the desired starting gear.
7.
Release the clutch.
Selecting a Starting Gear
1.
In automatic mode, select drive (D) by sliding the
gear selector switch downward to the next position below the neutral position.
2.
Depress the clutch to engage the gear selected.
Release the clutch and drive the vehicle.
Changing the Default Starting Gear
To select a starting gear other than the default starting gear, follow the instructions below.
1.
Make sure the vehicle is stopped and in drive.
2.
In either automatic or manual mode, pull upward
(to increase) or push downward (to decrease) on
the SmartShift control lever. Each pull upward on
the control increases the starting gear by one
gear, but no higher than fourth gear.
3.
The number of the gear selected will flash on the
gear indicator until the driver releases the clutch.
This gear will be stored in memory as the default
starting gear until either a different starting gear
is selected by the driver or the engine is shut
down.
If the vehicle is stopped while in drive, pull up or
push down on the SmartShift control lever to change
the starting gear.
NOTE: The transmission may also be programmed so that it is not possible to select a
starting gear other than the preprogrammed default starting gear.
Power Up
Upshifting
1.
With the parking brake set, select neutral (N) by
moving the gear selector switch to the N position.
NOTE: With the transmission in drive in the automatic mode, upshifts require no driver interaction.
2.
Depress the clutch pedal all the way down to the
floor.
1.
3.
Start the engine. The CHECK TRANS and
TRANS TEMP lamps illuminate and go out again
(bulb check).
4.
Release the clutch to allow the speed sensor on
the input shaft to get a reading.
14.11
With the transmission in drive in the manual
mode, pull the control lever up (towards the
driver) to upshift. If the requested gear is available, the transmission will upshift and the new
gear will display on the gear indicator.
NOTE: Two consecutive, momentary upward
pulls will cause a skip shift when the next two
higher gears are available and conditions are
appropriate.
Automated and Automatic Transmissions
2.
To skip shift, move the control twice in less than
½-second. The number of the gear engaged will
appear on the gear indicator.
To select N, move the gear selector switch to the position below R. When neutral is selected, the letter N
displays on the current gear indicator. See Fig. 14.5.
NOTE: The Eaton Fuller AutoShift transmission
is able to perform triple upshifts when the next
three higher gears are available and conditions
are appropriate. To triple-shift, move the control
three times in less than ½-second.
NOTE: Neutral is always available during operation.
When in neutral, upshift and downshift requests are
ignored. If the gear selector switch is moved from
neutral (N) to drive (D) while the vehicle is moving,
the transmission will shift into the gear that is appropriate for the road speed of the vehicle.
If the gear requested is unavailable, a tone will
sound. An unavailable requested upshift is not
stored in memory; the upshift must be requested again.
Downshifting
NOTE: With the transmission in drive in the automatic mode, downshifts require no driver interaction.
1.
With the transmission in drive in the manual
mode, push the control lever down (away from
the driver) to downshift. If the requested gear is
available, the transmission will downshift.
NOTE: Two consecutive, momentary downward
pushes will cause a skip shift, when the next
two lower gears are available and conditions are
appropriate.
2.
To skip shift, move the control lever two times in
less than ½-second. The number of the gear engaged will appear on the gear indicator.
NOTE: The Eaton Fuller AutoShift transmission
is able to perform triple downshifts when the
next three lower gears are available and conditions are appropriate. To triple shift, move the
control lever three times in less than ½-second.
If the gear requested is unavailable, a tone will
sound. An unavailable requested downshift is
stored in memory and the shift will be made
when the gear is available. The time limit for this
memory is a programmable parameter.
Neutral
Select neutral by sliding the gear selector switch to
the N position.
N is located directly below R on the four-position
gear selector switch on the SmartShift control lever.
Drive
Drive (D) is located directly below N on the fourposition gear selector switch on the SmartShift control lever. To select D, press the neutral lock button
and move the gear selector switch to the position
below N. When D is selected, the number of the currently selected forward gear displays on the gear indicator. See Fig. 14.3.
When in drive, requests to upshift or downshift are
enabled. Either manual or automatic mode can be
selected on the slide switch.
Reverse
Reverse (R) is located at the upper end of the fourposition gear selector switch on the SmartShift control lever. To select R, press the neutral lock button
and move the gear selector switch upward to the position above neutral and depress the clutch pedal.
NOTE: AutoShift transmissions have a dualrange reverse. Reverse low (RL) is the default
reverse gear.
Select reverse high (RH) by pulling upward on the
SmartShift control lever. When reverse low is selected, the letter R displays on the current gear indicator. When reverse high is selected, the letter H displays on the current gear indicator. See Fig. 14.6.
NOTE: Reverse may be engaged below a programmable forward speed in order to rock the
vehicle. If reverse is selected above the programmed forward speed, an audible warning will
sound indicating that the gear is not available.
Low Gear Operation
Use low (L) to maximize engine braking and minimize the use of the brake pedal. It is most useful
when descending steep hills or when coming to a
stop. Engine speed will be increased by 200 rpm and
14.12
Automated and Automatic Transmissions
shift points will be offset by 200 rpm. The efficiency
of the exhaust brake will be maximized.
Low (L) is located at the lower end of the fourposition gear selector switch on the SmartShift control lever. To select L, press the neutral lock button
and move the gear selector switch to the position
below D.
1
2
Allison Automatic
Transmissions
Refer to the Allison website for additional information,
www.allisontransmission.com.
General Information, Allison
Transmissions
HD-series automatic transmissions have six forward
speeds and one reverse speed. These transmissions
have electronic shift controls that can be programmed to allow the use of different numbers of
geared speeds. For instance, the transmission can
be programmed to operate as a 4-speed, 5-speed, or
6-speed unit in the "primary" shift mode. If needed, a
"secondary" shift mode can be programmed to provide another shift configuration to optimize vehicle
use under different operating conditions. To activate
a secondary shift mode, or other special functions
programmed into the electronic control unit (ECU),
depress the Mode button. See Fig. 14.7. "Mode On"
is displayed in the indicator panel just above the
push buttons. A label just above the Mode button
identifies the special function.
NOTE: Each time a push button is depressed
on the shift selector, a short beep will be heard.
This indicates that the ECU has received input
to change operation.
Operation Tips, Allison Transmissions
WARNING
Never shift from neutral (N) to drive (D) or reverse (R) at engine speeds above idle. The vehicle will lurch forward or backward, which could
cause property damage and personal injury.
14.13
f600369a
10/31/94
1. Indicator Panel
2. Mode ID
Fig. 14.7, Allison Push Button Shift Selector
NOTICE
The engine should never be operated for more
than thirty seconds at full throttle with the transmission in gear and the output stalled. Prolonged
operation of this type will overheat the transmission fluid and will result in severe damage to the
transmission.
NOTICE
Do not allow the vehicle to coast in neutral. This
can result in severe transmission damage. Also,
no engine braking is available.
The following tips highlight important operation principles.
• Start the engine, then check the digital display
on the shift selector. Under "Select" at the top
of the unit, the display should always show the
"primary" shift mode. Under "Monitor," the current gear should be displayed.
• Use reverse (R) to back the vehicle. Com-
pletely stop the vehicle before shifting from a
forward gear to reverse, or from reverse to forward. There is only one reverse gear.
Automated and Automatic Transmissions
• Select drive (D) for all normal driving condi-
tions. The vehicle will start out in 1st gear, and
as speed increases, the transmission will upshift through each gear automatically. As the
vehicle slows down, the transmission will
downshift to the correct gear automatically.
• The pressure of your foot on the accelerator
pedal influences the automatic shifting. When
the pedal is fully depressed, the transmission
will automatically upshift near the governed
speed of the engine. A partially-depressed position of the pedal will cause the upshifts to
occur at a lower engine speed.
• Occasionally the road, load, or traffic conditions
make it desirable to restrict the automatic shifting to a lower range. The lower the gear range,
the greater the engine braking power.
• Use the up or down arrow buttons on the shift
selector to reach the desired gear. The "Select"
indicator will display your choice, and the
"Monitor" indicator will show the selected gear
once it is reached. In the lower gear ranges,
the transmission will not upshift above the
highest gear selected unless the engine governed speed is exceeded.
• Use neutral and apply the parking brake when
the vehicle is parked with the engine running.
14.14
15
Drive Axles
Differential Lock, Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Interaxle Lock, Tandem and Tridem Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Drive Axles
Differential Lock, Drive Axles
The driver-controlled differential lock feature (side-toside wheel lock, traction control, or traction equalizer)
is available on vehicles with single- or tandem-drive
axles.
The differential lock provides maximum traction for
slippery conditions by forcing the wheels on each
drive axle governed by the switch to rotate together.
When the differential lock is engaged, the clutch collar completely locks the differential case, gearing,
and axle shafts together, maximizing the traction of
both wheels.
Differential Lock Switch
See Fig. 15.1 for the differential lock switch on a vehicle with a single drive axle.
02/17/2006
f610797
Fig. 15.2, Differential Lock on Both Axles
that the blinking of the LED is barely noticeable.
If engagement of the differential lock mechanism is not possible for any reason (ignition is
turned off, vehicle is moving faster than 25
mph, etc.), the LED will stop blinking and turn
off.
• Slow Response: If engagement of the differen-
tial lock mechanism is slowed for any reason
(vehicle moving too fast, low air pressure, etc.),
the LED will continue to blink until the wheels
are able to lock. As in the normal response,
the LED illuminates steadily once the wheels
have locked.
10/26/2001
f610596
Fig. 15.1, Differential Lock on Single Drive Axle
For a vehicle with tandem axles, there are several
differential lock options available:
• one switch to control the differential lock on
only one of the drive axles (this switch will
show only one dot on one drive axle, varying
slightly from the switch shown in Fig. 15.2).
• one switch to control the differential locks on
both drive axles (Fig. 15.2).
• two switches, each of which controls the differ-
ential lock on one drive axle.
When the differential lock switch is pressed, three
responses are possible:
• Normal Response: The LED in the switch
blinks until the differential lock is engaged. At
this point, the LED illuminates steadily. In normal operation, the wheels may lock so quickly
15.1
• Abnormal Response: If the LED blinks for more
than 30 seconds, the lock mechanism may not
be fully engaged/disengaged. Bring the vehicle
to an authorized Freightliner service facility for
testing.
Differential Lock Operation
NOTE: On some vehicles, the differential lock
system is connected through the low speed
range of the transmission. If this system is used,
the transmission must be in the low speed
range for the wheels to fully lock. In addition,
shifting out of low speed range will also disengage the differential lock.
WARNING
Locking the wheels when the vehicle is traveling
down steep grades or when the wheels are slipping could damage the differential and/or lead to
loss of vehicle control, causing personal injury
and property damage.
Drive Axles
NOTICE
Engage the differential lock only when the vehicle is stopped or moving slowly at low speed,
less than 5 mph (8 km/h). Engaging the differential lock at high speeds can cause internal axle
damage.
1.
With the engine running, press the upper half of
the differential lock switch to engage the differential lock.
2.
If the vehicle is moving, briefly let up on the accelerator to relieve torque on the gearing, allowing the differential to fully lock.
WARNING
Be especially careful when driving under slippery
conditions with the differential locked. Though
forward traction is improved, the vehicle can still
slip sideways, causing possible loss of vehicle
control, personal injury, and property damage.
3.
Drive cautiously and do not exceed 25 mph (40
km/h). When the differential is fully locked, the
turning radius will increase because the vehicle
understeers. See Fig. 15.3.
A
NOTE: If the differential lock is engaged when
the engine is shut down, the differential lock will
disengage.
5.
If the vehicle is moving, briefly let up on the accelerator to allow the wheels to fully unlock, then
resume driving at normal speed.
Single Drive Axles with Traction
Equalizer
Some single drive axles are equipped with a traction
equalizer that is a load-sensing, self-actuating feature. A traction equalizer provides normal differential
action where traction is good. When one wheel begins to spin faster than the other, clutch plates in the
differential housing automatically engage, delivering
power to both wheels. There is no operator control
with this feature.
NOTICE
Tire sizes on both rear wheels should be the
same on axles equipped with a traction equalizer.
If not, excessive wear may occur in the traction
equalizer.
Interaxle Lock, Tandem and
Tridem Axles
The interaxle lock (axle lock, interaxle differential
lockout) feature causes the drive axle shafts to rotate
together, and is recommended for use under adverse
road conditions where greater traction is needed.
B
See the axle manufacturer’s website for more information.
f350079a
02/09/96
A. Turning Radius When the Differential Lock is
Engaged (understeer condition)
B. Turning Radius When the Differential Lock is
Disengaged
Fig. 15.3, Turning Radii
4.
Press the upper half of the differential lock switch
again to disengage the differential lock after leaving poor road conditions.
When engaged, the interaxle lock essentially makes
the driveshaft a solid connection between the drive
axles. Power entering the forward axle is transmitted
straight through to the rearmost axle(s). Driveline
torque is now delivered equally and the drive axles,
and wheels, turn together at the same speed. The
interaxle lock increases drivetrain and tire wear and
should be used only when improved traction is
required.
Interaxle Lock Switch
The interaxle lock switch (Fig. 15.4) allows the driver
to lock the drive axles together.
15.2
Drive Axles
lock. Do not wait until traction is lost and the tires
are spinning before engaging the interaxle lock.
2.
If the vehicle is moving, briefly let up on the accelerator until the interaxle lock engages. The
red interaxle indicator light illuminates on the
dash message center when interaxle lock is engaged.
NOTICE
10/26/2001
f610595
Fig. 15.4, Interaxle Lock Switch
When the interaxle lock switch is pressed, three responses are possible:
• Normal Response: The LED in the switch
blinks until the interaxle lock is engaged. At
this point, the LED illuminates steadily. In normal operation, the interaxle lock may engage
so quickly that the blinking of the switch is
barely noticeable.
If engagement of the interaxle lock mechanism
is not possible for any reason (ignition is
turned off, vehicle is moving too fast, etc.), the
LED will stop blinking and turn off.
• Slow Response: If engagement of the interaxle
lock mechanism is slowed for any reason (by
cold weather, low air pressure, etc.), the switch
will continue to blink until the axles lock together, or for a maximum of 10 seconds. As in
the normal response, the LED illuminates
steadily once the lock mechanism is engaged.
• Abnormal Response: If the LED blinks for more
than 30 seconds, the lock mechanism may not
be fully engaged/disengaged. Bring the vehicle
to an authorized Freightliner service facility for
testing.
Interaxle Lock Operation
NOTICE
The interaxle lock should not be engaged on a
vehicle with obviously spinning wheels. Engagement at high speed or power can damage the
axle(s).
1.
15.3
With the engine running, press the upper half of
the interaxle lock switch to engage the interaxle
Do not operate the vehicle continuously with the
interaxle locked during extended good road conditions. To do so could result in damage to the
axle gearing and excessive driveline and tire
wear.
3.
Proceed over poor road conditions with caution.
4.
Press the upper half of the interaxle lock switch
again to disengage the interaxle lock after leaving poor road conditions.
NOTE: If the interaxle lock is engaged when the
engine is turned off, the interaxle lock will disengage.
5.
If the vehicle is moving, briefly let up on the accelerator to allow the interaxle lock to disengage,
then resume driving at normal speed. Once the
interaxle lock disengages, the indicator light will
go off.
16
Steering System
Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Steering System
Power Steering System
The power steering system includes the power steering gear, hydraulic hoses, power steering pump, reservoir, steering wheel and column, and other components. Some models are also equipped with a
separate hydraulic power cylinder on the right side of
the front axle, or a right-hand slave gear.
ing wheel spokes should be at the 3 o’clock and 9
o’clock positions or within 10 degrees of these positions. See Fig. 16.1.
The power steering pump, driven by the engine, provides the power assist for the steering system. If the
engine is not running, there is no power assist.
WARNING
Driving the vehicle without the power-assist feature of the steering system requires much greater
effort, especially in sharp turns or at low speeds,
which could result in an accident and possible
injury.
If the power-assist feature does not work due to hydraulic fluid loss, steering pump damage, or another
cause, bring the vehicle to a safe stop. Do not drive
the vehicle until the cause of the problem has been
corrected.
NOTICE
Never steam clean or high-pressure wash the
steering gear. Internal damage to gear seals, and
ultimately the steering gear, can result.
Drivers should carefully use the power available with
a power steering system. If the front tires become
lodged in a deep hole or rut, drive the vehicle out
instead of using the steering system to lift the tires
out of the hole.
NOTICE
Avoid turning the tires when they are against a
curb, as this places a heavy load on steering
components and could damage them.
Steering Wheel Adjustment
Two steering wheels are available: a standard 18inch (450-mm) steering wheel and an optional 20inch (500-mm) steering wheel.
When there is no load on the vehicle and the front
tires are pointed straight ahead, the standard steer-
16.1
10°
10°
2
1
10°
10°
05/10/2007
f462075
1. 9 o’Clock
2. 3 o’Clock
Fig. 16.1, Steering Wheel Centered
On the optional 20-inch (500-mm) wheel, the steering
wheel spokes should be at the 4 o’clock and 8
o’clock positions or within 10 degrees of these positions. For steering wheel adjustment procedures, see
Group 46 of the 108SD and 114SD Workshop
Manual.
17
Fifth Wheels
Fifth
Fifth
Fifth
Fifth
Wheels, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17.1
17.1
17.4
17.7
Fifth Wheels
Fifth Wheels, General
Information
Fifth Wheel Lubrication
WARNING
WARNING
Do not use any fifth wheel that fails to operate
properly. Doing so may cause loss of vehicle
control, possibly resulting in severe personal injury or death.
Air-Suspension Dump Valve
The air-suspension dump valve may be used to adjust the vehicle height in order to aid with coupling to
or uncoupling from a trailer. See Fig. 17.1. When the
switch is set to LOWER, the air-suspension dump
valve deflates the air springs to lower the rear of the
vehicle. In the AUTO position, the automatic ridecontrol valves operate for normal driving.
WARNING
Keep the fifth wheel plate lubricated to prevent
binding between the tractor and trailer. A binding
fifth wheel could cause erratic steering and loss
of vehicle control, possibly resulting in personal
injury or death.
The standard fifth wheel plate must be kept well lubricated with chassis grease to prevent friction and
binding between the vehicle fifth wheel plate and the
trailer.
For a low-lube fifth wheel plate, inspect the condition
of the low-lube pads. There should be no damaged
or missing pieces. Slight puckering at the outside
edges is normal.
For lubrication instructions, see Group 31 of the
108SD and 114SD Maintenance Manual.
Fifth Wheel Coupling
Never exhaust air from the suspension while
driving. The suspension will not absorb road
shocks, possibly damaging components, and vehicle handling may be compromised. This could
result in loss of vehicle control, possibly resulting in severe personal injury or death.
Fifth wheel coupling is activated with the lock control
handle located on either the right or left side of the
fifth wheel. Coupling is complete when the kingpin
has been forced into the jaws and the lock control
handle has moved to the locked position.
NOTICE
NOTICE
Do not operate the vehicle over uneven ground
such as ramps, speed bumps, curbs, etc. with
the air springs deflated. Doing this may lead to
air bag separation from the piston, preventing the
suspension air springs from inflating.
Some fifth wheels may be mounted on sliding
rails. Before attempting to couple a trailer to a
sliding fifth wheel, the slide feature must be
locked to prevent the top plate from sliding rapidly forward or rearward, causing damage to the
fifth wheel or kingpin.
Fontaine and Holland Fifth Wheels
Coupling
10/26/2001
Fig. 17.1, Air-Suspension Dump Valve
17.1
f610597
1.
Chock the front and rear trailer tires.
2.
Ensure the fifth wheel jaw is fully open and the
operating rod is in the unlocked position. See
Fig. 17.2 or Fig. 17.3.
3.
Make sure the fifth wheel top plate is tilted so the
ramps are as low as possible.
Fifth Wheels
1
1
2
A
2
1
1
3
B
2
f310110a
10/26/2010
NOTE: Make sure the safety latch is down when the
control handle is locked.
A. Unlocked
1. Safety Latch
B. Locked
2. Lock Control Handle
Fig. 17.2, Fontaine Locking Mechanism
4.
f310447
11/02/2010
1. Safety Latch
2. Operating Rod
(locked)
3. Operating Rod
(unlocked)
Fig. 17.3, Holland Simplex SE Locking Mechanism
Position the vehicle so that the center of the fifth
wheel is in line with the trailer kingpin. The kingpin should be in a position to enter the throat of
the locking mechanism.
D
C
A
NOTICE
Attempting to couple at the wrong height may
cause improper coupling, which could result in
damage to the fifth wheel or kingpin.
5.
Adjust the trailer height if required.
For a standard fifth wheel plate, the trailer
should contact the fifth wheel approximately 4 to
8 inches (10 to 20 cm) behind the fifth wheel
pivot. See Fig. 17.4.
For a low-lube fifth wheel plate, the fifth wheel
must slide freely under the trailer, and the trailer
should contact the fifth wheel at the pivot. See
Fig. 17.5.
6.
With the fifth wheel lock opening aligned with the
trailer kingpin, back the vehicle slowly toward the
trailer. After sliding under the trailer, STOP to
B
10/28/2010
A. Fifth wheel must lift
trailer
B. Adjust trailer height
f311124
C. Ramps tilted down
D. 4 to 8 inches
Fig. 17.4, Trailer Connection Point, Standard Fifth
Wheel Plate
prevent from hitting the kingpin too hard, then
resume backing slowly until the fifth wheel locks.
On a standard fifth wheel, the fifth wheel must lift
the trailer.
On a low-lube fifth wheel, do not lift the trailer as
this may damage the fifth wheel plate.
17.2
Fifth Wheels
B
A
B
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f311126
A. No gap between trailer
and fifth wheel
B. Kingpin inside lock
A
Fig. 17.6, Coupling Inspection
09/10/2010
f311125
A. Adjust trailer height
Fig. 17.5, Trailer Connection Point, Low-Lube Fifth
Wheel Plate
7.
Apply the vehicle parking brake.
WARNING
A visual inspection is required by law. Some improper couplings can pass a pull test. Sound is
not reliable. Get out of the cab and look. Incorrect coupling could cause the trailer to disconnect, possibly resulting in serious personal injury
or death.
8.
Perform a coupling inspection, checking that
there is no gap between the bottom of the trailer
and the fifth wheel, and that the kingpin is securely locked. See Fig. 17.6
When lockup has occurred, the fifth wheel control handle moves to the locked position. Make
sure that the safety latch is down over the lock
control handle to hold the control handle in the
locked position (the safety latch will only rotate
down if the operating rod is fully retracted in the
locked position). See Fig. 17.2 for Fontaine fifth
wheels. See Fig. 17.3 for Holland fifth wheels.
9.
Release the vehicle parking brake. Test for kingpin lockup by slowly inching the vehicle forward,
pulling on the trailer against the chocks.
10. After lockup is completed, connect the tractor-to-
trailer air system lines and the electrical cable to
the trailer. Take care to prevent dirt or foreign
material from entering the air system lines.
17.3
NOTICE
B. Ramps tilted down
Always make sure the connection hanger keeps
the trailer air hoses and electrical cables positioned so that they do not rub on anything. Rubbing may wear through hoses or cables, resulting
in air leaks, or exposed or broken wires, potentially affecting trailer brake or electrical systems.
11. Charge the air brake system with air, checking
that the air connections do not leak.
WARNING
Incorrect fifth wheel lock adjustment could cause
the trailer to disconnect, possibly resulting in serious personal injury or death.
12. With the trailer tires chocked and the brakes set,
check for clearance between the kingpin and the
fifth wheel jaws by moving the vehicle forward
and backward against the locked kingpin. If slack
is present, uncouple the trailer and have the fifth
wheel inspected and adjusted by a certified
technician.
Jost Fifth Wheel Coupling
1.
Tilt the ramp down.
2.
Open the kingpin locks. See Fig. 17.7.
3.
Back the vehicle close to the trailer, centering the
kingpin on the fifth wheel.
4.
Chock the trailer tires.
5.
Connect the air lines and electrical cable.
6.
Ensure that the red trailer air supply valve (trailer
brake) is pulled out, and that the trailer parking
Fifth Wheels
not reliable. Get out of the cab and look. Incorrect coupling could cause the trailer to disconnect, possibly resulting in serious personal injury
or death.
A
11. Perform a physical check for positive kingpin
lockup, ensuring that there is no gap between
the trailer and the fifth wheel. See Fig. 17.6.
12. Ensure that the release handle is in the locked
position adjacent to the casting. See Fig. 17.8.
13. Release the vehicle parking brake and test for
09/10/2010
kingpin lockup by slowly moving the vehicle forward, pulling on the trailer against the chocks.
f311128
A. Lock held open by catch mechanism
Fig. 17.7, Jost Release Handle Unlocked
brakes are set. See Chapter 5 in this manual for
operation of the dash-mounted brake controls.
NOTICE
Attempting to couple at the wrong height may
cause improper coupling, which could result in
damage to the fifth wheel or kingpin.
7.
Manual Uncoupling
1.
Apply the vehicle and trailer parking brakes.
2.
Chock the trailer rear wheels.
3.
Lower the trailer landing gear until the weight is
removed from the fifth wheel.
4.
Disconnect the tractor-to-trailer air system lines
and electrical cable. Plug the air lines to prevent
dirt or foreign material from entering the lines.
5.
Verify that both the yellow parking-brake and red
trailer air supply knobs are out, the vehicle and
trailer parking brakes are set, and that the trailer
is prepared for uncoupling.
6.
Release the kingpin locking mechanism following
the instructions for each manufacturer lilsted
below.
Adjust the trailer height (if required).
For a standard fifth wheel plate, the trailer
should contact the fifth wheel approximately 4 to
8 inches (10 to 20 cm) behind the pivot. See
Fig. 17.4.
For a low-lube fifth wheel plate, the fifth wheel
must slide freely under the trailer, and the trailer
should contact the fifth wheel at the pivot. See
Fig. 17.5.
8.
Fifth Wheel Uncoupling
Back the vehicle under the trailer.
6.1
Fontaine: Lift the safety latch and pull the
lock control handle to the unlocked position. See Fig. 17.2.
6.2
Holland: In the locked position the safety
indicator swings freely over the operating
rod. See Fig. 17.9, View A.
On a standard fifth wheel, the fifth wheel must lift
the trailer.
On a low-lube fifth wheel, do not lift the trailer as
this may damage the fifth wheel plate.
9.
After sliding under the trailer, STOP to prevent
from hitting the kingpin too hard, then resume
backing slowly until the fifth wheel locks.
10. Apply the vehicle parking brake.
WARNING
A visual inspection is required by law. Some improper couplings can pass a pull test. Sound is
To unlock the mechanism, manually rotate
the safety indicator toward the rear of the
fifth wheel. See Fig. 17.9, View B.
Pull the operating rod out. When the
upper operating rod shoulder is outside
the slot, raise the handle and place the
shoulder of the upper rod against the plate
casting, above the slot. See Fig. 17.9,
View C.
17.4
Fifth Wheels
OK
OK
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f311127
Fig. 17.8, Jost Release Handle Locked
The fifth wheel is now in the lockset position and is ready for uncoupling. As the
vehicle pulls away from the trailer the
kingpin forces the jaw to rotate, contacting
the lock. Continued rotation of the jaw
forces the lock to move outward, and
drops the upper rod back into the slot.
See Fig. 17.9 View D. The wheel is now
ready for coupling.
6.3
7.
Jost: Pull the retractable handle out, then
secure it in the open position with the
catch. See Fig. 17.7.
Release the vehicle parking brake, then drive
forward slowly, allowing the trailer to slide down
the fifth wheel and pick-up ramps.
been uncoupled and coupled again. Failure to do
so may result in separation of the trailer from the
tractor, possibly causing serious personal injury
or death.
Preparing the Trailer for Uncoupling
Before using the air valve to unlock a fifth wheel
kingpin, prepare the trailer as follows.
1.
Apply the vehicle and trailer parking brakes.
2.
Chock the rear trailer tires.
3.
Lower the trailer landing gear until the weight is
removed from the fifth wheel.
4.
Disconnect the tractor-to-trailer air lines and electrical cable. Plug the air lines to prevent dirt or
foreign material from entering the lines.
Air-Actuated Uncoupling
An air-actuated kingpin release valve is optional with
all fifth wheels. See Fig. 17.10.
Air-Activated Kingpin Unlock, Fontaine
and Holland Fifth Wheels
NOTE: In the event of an air system failure, airactuated kingpins can be manually released following the instructions for manual unlocking.
1.
WARNING
Once the kingpin release valve has been pulled
the kingpin lock is released. The vehicle MUST
NOT be driven with the trailer until the trailer has
17.5
Verify that both the yellow parking-brake and red
trailer-air supply knobs are out, the vehicle and
trailer parking brakes are set, and that the trailer
is prepared for uncoupling.
NOTE: If the vehicle parking brake is not set,
the air-actuated kingpin-release valve will not
activate.
Fifth Wheels
3
1
A
4
C
2
B
D
11/02/2010
A.
B.
C.
D.
1.
2.
f311133
Locked Position
Unlatched Position (safety indicator rotated towards the rear of the fifth wheel)
Lockset Position (upper rod resting against casting above slot)
Open Position (ready for coupling)
Safety Indicator
3. Upper Rod
Operating Rod
4. Plate Casting
Fig. 17.9, Holland Kingpin Locking Mechanism
2.
Pull and hold the kingpin release valve until the
kingpin lock mechanism opens and locks in
place. See Fig. 17.10.
3.
Let go of the kingpin release valve.
4.
Release the vehicle parking brake.
5.
Drive out from under the trailer.
Air-Activated Kingpin Unlock, Jost Fifth
Wheels
1.
Verify that both the yellow parking-brake and red
trailer air supply knobs are out, the vehicle and
trailer parking brakes are set, and that the trailer
is prepared for uncoupling.
17.6
Fifth Wheels
The maximum axle weight ratings are shown on the
Federal Motor Vehicle Safety Standard (FMVSS)
label or Canadian Motor Vehicle Safety Standard
(CMVSS) label attached to the left rear door post of
the vehicle. The desired load on the axle is no less
than 80 percent of the maximum axle weight rating,
but in no instances should the axle load exceed the
maximum axle weight rating given on the FMVSS or
CMVSS label.
Manual Slide Operation
Use the following procedure to manually slide the
fifth wheel. See Fig. 17.11.
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f611102
1
Fig. 17.10, Air-Actuated Kingpin Release Valve
NOTE: If the trailer parking brake is not set, the
air-actuated valve will not activate.
2.
Release the vehicle parking brake.
3.
Pull and hold the kingpin release valve, then
drive forward slowly.
4.
After the trailer has slid down the fifth wheel and
pick-up ramps, let go of the kingpin release
valve.
Fifth Wheel Slide
WARNING
2
07/25/95
Adjust the fifth wheel slide correctly, and do not
overload any tractor axle by incorrectly loading
the trailer. Incorrect slide adjustment or improper
axle loading could cause erratic steering and
loss of vehicle control, possibly resulting in serious personal injury or death.
On sliding fifth wheel assemblies, the fifth wheel
plate is attached to rails that allow forward and rearward movement of the fifth wheel in order to optimally distribute the load across the axles. Slots are
evenly spaced along the slide rails, and retractable
wedges are positioned through the slots to hold the
fifth wheel in the desired position.
The amount of load distribution on the front steering
axle and rear drive axle(s) will have a direct effect on
the steering control of the vehicle. Determine the
front and rear axle weights by weighing the vehicle
on scales designed for this purpose.
17.7
f310190
1. Locking Wedge
2. Slide Release Pull Handle
Fig. 17.11, Manual Release Sliding Fifth Wheel,
Fontaine
1.
Stop the vehicle and trailer in a straight line on
level ground. Pull the red trailer air supply knob
to apply the trailer parking brakes.
2.
Apply the vehicle parking brake, then release the
sliding mechanism using the appropriate method
for the fifth wheel manufacturer.
2.1
Fontaine: Lift the slide release pull handle
to disengage it from the guide plate. Then,
pull out the handle until it is in the unlocked position and can be positioned
against the guide plate to hold it out. The
Fifth Wheels
handle will stay in the unlocked position
until it is manually disengaged from the
guide plate. See Fig. 17.12.
2.2
3.
Holland: Pull the operating rod out. Make
sure both side plungers have released.
See Fig. 17.13.
Lower the trailer landing gear just enough to remove the weight from the vehicle.
4.
Chock the front and rear trailer tires to prevent
the trailer from moving.
NOTICE
When moving the fifth wheel to the desired position, be sure the trailer landing gear will not at
any time come in contact with the vehicle frame
or other components. Make sure that the front of
the trailer will not come in contact with the rear
of the cab or with other components if they extend beyond the rear of the cab.
5.
Release the vehicle parking brake, then slowly
move the vehicle forward or backward until the
fifth wheel is in the desired location.
WARNING
Check that the locking wedges have seated in the
slots. Failure to achieve complete lockup may
allow disengagement of the tractor from the
trailer, possibly resulting in serious personal injury or death.
10/26/2010
f310050
Fig. 17.12, Sliding Fifth Wheel Manual Release,
Fontaine
6.
Apply the vehicle parking brake, then lock the
sliding member in position using one of the following methods:
6.1
Fontaine: Disengage the slide release
pull handle from the guide plate. The slide
release pull handle is spring-loaded in the
locked position and will seek the locked
position when disengaged from the guide
plate. After the slide release pull handle
returns to the fully locked position, visually
and physically check the locking wedges
to make sure they are fully inserted into
the slots in the slide rails. Make sure the
handle is locked in position against the
guide plate.
6.2
Holland: Raise the operating rod so that it
is free to move inward. Make sure that the
lock pins have seated in the base plate
rail holes and the operating rod moves
into the locked position.
5
4
6
3
8
3
2
7
1
10/26/2010
1.
2.
3.
4.
Baseplate
Bolted Stop
Baseplate Rail
Fifth Wheel Mount
f310445
5.
6.
7.
8.
Slider Saddle Plate
Safety Latch
Operating Rod
Operating Lever
Fig. 17.13, Sliding Fifth Wheel Manual Release, Holland
Simplex
NOTE: The fifth wheel may need to be moved
slightly to enable the locking wedges to enter
the fully locked position.
17.8
Fifth Wheels
Air Slide Operation
The slide feature may be operated with a dashmounted air-slide switch that operates an air cylinder
that locks and unlocks the slide. See Fig. 17.14.
A
02/22/2011
f611114
Fig. 17.14, Air-Slide Switch
1.
Set the air-slide switch to SLIDE. See Fig. 17.14
Ensure the locking plungers have released. See
Fig. 17.15.
B
For Jost fifth wheels, the mechanism activates as
shown in Fig. 17.16.
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f311131
A. Unlocked
1
B. Locked
Fig. 17.16, Jost Sliding Fifth Wheel
4.
Slowly move the vehicle forward or backward
until the fifth wheel is in the desired location.
NOTICE
Ensure the trailer landing gear does not come in
contact with the vehicle frame or other components, and that the front of the trailer will not
come in contact with the rear of the cab or other
components if they extend beyond the rear of the
cab.
5.
Apply the vehicle parking brake.
2
f310189
07/25/95
1. Locking Wedge
Fig. 17.15, Air-Operated Sliding Fifth Wheel, Fontaine
2.
Lower the trailer landing gear just enough to remove the weight from the vehicle.
3.
Pull the red trailer air supply knob to set the
trailer parking brakes.
17.9
WARNING
2. Air Cylinder
Check that the locking wedges have seated in the
slots. Failure to achieve complete lockup may
allow disengagement of the tractor from the
trailer, possibly resulting in serious personal injury or death.
Fifth Wheels
6.
Set the air-slide switch to LOCK. Visually inspect
the locking wedges or plungers to make sure
that they are fully inserted in the slide rail slots.
Verify that the plungers have engaged by tugging
the vehicle forward while the trailer brakes are
locked and the tires are chocked.
NOTE: The fifth wheel may need to be moved
slightly to enable the locking wedges to fully
lock.
17.10
18
Trailer Couplings
Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Premier Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
Trailer Couplings
Air-Suspension Dump Valve
1
The air-suspension height switch may be used to aid
in connecting or disconnecting from a trailer. When
the switch is set to LOWER, the air-suspension
dump valve deflates the air springs to lower the rear
of the vehicle. In the normal position, the automatic
ride-control valves operate for normal driving.
2
3
NOTICE
Do not operate the vehicle over uneven ground
such as ramps, speed bumps, curbs, etc. with
the air springs deflated. Doing this may lead to
air bag separation from the piston, preventing the
suspension air springs from reinflating.
4
12/08/2010
f311139
1. Lock
2. Cotter Pin
3. Latch
4. Pintle Hook
Fig. 18.1, Holland PH-760 Trailer Coupling
NOTICE
Never exhaust air from the suspension while
driving. When the air is exhausted, the suspension will not absorb road shocks, and components may be damaged.
Holland Trailer Coupling
General Information
IMPORTANT: Refer to the Holland web site
(www.hollandhitch.com) for additional information.
The Holland trailer coupling (Fig. 18.1) is designed
for use with trailers having a maximum gross weight
of 49,000 lbs (22 226 kg). It is a swivel-mount pintle
hook designed for heavy-duty construction, utility,
and off-road applications. It is fastened to the rear
closing crossmember of the vehicle and is a non-airadjusted coupling.
Trailer Hookup
1.
Chock the front and rear tires of the trailer.
2.
Remove the cotter pin, then lift the lock and raise
the latch.
3.
Back the vehicle up until the drawbar eye is over
the horn of the pintle hook.
4.
Lower the trailer until the drawbar eye rests on
the pintle hook.
5.
Close the latch, then insert the cotter pin.
18.1
NOTICE
Always make sure the connection hanger keeps
the trailer air hoses and electrical cables positioned so that they do not rub on anything. Rubbing may wear through hoses or cables, resulting
in air leaks, or exposed or broken wires, potentially affecting trailer brake or electrical systems.
6.
Connect the trailer electrical and air lines.
Trailer Release
1.
Apply the truck and trailer parking brakes.
WARNING
Do not use the trailer air supply for parking trailers not equipped with spring parking brakes.
This applies the trailer service brakes only. As air
bleeds from the trailer brake system, brake application is lost. This could allow the unattended
vehicle to roll away, possibly resulting in serious
personal injury or death.
2.
Chock the front and rear tires of the trailer.
3.
Disconnect the trailer air and electrical lines.
Plug the air lines to keep them free of dirt.
4.
Take the weight of the trailer drawbar off the
pintle hook.
5.
Open the latch by first removing the cotter pin,
then lift up the lock and raise the latch.
Trailer Couplings
6.
Trailer Hookup
Slowly drive the vehicle away from the trailer.
Premier Trailer Couplings
General Information
IMPORTANT: Before operating the Premier coupling, refer to the Premier web site at
www.premier-mfg.com for complete safety,
operation, and maintenance instructions.
Trailer couplings are attached to the rear closing
crossmember. The Premier trailer couplings
(Fig. 18.2) are designed for use with trailers having a
maximum gross weight of 100,000 lbs (45 455 kg).
The Premier 2200 and 2400 trailer couplings are air
adjusted couplings with a rigid pintle hook, attached
to the rear closing crossmember. An air chamber,
mounted forward of the coupling, operates a push
rod, which pushes against a shoe inside the coupling. The shoe maintains constant pressure on the
eye of the trailer drawbar when it’s over the pintle
hook. This takes up any slack in the trailer connection, providing smoother towing and less wear on the
pintle hook. The air pressure is activated when the
trailer brakes are released.
1.
Chock the front and rear tires of the trailer.
2.
Push the latch lock towards the mounting plate
as far as possible then, while holding the latch
lock in place against the mounting plate, pull the
top of the latch as far as possible toward the
pintle hook.
3.
While holding the latch in place, release the latch
lock.
4.
Back the vehicle up until the drawbar eye is over
the pintle hook, then lower the trailer.
5.
Pull the top of the latch as far as possible toward
the pintle hook then, while holding the latch in
position, push the latch lock towards the mounting plate.
6.
While holding the latch lock in place against the
mounting plate, release the latch.
7.
Release the latch lock and make sure it is fully
seated in the slot on top of the latch.
1
1
2
2
3
3
A
B
12/08/2010
f311138
A. Premiere 2400 Trailer Coupling
1. Latch Lock
2. Latch
B. Premiere 2200 Trailer Coupling
3. Pintle Hook
Fig. 18.2, Premiere 2200 and 2400 Trailer Couplings
18.2
Trailer Couplings
NOTICE
Always make sure the connection hanger keeps
the trailer air hoses and electrical cables positioned so that they do not rub on anything. Rubbing may wear through hoses or cables, resulting
in air leaks, or exposed or broken wires, potentially affecting trailer brake or electrical systems.
8.
Connect the trailer’s electrical and air lines.
Trailer Release
1.
Apply the truck and trailer parking brakes.
WARNING
Do not use the trailer air supply for parking trailers not equipped with spring parking brakes.
This applies the trailer service brakes only. As air
bleeds from the trailer brake system, brake application is lost. This could allow the unattended
vehicle to roll away, possibly resulting in serious
personal injury or death.
2.
Chock the front and rear tires of the trailer.
3.
Disconnect the trailer air and electrical lines.
Plug the air lines to keep them free of dirt.
4.
Take the weight of the trailer drawbar eye off the
pintle hook.
5.
Push the latch lock towards the mounting plate
as far as possible then, while holding the latch
lock in this position, pull the top of the latch as
far as possible toward the pintle hook.
6.
While holding the latch in place, release the latch
lock.
7.
Slowly drive the vehicle away from the trailer.
18.3
19
Natural Gas Vehicle
Natural Gas Vehicles, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Natural Gas Vehicles, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Natural Gas Fuel Tank Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2
Natural Gas Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5
Natural Gas Vehicles, Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9
Major Repair and Replacement of Natural Gas Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10
Natural Gas Vehicle
Natural Gas Vehicles, General
Information
The vehicle can be equipped with a compressed
natural gas (CNG) fuel system, or a liquefied natural
gas (LNG) fuel system. CNG is made by compressing natural gas to less than 1% of its volume at standard atmospheric pressure. LNG is created by condensing natural gas into a liquid by cooling it to
approximately -259°F (-162°C). CNG often contains
an odor-producing chemical, while LNG does not
have any odor.
Natural Gas Vehicles, Safety
Precautions
DANGER
Natural gas is highly flammable. Failure to observe the following safety precautions could lead
to the ignition of the natural gas, which could
cause serious bodily injury or death.
Follow these safety precautions when operating or
repairing a natural gas vehicle.
When vaporized at ambient temperatures, natural
gas is less dense than air, and it rises and disperses.
However, LNG is intially heavier than air due to its
cryogenic temperature. When released in large
amounts, it may drop or pool on the ground before
its temperature rises enough to vaporize. Cold atmospheric conditions may prevent natural gas from
dispersing quickly when released in large amounts.
• Do not start the engine if a natural gas leak is
Natural gas is nontoxic, but it can cause asphyxiation
if present in very large concentrations.
• Avoid open flames or sparks near a natural
For natural gas to burn, it must first vaporize, then
mix with air in the proper proportions (flammable
range is 5 to 15% by volume in air), and then be ignited.
• Cover eyes and exposed skin when working on
A typical natural gas fuel system consists of:
• Fuel supply cylinders that store compressed
gas at high pressure (CNG), or a tank that
stores liquefied gas at an extremely low temperature (LNG).
• A vaporizor or heat exchanging device that
changes LNG to gaseous form (LNG fuel systems 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 fuel
filling line.
• High-pressure and low-pressure fuel filters.
• A pressure control regulator that reduces the
high fuel tank or cylinder pressure to the lower
pressure needed for the engine.
• A fuel contents gauge that indicates the fuel
supply in the tank or cylinders.
19.1
detected.
• Do not transfer CNG from one vehicle to an-
other, as a buildup of static electricity could
cause a spark and ignite the fuel.
• Do not attempt to cut any fuel supply piping
components.
gas vehicle.
a natural gas fuel system or fueling a natural
gas vehicle.
• Permit no smoking or other ignition sources
within thirty feet of a natural gas vehicle.
• Have CO2 fire extinguishers (ABC minimum)
located in a highly visible and easily accessible
location.
• Use Purple-K powder (PKP) or a similar dry
powder to extinguish an LNG fire. Do not attempt use water around an LNG fire.
• Always purge the fuel lines before performing
maintenance or repairs on a natural gas fuel
system. To purge the lines, close the manual
fuel shutoff valve, and start the engine. Let the
vehicle idle until the fuel lines are empty and
the engine stops.
• Always use a natural gas detector to test the
system for leaks, whether an odor is present or
not. Routinely inspect the fuel filtering and
regulating mechanisms, and the fuel lines. A
bubble solution can be used to pinpoint the
exact location of leaks.
Natural Gas Vehicle
• Always tighten fasteners and fuel connections
to the required torque specification. Overtightening 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 for
any extended period of time. Do not bring a
natural gas vehicle indoors unless the workshop is equipped with a methane detection and
ventilation system.
In Case of Emergency
If a vehicle has sustained damage or a leak has
been discovered:
1.
Turn the ignition switch off, set the parking brake,
and disconnect the battery.
2.
Remove all ignition sources from the area surrounding the vehicle.
3.
If it is safe to do so, close all fuel shutoff valves.
4.
Open the vehicle doors to introduce fresh air.
5.
Use a natural gas detector to identify leaks in the
fuel system.
Natural Gas Fuel Tank Filling
Procedures
CNG Vehicle Fueling
CNG is moved from the fuel station storage tanks to
the vehicle cylinders through a metered dispenser.
During fueling, as pressure inside of the vehicle cylinders increases, so does the temperature. The dispenser shuts off when it determines the CNG cylinders are full.
CNG fuel cylinders cannot be filled to their full capacity of 3600 psi (24 800 kPa) in cooler weather. Since
temperature change causes gas to expand and contract, less pressure in the cylinders on a cold day is
equal to the same amount of gas at a higher pressure on a warm day. The fuel station dispenser has a
temperature-pressure compensating device, which
accounts for ambient temperature during fueling. See
Table 19.1 for approximate full cylinder pressures at
various temperatures.
CNG Temperature/Pressure Compensation Values
Fill Station Pressure Set Point
Temperature:
3000 psi (20 684
3600 psi (24 821
°F (°C)
kPa) Set Point
kPa) 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 19.1, CNG Temperature/Pressure Compensation
Values
Use the following steps to fuel a CNG vehicle.
1.
Shut down the engine and apply the parking
brake.
IMPORTANT: Close all windows and doors during the fueling process. Keeping windows and
doors closed allows for easier leak detection
inside the cab after fueling.
WARNING
Natural gas fuel tanks, lines, and valves are always pressurized. Always observe safety precautions. Failure to do so could lead to loss of control over a filling hose or to ignition of the natural
gas, which could cause serious bodily injury,
death, or severe property damage.
2.
Ensure all fuel cylinder shutoff valves are open.
See Fig. 19.1.
3.
Ensure the vehicle fuel system main shutoff
valve is open.
4.
Open the CNG fuel panel access door and remove the dust cap from the vehicle fuel fill port.
19.2
Natural Gas Vehicle
1
2
tion emergency shut-off switch to cease the flow
of CNG.
9.
Switch on the service pump. A slight hissing
noise may be heard as the fuel cylinders fill.
10. Watch the pressure gauge on the service pump.
3
When the gauge reads approximately 3600 psi
(24 800 kPa), or when the fill pressure stops
climbing, the CNG cylinders are full. The service
pump will shut itself down automatically. See
Table 19.1 for pressure compensation values
based on ambient temperatures.
4
11. Move the selector knob on the service pump to
8
7
6
5
the VENT position, if equipped. A short hiss will
be heard as a small amount of natural gas is
vented into the hose.
WARNING
04/22/2010
1.
2.
3.
4.
5.
6.
7.
8.
f470554
Fuel Cylinder Storage Box
Fuel Cylinder Shutoff Valves (qty 5)
High-Pressure Gauge
Low-Pressure Gauge
Fuel Fill Port
Dust Cap
Manual Shutoff Valve
Fuel Panel Access Door
Fig. 19.1, CNG Fuel Cylinder Storage Box (5-cylinder
system shown)
5.
Ensure the O-ring is present inside the fuel fill
port. If the O-ring has been dislodged or is missing, the station dispensing nozzle will not connect securely to the fill port.
6.
Turn the selector knob on the service pump to
the VENT position, if equipped.
7.
Connect the quick coupling on the dispensing
nozzle securely to the vehicle fuel fill port.
8.
Turn the selector knob on the service pump to
the FILL position, if equipped.
IMPORTANT: If at any time the service pump or
vehicle begins to vent CNG uncontrollably, notify
a station attendant or activate the service sta-
19.3
Do not attempt to remove the fill station nozzle
from the tank fill fitting until venting of pressure
is noted. If no venting occurs, ask for assistance
from the station attendant. Removing an unvented coupling could result in an uncontrolled
hose, which could lead to property damage or
personal injury.
12. Remove the station dispensing nozzle from the
vehicle fill port.
13. Install the dust cap on the vehicle fuel fill port
and close the fuel panel access door.
LNG Vehicle Fueling
The LNG fuel tank is designed to be filled from any
LNG fuel source that has a 100 micron or finer fuel
filter and a fuel delivery pressure between 120 and
225 psi (827 and 1551 kPa).
The LNG fuel tank is designed to be top-filled
through a single hose with no vent return. As cold
LNG is sprayed into the vapor space of the tank, the
cold liquid condenses the vapor and creates space
for itself inside the tank, eliminating any need to vent
during the filling process.
The LNG tank is equipped with a small internal ullage tank for vapor space, which allows for fuel expansion and increases vehicle standby time. When
an LNG tank is full, fuel can continue to flow into the
ullage tank. However, if the ullage tank is completely
filled during fueling, standby time will be reduced to
Natural Gas Vehicle
zero and the primary relief valve will open almost
immediately after fueling, allowing excess LNG vapor
to escape. If fueling is stopped when the ullage tank
is empty (i.e., the fuel tank has sufficient vapor space
to accommodate fuel expansion due to temperature
increase), the vehicle will have approximately one
week of standby time before venting will occur.
2
4
Use the following steps to fuel an LNG vehicle.
1.
3
6
Shut down the engine and apply the parking
brake.
IMPORTANT: Close all windows and doors during the fueling process. Keeping windows and
doors closed allows for easier leak detection
inside the cab after fueling.
5
1
WARNING
Liquefied natural gas is a cryogenic liquid stored
at approximately -259°F (-162°C). Cryogenic
burns can be caused by coming into contact with
the pressurized liquid stream, or by coming into
contact with fuel system components that have
been cooled to cryogenic temperatures. Always
wear gloves and a face shield, and cover exposed skin when fueling.
2.
Remove the fuel fill fitting dust cap. See
Fig. 19.2.
3.
Using compressed air, remove any dirt, debris, or
water that may have collected in the fuel fill fitting and the station dispensing nozzle. Contaminants in the fuel system can cause drivability
problems.
WARNING
Natural gas fuel tanks, lines, and valves are always pressurized. Always observe safety precautions. Failure to do so could lead to loss of control over a filling hose or to ignition of the natural
gas, which could cause serious bodily injury,
death, or severe property damage.
4.
Connect the station fueling nozzle to the tank
fuel fill fitting.
5.
Connect an electrical ground clamp and cable to
the fuel tank.
IMPORTANT: An LNG tank which is first installed, or is on a vehicle that has not been op-
05/29/2009
6
1. Fuel Fill Fitting
2. Fuel Outlet Line
3. Primary Relief Vent
Line
f470534
4. Fill Vent Fitting
5. Shroud Cover
6. Shroud Cover Latches
Fig. 19.2, LNG Fuel Tank
erated in approximately ten days, is considered
to be a hot tank. When fueling a hot tank, LNG
entering the tank will immediately vaporize,
causing tank pressure to spike above 250 psi
(1724 kPa) and automatically shutting down the
station fuel pump. To prevent the pump from
shutting down, connect a vent line to the fill vent
fitting on the LNG tank to capture escaping
vapor, then open the shroud cover and open the
vapor shutoff valve (Fig. 19.3, Item 2).
6.
Open the station’s fill valve, if equipped, and
start fueling. Monitor the flow or line pressure as
filling progresses. When filling begins, line pressure will spike quickly until the vehicle tank cools
down. The flow and pressure will then remain
stable during the remainder of the filling
procedure.
IMPORTANT: When fueling a hot tank, initially
put 5 to 10 gallons (19 to 37 liters) of LNG in
the tank and manually stop the fueling process.
Drive the vehicle for 15 to 20 minutes to cool
the tank and reduce tank pressure, then continue fueling the tank to full.
19.4
Natural Gas Vehicle
7
8
Natural Gas Detection System
9
6
10
5
11
12
4
3
2
1
05/05/2010
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
f470533
Pressure Control Regulator
Vapor Shutoff Valve
Fuel Fill Hose
Secondary Relief Valve (red cap)
Fuel Fill Fitting
Fuel Level Sender Box
Primary Relief Valve
Tank Pressure Gauge
Fill Vent Fitting
Excess Flow Valve
Fuel Shutoff Valve (liquid)
Fill Check Valve
Fig. 19.3, LNG Fuel Tank Plumbing Components
7.
When the tank is full, the line pressure will rapidly spike and the flow rate will fall. When a pressure rise or flow rate drop is observed, close the
station’s fill valve, if equipped.
NOTE: Do not over-fill an LNG tank. If the ullage tank is completely filled during fueling, tank
standby time will be reduced to zero and the
primary relief valve will open almost immediately
after fueling.
8.
Disconnect the station hose from the tank fuel fill
fitting.
9.
Disconnect the electrical ground clamp and cable
from the fuel tank.
10. Install the dust cap on the tank fuel fill fitting.
19.5
A gas detection system is standard equipment in all
Daimler Trucks natural-gas-fueled vehicles. This system has a sensor in the engine compartment and
one in the cab, both situated in high areas to detect
natural gas buildup as a result of leaks.
The AMGaDS III Plus is a natural gas detection system. This device is meant to serve as a supplemental warning only. It is not intended to replace standard safety practices that should be conducted
around flammable gases.
IMPORTANT: To function properly, the gas detection system must be powered at all times.
The gas detection system is directly powered by
the batteries, and can only be powered off by
disconnecting the batteries.When servicing a
natural-gas-fueled vehicle, disconnect the batteries only when necessary, and do not leave
the batteries disconnected for extended periods
of time.
The lower flammability limit (LFL) is the smallest
amount of the gas that supports a flame when mixed
with oxygen and ignited. Zero percent (0%) LFL indicates a gas-free atmosphere. One hundred percent
(100%) LFL indicates that gas concentration has
reached its lower flammability limit (5% gas in air by
volume). The red warning light and audible alarm
located in the overhead console activate when a sensor detects gas fumes in concentrations above 50%
LFL, and should allow ample time to utilize safety
procedures. However, individuals with special needs
should review the system with a professional safety
engineer.
Alarm Procedure
Before operating the vehicle, the driver must be familiar with the procedures as shown on the interior
sticker on the overhead panel (Fig. 19.4) and the
exterior sticker on the door (Fig. 19.5).
IMPORTANT: If an audible alarm activates, do
not operate any electrical switch, including
lights. Avoid causing sparks and stay away from
arcing switches and equipment. Do not use a
telephone, including cellular phones or any
types of portable communication or electronic
devices that have a battery.
Natural Gas Vehicle
If outside the vehicle when the audible alarm activates, do not open the cab door or hood.
In the event of an audible alarm, immediately follow
these procedures, as allowed by conditions:
04/28/2009
1.
Immediately shut off all engines. Extinguish any
cigarettes, pilot lights, flames, or other sources of
ignition in the area and adjacent areas.
2.
Manually close all fuel shutoff valves, including
those on the LNG tank or CNG cylinders.
3.
If the vehicle is indoors (as in a service shop),
immediately open windows and doors to provide
extra ventilation to the area. Do not start the engine or any other type of equipment until the gas
leak is corrected and the area cleared of natural
gas.
4.
Evacuate the area.
5.
Check the fuel lines, LNG tank/CNG cylinders,
and fittings to locate the leak. After the area is
cleared of natural gas and the alarm is no longer
active, have the vehicle inspected by a qualified
technician.
f080157
Fig. 19.4, Interior Warning Sticker
IMPORTANT: Do not consider the area clear
until all alarm indicators are off, and the alarm
panel light returns to green.
Sensors
Gas detection sensors are located on the cab overhead 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 has
been disconnected or has malfunctioned, the sensor
fault light for that zone will illuminate. A failed sensor
may trigger and lock on an alarm. If a fault condition
or locked alarm continues after the sensor’s connection and wiring integrity has been verified, replace
the sensor.
04/28/2009
f080158
Fig. 19.5, Exterior Warning Sticker
If the vehicle is in motion when the audible alarm
activates, bring it to a safe stop, shut down the engine, and exit the vehicle. Do not open the hood.
The sensors are sensitive to all hydrocarbon vapors.
An alarm may be triggered by the use of chemicals
such as cleaners, paint, polish, lacquer, gasoline,
silicone, silicone spray, or other harsh chemicals.
The sensors will also detect hydrogen fumes from an
overcharged battery. If a sensor sends an alarm, but
no gas fumes are present, check for recent use of
chemicals or a battery charger.
19.6
Natural Gas Vehicle
NOTICE
Silicone-based chemicals and cleaners will permanently disable the sensors. When cleaning the
vehicle, cover the sensors with a plastic covering. Keep the sensors covered until the area has
been cleared of any cleaning fumes.
Harsh chemicals and extremely high temperatures may damage the sensor.
Puncture of or damage to the seal located inside
the sensor housing will significantly shorten the
sensor life.
Frequent exposure to high concentrations of gas
will accelerate sensor deterioration.
Overhead Console
The overhead console consists of an alarm panel on
the right side and the control module on the left side.
The alarm panel has a green light, a red light, a
buzzer, and a sensor. See Fig. 19.6. It is located
within view from outside of the vehicle. The large
green light is continuously illuminated during normal
operating conditions.
Before entering the vehicle, always verify that the
green light is illuminated. If the green light is not illuminated, do not enter the vehicle. Complete the
alarm procedure previously outlined.
The alarm panel meets the California Highway Patrol
Title 13-2008 and NFPA 52 2010 requirements. All
drivers and technicians using it should be trained regarding the red and green lights, and the audible
warning.
The control module, located on the left side of the
overhead console, contains the status lights and control buttons for the system. The areas that the sensors monitor are defined as Zone 1 (cab) and Zone 2
(engine compartment). The control module has lights
assigned to each zone that will illuminate if a sensor
detects a trace level leak (between 20% and 30%
LFL), a significant level leak (above 50% LFL), or if a
sensor is disconnected or malfunctioning.
• Trace Level: If either sensor detects gas fumes
at a concentration greater than 20% to 30%
LFL (1% gas in air by volume), the amber light
next to the Trace indicator for that zone will
flash. There is no buzzer alarm for a trace
19.7
level detection, and the large green light on the
alarm panel will remain illuminated.
• Significant Level: If either sensor detects gas
fumes at a concentration greater than 50% to
60% LFL (2.5% gas in air by volume), the
small red light next to the SIGNIFICANT indicator for that zone will flash. After approximately 15 seconds, the large green light on the
alarm panel will switch off, the red light will illuminate, and the buzzer will sound. All alarm
indicators will remain on as long as fumes are
detected.
• Sensor Fault: If the system detects that either
of the sensors has been disconnected or has
malfunctioned, an amber light next to the Sensor Fault indicator for that zone will illuminate.
The control module also has buttons used to test or
reset the the control module after an alarm. Red
lights next to each button indicate when they are engaged.
• Shutdown Reset: If an alarm has been acti-
vated and the Relay Engaged light is illuminated, the Shutdown Reset button will reset
the internal relay. Press the Shutdown Reset
button only after the gas has cleared, the
buzzer has turned off, and the alarm panel
light has returned to green.
• Push To Silence: If an alarm has been acti-
vated, the Push To Silence button will silence
the buzzer.
See Table 19.2 for the functions of all lights and buttons on the overhead console.
Testing
Daimler Trucks North America strongly recommends
that all operators follow California Code of Regulations (CCR) inspection requirements, regardless of
where the vehicle is operated. Per Title 13 CCR §
935 (2), gas detection systems should be tested
three times per calendar year at equal intervals. The
testing procedure should simulate the same operating environment in which the vehicle is used, with the
same gaseous fuel.
Natural Gas Vehicle
5
6
7
4
AMGaDS III Plus
Gas Detection System
Power
Push
To
Silence
Gas Concentration:
SIGNIFICANT
3
Silence
Engaged
10
11
Trace
12
13
2
ne
Zo
1
ne
Zo
Shutdown
Relay
Reset
Engaged
Sensor Fault
Push To Test
8
2
1
9
04/28/2009
1.
2.
3.
4.
5.
f611034
Test Button
Sensor Fault Indicator Lights
Zone 1 Leak Indicator Lights
Power Indicator Light
Zone 2 Leak Indicator Lights
6.
7.
8.
9.
Silence Button
Silenced Engaged Light
Relay Engaged Light
Shutdown Reset Button
10.
11
12.
13.
Buzzer Alarm
Red Light
Green Light
Sensor
Fig. 19.6, AMGaDS III Plus Overhead Console
Item
Green Power Light
Display
Illuminated
Control Module Functions
Function
System is on.
Unlit
SIGNIFICANT Gas
Concentration Lights
Red (illuminated)
Trace Gas Concentration
Lights
Amber (flashing)
Sensor Fault Lights
Off
On
Action Required
None required.
Ensure the batteries are
connected and replace any blown
Detection system is not
fuses. If the gas detection system
functioning.
is still not functioning, replace the
system immediately.
Suspend vehicle operation
Dangerous gas concentration
immediately and follow alarm
detected.
procedures.
Use caution and monitor the
Minor gas concentration detected.
system.
Sensor is functioning properly.
None required.
Sensor has malfunctioned.
Replace the sensor immediately.
19.8
Natural Gas Vehicle
Item
Shutdown Reset Button
Relay Engaged Light
Display
—
On
Off
Control Module Functions
Function
Resets the system after an alarm
activation.
Relay is engaged and test or
alarm is being cleared.
Normal condition.
Test Button
—
Tests the overhead console
operation and circuitry.
Silence Button
—
Silences the alarm buzzer.
On
Indicates the buzzer is active but
silenced.
Off
Normal condition.
Silence Engaged Light
Action Required
Press to reset the system only
after the gas has cleared, the
buzzer has turned off, and the
alarm panel light has returned to
green.
Press the Shutdown Reset button.
None required.
Press and hold for one minute to
to activate a test of all overhead
console components.
Press to silence the alarm buzzer.
Suspend vehicle operation
immediately and follow alarm
procedures.
None required.
Table 19.2, Control Module Functions
Test results validating the performance of the gas
detection system within the parameters established
by the component manufacturer and NFPA 52 2010
should be maintained as a permanent part of the vehicle service records. Use of alcohol, propane, and
other harsh liquids or gases are not acceptable
methods for testing.
Always test the system and sensors after any component has been replaced, or if the vehicle has been
involved in an accident or fire. Ensure that the gas
detection system is wired directly to the battery.
It is recommended that the highest level of safety
validation be utilized if there are multiple validation
requirements in the state or locality where the vehicle
is operated or domiciled.
Overhead Console Test
Press and hold the Push To Test button for one minute. The system will proceed with a self-diagnostic
test that will include illumination of the Trace and
SIGNIFICANT gas concentration lights, and the sensor fault lights. Verify the large red light and buzzer
activate, and that all lights illuminate or flash to ensure that all bulbs are operational.
such as butane or propane does not satisfy CCR §
935 (2) or NFPA 52 regulations.
Expose each sensor to certified test gas for at least
thirty seconds. The system will proceed through the
alarm procedure consistent with a significant leak
and the buzzer will sound after approximately fifteen
seconds. If a sensor fails to respond after exposure
to the test gas, replace the sensor.
Natural Gas Vehicles, Engine
Starting
NOTE: Before starting the engine, read Chapter 4 for detailed information on how to read the
instruments and Chapter 5 for detailed information on how to operate the controls. Read the
operating instructions in the engine manufacturer’s operation manual before starting the engine.
1.
Before engine start-up, complete the engine pretrip and post-trip inspections and maintenance
procedures in Chapter 20 and Chapter 21.
2.
Ensure the fuel shutoff valve is open.
Sensor Test
3.
Set the parking brake.
The gas detection system sensors must be tested
using certified test gas, which can be purchased as
part of a test kit. Testing with alcohol or heavy gases
4.
Ensure that the transmission shift control is in
Neutral (N), Park (P), or the Park Brake (PB) position.
19.9
Natural Gas Vehicle
5.
Without starting the engine, turn the ignition
switch to the ON position (Fig. 19.7). The electronic gauges on the instrumentation control unit
(ICU) will complete a full sweep of their dials, the
warning and indicator lights will illuminate, and
the buzzer will sound for three seconds.
09/12/2001
Replace any leaking or damaged fuel tanks/cylinders
and fuel lines; repair or replace leaking or damaged
fittings. Install parts and components in accordance
with the manufacturer’s instructions.
f610509
Fig. 19.7, Ignition Switch Positions
6.
Turn the ignition switch to the START position.
Press down on the clutch pedal, if equipped, but
do not press down on the accelerator pedal.
Release the key the moment the engine starts.
7.
Bring the engine up to operating speed gradually
as it warms up and develops stable oil pressure.
If the vehicle has not been operated previously in
a 24-hour period, allow the vehicle to idle for five
minutes.
NOTICE
Do not rev the engine if the oil pressure gauge
indicates no oil pressure. Shut down the engine
within approximately ten seconds to avoid engine
damage.
8.
Check the oil pressure gauge for any drop in lubricating oil pressure or mechanical malfunction
in the lubricating oil system.
Major Repair and Replacement
of Natural Gas Components
If a natural-gas-fueled vehicle is involved in an accident, remove the fuel tank or cylinders from service
and have them inspected by a qualified technician.
19.10
20
Pre- and Post-Trip
Checklists
Periodic Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Pre- and Post-Trip Checklists
Periodic Inspections and
Maintenance
Use the following checklists to ensure that vehicle
components are in good working condition before
each trip. Careful inspections eliminate stops later to
fix overlooked or forgotten items.
The checklists in this chapter can be copied and kept
as a record that the procedures have been completed. For details on how to inspect each item on
the checklists, see the corresponding procedure
(step number) in Chapter 21.
Checklists
NOTE: Checklists in this chapter correspond
with the procedures and steps in Chapter 21,
Pre- and Post-Trip Inspections and Maintenance. Your vehicle may not be equipped with
all components listed below.
Daily Pretrip Inspection Checklists
See the following tables for a list of procedures that
should be performed daily, before the first trip. Place
a check mark in the complete (Comp.) column to
indicate a procedure has been performed.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Date
1
2
Suspension and Slack Adjusters
Suspension components
Slack adjusters
1
2
3
4
5
6
Wheels and Tires
Comp.
Wheel covers
Tire condition
Tire inflation
Rims and wheel components
Wheel bearing oil seals and lubrication levels
Mud Flaps
20.1
Engine Compartment
Leakage under engine
Air intake system
Engine oil level
Power steering reservoir level
Engine coolant level
Visible engine wiring
Frame rails
Comp.
1
2
3
4
5
6
7
1
Regulations in Canada and the U.S. clearly indicate
that it is the driver’s responsibility to perform an inspection, and ensure the complete road-worthiness
of a vehicle, before placing it into service. Commercial vehicles may be subject to inspection by authorized inspectors, and an unsafe vehicle can be taken
"out of service" until the driver or owner repairs it.
Inspector
Comp.
2
3
4
Saddle Tank Areas
Drain air reservoirs (without automatic drain
valves)
Fuel tank(s) secure
Frame rails and crossmembers
Visible exhaust components
Comp.
1
2
3
4
5
6
7
8
Cab
Comp.
Reset dash-mounted air intake restriction
indicator
Air-pressure warning systems
Air governor cut-in and cut-out pressures
Air pressure build-up time
Air system leakage
Air pressure reserve
Mirrors, windows, windshield
Horn, windshield wipers, windshield washers
Heater and defroster
Interior lights
Exterior lights
Seat belts and tether belts
Fuel level
Mirror adjustment
Service brakes
Backup alarm
Natural Gas Fuel System Inspection
Fuel tanks
Required decals
Vent caps
Plumbing components, fuel fill fitting, fuel
lines
Fuel gauge components, LNG fuel tank
pressure
Coolant hoses
LNG fuel tank pressure
LNG vaporizer
Comp.
Pre- and Post-Trip Checklists
Weekly Post-trip Inspection Checklist
See the following table for procedures that should be
performed weekly, post-trip. Place a check mark in
the complete (Comp.) column to indicate a procedure has been performed.
Inspector
1
2
3
4
5
6
7
Engine Compartment
Windshield washer reservoir level
Air intake restriction indicator
Water evacuation components
Automatic transmission fluid level
Water in fuel/water separator
Steering components
Serpentine drive belts
Date
Comp.
Monthly Post-trip Inspection
Checklists
1
2
Natural Gas Fuel System
System leak test
Drain CNG high-pressure fuel filter housing
Comp.
Fluids Added
Use the following table to note any fluids that were
added during the inspection and maintenance procedures.
Fluids Added During Inspection
Fluid
Amount Added
Wheel Bearing Lubricant
Engine Oil
Power Steering Fluid
Engine Coolant
Windshield Washer Fluid
Automatic Transmission
Fluid
Hydraulic Clutch Fluid (DOT
4 brake fluid)
See the following tables for procedures that should
be performed monthly, post-trip. Place a check mark
in the complete (Comp.) column to indicate a procedure has been performed.
Inspector
Date
Brake Components
Brake system components
Brake chambers
Air brake lines
Flex air hoses
Brake linings and brake drums
Brake lining thickness
Comp.
Comp.
2
3
Saddle Tank Areas
Drain air reservoirs (with automatic drain
valves)
Batteries (location may vary)
Aerodynamic components
Engine Compartment
Hood and bumper
Hydraulic clutch reservoir
Radiator and heater hoses
Steering wheel play
Comp.
1
2
3
4
1
2
3
4
5
6
1
20.2
21
Pre- and Post-Trip
Inspections and
Maintenance
Daily Pretrip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Weekly Post-Trip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.9
Monthly Post-Trip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.11
Pre- and Post-Trip Inspections and Maintenance
Daily Pretrip Inspection and
Maintenance
4
Complete the following inspection and maintenance
procedures to ensure that vehicle components are in
good working condition before each trip. A driver who
is familiar with the vehicle and drives it regularly can
perform the daily inspections, then add the weekly
and monthly post-trip inspections as scheduled.
6
7
3
NOTE: If any system or component does not
pass this inspection, it must be corrected before
operating the vehicle. Whenever equipment requires adjustment, replacement, and/or repair,
see the 108SD and 114SD Workshop Manual
for procedures and specifications.
8
2
If the driver does not operate the vehicle on a consistent basis, all daily, weekly, and monthly inspection and maintenance procedures should be performed before the trip.
IMPORTANT: The pre- and post-trip checklists,
inspections, and maintenance procedures detailed in this chapter are not all-inclusive.
Refer to other component and body manufacturers’ instructions for specific inspection and
maintenance instructions, as well as local, state,
and federal guidelines.
5
9
1
10
f421398
06/17/2003
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
7/16-inch Adjusting Nut
Grease Fitting
Boot
Link
Brake Chamber Piston Rod
Clevis
1/2-inch Clevis Pin
1/4-inch Clevis Pin
Grease Relief Opening
Slack Adjuster Spline
Fig. 21.1, Gunite Automatic Slack Adjuster
• Inspect slack adjuster boots, if equipped,
for cuts or tears.
Suspension and Slack Adjuster
Inspection
• Inspect anchor straps, if equipped, for
Walk around the vehicle and visually inspect suspension and slack adjuster components.
• Look for worn clevis pins on brake cham-
1.
• Look for missing or damaged cotter pins
Inspect the following suspension components for
signs of structural damage, cracks, or wear.
• springs
• spring hangers
• shocks
• suspension arms
• suspension brackets
• axle seats
• bushings
2.
21.1
Inspect slack adjusters for signs of damage. See
Fig. 21.1, Fig. 21.2, or Fig. 21.3.
damage.
ber pushrods.
on the clevis pins.
• Ensure chamber piston rods are in line
with the slack adjusters.
Wheel and Tire Inspection
Walk around the vehicle and visually inspect each
wheel and tire assembly.
IMPORTANT: Wheel covers decrease drag force
as a vehicle moves, thereby improving fuel efficiency. If replacement of a wheel cover is necessary, the replacement cover must meet or exceed the drag reduction performance of the
Pre- and Post-Trip Inspections and Maintenance
1
2
3
4
3
5
6
7
9
8
4
8
7
6
2
5
10/11/2005
A
f421397
A. Rotate the control arm toward the brake chamber
until you can feel it contacting the internal stop.
1. Clevis
2. Slack Adjuster
3. Clevis Pin
4. Manual Adjusting Nut
5. Control Arm
6. Control-Arm Washers and Nut
7. Anchor Strap Slot
8. Anchor Strap
9. Brake Chamber
Fig. 21.2, Haldex Automatic Slack Adjuster
originally installed cover in order to maintain
compliance with greenhouse gas and full efficiency regulations (GHG14).
1.
If the vehicle was originally equipped with wheel
covers, ensure all wheel covers are present. Inspect wheel covers for damage or wear. Remove
wheel covers from rear drive wheels, if equipped,
prior to inspecting the tires and wheel components.
NOTE: During wheel cover installation, ensure
the V-notch in the liner inner retaining ring is
centered on the valve stem. The inner and outer
retaining rings should be uniformly aligned to
each other and to the wheel rim. The outer retaining ring of the liner is equipped with two
canvas flaps. When installing the face cover,
make sure the cover retaining ring is inserted
between the two canvas flaps on the liner outer
9
01/31/2011
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1
10
f422530
Grease Fitting (if equipped)
Slack Adjuster Housing
Brake Chamber Pushrod
Clevis
Clevis Pin (large)
Clevis Pin (small)
Actuator Rod
Boot
Manual Adjusting Nut
Camshaft Splines
Fig. 21.3, Meritor Automatic Slack Adjuster
retaining ring so that the Velcro strips line up
between the face cover and the liner. Make certain the detachable view cover is centered on
the face cover, and the Velcro strips are
pressed firmly in place.
2.
Inspect each tire for the following:
• valve stem caps on every tire, screwed on
finger-tight
• bulges, cracks, cuts, and penetrations
• oil contamination (petroleum derivatives will
soften the rubber and destroy the tire)
21.2
Pre- and Post-Trip Inspections and Maintenance
• tread depth—if tread is less than 4/32 inch
(3 mm) on any front tire, or less than 2/32
inch (1.5 mm) on any rear tire, replace the
tire
• debris lodged between duel tire sets
Consult the rim or wheel manufacturer for the
correct tire inflation pressure for the vehicle
load.
4.
IMPORTANT: Low-rolling resistance (LRR) tires
minimize wasted energy as a tire rolls, thereby
decreasing rolling effort and improving fuel efficiency. If tire replacement is necessary, replacement tires must meet or exceed the rolling resistance of the originally installed tires in order to
maintain compliance with greenhouse gas and
full efficiency regulations (GHG14).
Contact your tire manufacturer/supplier to determine the rolling resistance of the originally installed tires. Visit www.epa.gov/smartway for
additional information and resources.
WARNING
Do not operate the vehicle with underinflated or
overinflated tires. Incorrect inflation can stress
the tires and make the tires and rims more susceptible to damage, possibly leading to rim or
tire failure and loss of vehicle control, resulting
in serious personal injury or death.
3.
Check tire inflation.
For inflation pressures and maximum loads, see
the tire manufacturer’s guidelines. Inflate the tires
to the applicable pressures if needed.
If a tire has been run flat or under-inflated, check
the wheel and tire for damage before adding air.
Keep compressed air reservoirs and lines dry
during tire inflation. Use well-maintained inline
moisture traps and service them regularly.
4.1
Have any worn or damaged wheel components
replaced by a qualified person using the wheel
manufacturer’s instructions and the wheel industry’s standard safety precautions and equipment.
Otherwise a vehicle or workshop accident could
occur, possibly resulting in serious personal injury or death.
4.2
Inspect for broken, cracked, badly worn,
bent, rusty, or sprung rings and rims.
NOTICE
Use the recommended torque values and follow
the proper tightening sequence. Insufficient
wheel nut torque can cause wheel shimmy, resulting in wheel damage, stud breakage, and extreme tire tread wear. Excessive wheel nut torque
can break studs, damage threads, and crack
discs in the stud hole area.
4.3
5.
A weekly pressure loss of 4 psi (28 kPa) or more
in a tire may indicate damage. The tire should be
inspected and, if necessary, repaired or replaced
by a qualified tire service facility.
21.3
Remove all dirt and debris from the assembly. Rust streaks or metal build-up
around stud holes, or out-of-round or worn
stud holes, may be caused by loose wheel
nuts.
WARNING
NOTICE
IMPORTANT: The load and cold inflation pressure must not exceed the rim or wheel manufacturer’s recommendations, even though the
tire may be approved for a higher load inflation.
Examine each rim and wheel component. Check
the wheel nuts or rim nuts for indications of
looseness.
Make sure all wheel nuts are tightened. If
tightening is necessary, use the tightening
pattern in Fig. 21.4 or Fig. 21.5.
Inspect the outboard side of all wheel hubs and
the hub oil seal area on the inboard side of each
wheel for signs of oil leakage. If any oil is found
on wheel and tire or brake components, remove
the vehicle from service until the leak has been
fixed.
If needed, fill the hubs to the level indicated on
the hub cap. See Group 35 of the 108SD and
114SD Maintenance Manual for recommended
lubricants.
6.
Check that mud flaps are undamaged and hang
10 inches (25.4 cm) or less from the ground.
Pre- and Post-Trip Inspections and Maintenance
10
1.
Drain the brake system air reservoirs (reservoirs
without automatic drain valves only).
2.
Ensure fuel tanks are secured to their mounting
brackets and that the mounting brackets are secured to the frame.
3.
Inspect visible frame rails for missing bolts, shiny
areas, or rust streaks. Check all visible crossmembers for damage or signs of looseness.
4.
Inspect visible components of the exhaust system to ensure connections are tight.
1
8
3
6
5
4
7
9
Inspect upstream of the aftertreatment device
(ATD) for cracking or signs of leaks, such as soot
trails. Inspect downstream of the ATD for signs of
exhaust leaks, such as blistering or warping of
nearby components.
2
f400081a
08/23/93
Fig. 21.4, Tightening Pattern, 10-Hole Wheels
1
Engine Compartment Inspection
2
1.
Check the ground underneath the engine for fuel,
oil, or coolant leaks.
2.
Inspect the air intake system for leaks or damage.
4
7
NOTICE
6
5
3
8
03/08/2012
f400052a
Failure to maintain a sealed air intake system
could allow the entry of dirt and contaminants
into the engine. This could adversely affect engine performance and result in engine damage.
Fig. 21.5, Tightening Pattern, 8-Hole Wheels
2.1
Push the reset button on the air intake
restriction indicator located on the air
cleaner, if equipped.
2.2
Check the engine air intake duct from the
air cleaner to the engine intake. Make
sure the duct components are secure and
airtight.
2.3
Check the vacuator (spitter) valve(s) for
damage, and make sure the lips of the
valve are pliable and free of debris.
Saddle Tank Areas Inspection
WARNING
When draining the air reservoir, do not look into
the air jets or direct them toward anyone. Dirt or
sludge particles may be in the airstream and
could cause injury.
NOTICE
If the water drained from the air reservoirs is
cloudy or oily, it may indicate a problem with the
compressor. If oil is allowed to contaminate the
air dryer, it will not remove the water from the air
brake system, which could adversely affect braking.
3.
Check the engine oil level.
NOTICE
Operating the engine with the oil level below the
minimum fill (or "add") mark or above the maximum fill (or "full") mark could result in engine
damage.
21.4
Pre- and Post-Trip Inspections and Maintenance
3.1
Check the oil level with the vehicle parked
on a level surface. See the engine manufacturer’s guidelines for engine shutdown
time requirements prior to checking the oil
level.
IMPORTANT: Vehicles domiciled in the U.S.
or Canada require the use of CJ-4 engine oil
with less than 1% sulfated ash. Failure to
use CJ-4 oil may void the warranty on emission aftertreatment components.
3.2
Coolant must be filled to the COLD MAX line of
the surge tank. Low coolant could result in engine overheating, which could cause engine damage.
5.1
If the oil level is at or below the minimum
fill (or "add") mark on the dipstick, add
enough oil to maintain the level between
the minimum and maximum fill marks. See
the engine operation manual for recommended lubricants.
For natural gas vehicles, use only Exxon
Busgard® Geo 15W-40 natural gas engine
oil.
4.
NOTICE
Check the power steering reservoir fluid level.
The power steering fluid level should be between
the MIN COLD mark and the middle mark just
above it. See Fig. 21.6. If needed, fill the reservoir with automatic transmission fluid that meets
Dexron III or TES-389 specifications.
For natural gas vehicles, use only Fleetguard ES Compleat™ EG Premix 50/50
engine coolant.
5.2
Inspect visible engine wiring for damage or
looseness. See Fig. 21.7.
7.
Inspect visible frame rails for missing bolts, shiny
areas, or rust streaks.
Cab Inspection
1.
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 reservoirs using moderate brake applications
until pressure in both reservoirs is less
than 70 psi (483 kPa).
2.2
Turn the ignition to the ON position. The
ICU will complete a full gauge sweep and
bulb check, and the warning buzzer will
sound. Ensure the BRAKE AIR lamp remains illuminated and the warning buzzer
continues to sound after the gauge sweep
is complete.
f462079
1. Filler Cap
Fig. 21.6, Power Steering Fluid Reservoir
IMPORTANT: The surge tank must be cool to
check the coolant level.
5.
21.5
Check the engine coolant level in the radiator
surge tank.
If the surge tank was empty, start the engine after refilling and check the level
again when the engine is at operating
temperature.
6.
1
05/21/2007
If the coolant is low, fill the surge tank to
the MAX line with a 50/50 mixture of water
and the type of antifreeze currently installed in your vehicle.
3.
Check air governor cut-in and cut-out pressures.
3.1
Start the engine and ensure the BRAKE
AIR lamp goes out and the buzzer silences when pressure reaches approximately 70 psi (483 kPa) in both air reservoirs.
Pre- and Post-Trip Inspections and Maintenance
4.2
Further reduce air pressure using moderate brake applications, then run the engine at governed rpm.
4.3
Note the time that the pressure reaches
the previously noted reading on the primary air gauge, then note the time that
the air pressure reaches cut-out pressure.
4.4
If it takes longer than 30 seconds to reach
cut-out pressure after the primary air
gauge passes the previously noted pressure (noted after one full brake application), eliminate any leaks or replace the air
compressor before operating the vehicle.
1
2
3
5.
Check air leakage in the system.
5.1
With the parking brake applied, the transmission out of gear, and the air system
fully charged, release the service brakes
and shut down the engine.
5.2
Wait one minute and note the air pressure
drop in psi (kPa) per minute from the primary air reservoir.
4
If the pressure drop exceeds the limits
shown in Table 21.1, eliminate any leaks
before operating the vehicle.
6.
11/24/2010
1.
2.
3.
4.
f545704
With the engine still off, make one full brake application and observe the pressure drop on the
primary air gauge. If pressure drops more than
25 psi (172 kPa), eliminate any leaks before operating the vehicle.
Bulkhead Module
Powernet Distribution Box (PNDB)
Main Power Distribution Module (PDM)
Powertrain PDM (PTPDM)
Fig. 21.7, Visible Engine Wiring
The air governor should cut out at approximately 120 psi (827 kPa). For vehicles with an optional dryer reservoir
module (DRM), the cut-out pressure is
approximately 130 psi (896 kPa).
3.2
4.
With the engine idling, apply the brake
pedal several times. The air governor
should cut in when pressure in the primary
air reservoir (top air gauge) reaches approximately 100 psi (689 kPa).
Maximum Allowable Air Leakage
Pressure Drop:
psi (kPa) Per Minute
Description
Released Applied
Truck or Tractor Only
2 (14)
3 (21)
Truck or Tractor w/Single Trailer
3 (21)
4 (28)
Table 21.1, Maximum Allowable Air Leakage
7.
With the air system fully charged, make
one full brake application and note the air
pressure reading on the primary air
gauge.
Check for fault codes.
Turn the ignition switch to the ON position and
check the instrumentation control unit (ICU3) for
fault codes. Have any active fault codes serviced
before operating the vehicle.
Check air pressure build-up time.
4.1
Check the air pressure reserve.
8.
Inspect the mirrors, window glass, and windshield for cracks or other damage.
21.6
Pre- and Post-Trip Inspections and Maintenance
9.
Ensure that the horn, windshield wipers, and
windshield washers are operating properly.
These devices must be in good working order for
safe vehicle operation.
10. Ensure the heater and defroster are operating
12.3
Check that the brake lights, taillights,
headlights, turn signals, marker lights,
identification lights, and clearance lights
are working properly.
13. Inspect the seat belts and tether belts.
properly.
WARNING
11. Check the operation of all interior lights.
11.1
Turn on the headlights and leave them on.
Ensure all equipped gauge bulbs illuminate in the dash message center.
11.2
Ensure all equipped driver control
switches illuminate.
11.3
Ensure both turn signal indicator bulbs
illuminate in the dash message center
when the turn signal switch is activated.
12. Check the operation of all exterior lights. See
Fig. 21.8.
3
4
3
Inspect and maintain seat belts. When any part of
a seat belt system needs replacement, the entire
seat belt must be replaced, both retractor and
buckle side. Any time a vehicle is involved in an
accident, and the seat belt system was in use,
the entire vehicle seat belt system must be replaced before operating the vehicle. Do not attempt to modify the seat belt system; doing so
could change the effectiveness of the system.
Failure to replace worn or damaged seat belts, or
making any modifications to the system, may result in personal injury or death.
13.1
Check the web for fraying, cuts, extreme
dirt and dust, or for severe fading from
exposure to sunlight, especially near the
buckle latch plate and in the D-loop guide
area.
13.2
Check operation of the buckle, latch, Komfort Latch or Sliding Komfort Latch (if
equipped), web retractor, and upper seat
belt mount on the door pillar. Check all
visible components for wear or damage.
13.3
Check the seat belt and tether belt connection points and tighten any that are
loose.
5
2
1
IMPORTANT: Use ultralow-sulfur diesel (ULSD)
with 15 ppm sulfur content or less. Failure to
use ULSD fuel may void the warranty on emission components.
01/31/2011
f545733
1. Headlight
2. Turn Signal
3. Clearance Marker
Lights
4. I.D. Marker Lights
5. Fender Marker Light
Fig. 21.8, Exterior Lights
12.1
12.2
21.7
Activate the high-beam headlights and
hazard warning lights.
Exit the cab and check that all exterior
lights and reflectors are clean and intact.
14. Check the fuel level in the fuel tank(s). To keep
condensation to a minimum, fuel tanks should be
filled at the end of each day.
15. Adjust the rearview and down view mirrors as
necessary.
16. Test the service brakes.
16.1
With the engine running and air system
fully charged, set the parking brake.
Pre- and Post-Trip Inspections and Maintenance
16.2
Put the vehicle in the lowest gear and
gently attempt to move it forward. The vehicle should not move.
7
8
9
6
If the vehicle moves, the parking brakes
are not operating correctly and must be
repaired before the vehicle is operated.
10
5
11
Natural Gas Fuel System Inspection,
If Equipped
1.
Inspect fuel tanks for dents, scratches, gouges,
or other signs of damage. Inspect the fuel lines
and connections for leaks.
12
4
3
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 is
secured to the frame. Inspect for signs of looseness.
Liquefied Natural Gas (LNG) Fuel System: Ensure that the LNG fuel tank is secured to the
mounting brackets and that the mounting
brackets are secured to the frame. Ensure all
rubber isolator straps are secure around the LNG
fuel tank.
2.
Check for the presence of all required decals
present in the following locations:
• Gas detection system overhead console;
• Above the door handle on both doors;
2
1
05/05/2010
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
• Left front bumper;
• End-of-frame crossmember;
4.
equipped.
Check for the presence of vent caps on pressure
relief valves and devices. If any caps are missing, have the fuel system inspected by a qualified technician.
CNG Fuel System: Each fuel cylinder should
have two caps (one on each end), which are visible on the back of the CNG fuel cylinder storage
box. One additional cap is located on the pressure relief valve on the inboard side of the CNG
fuel box, next to the fuel outlet line.
LNG Fuel System: A red cap should be present
on the secondary relief valve (Fig. 21.9).
Pressure Control Regulator
Vapor Shutoff Valve
Fuel Fill Hose
Secondary Relief Valve (red cap)
Fuel Fill Fitting
Fuel Level Sender Box
Primary Relief Valve
Tank Pressure Gauge
Fill Vent Fitting
Excess Flow Valve
Fuel Shutoff Valve (liquid)
Fill Check Valve
Fig. 21.9, LNG Tank Plumbing Components
• LNG fuel tank fill port (maximum psi), if
3.
f470533
Inspect all plumbing components, including the
fuel shutoff valve(s), primary and secondary relief
valves, and the LNG vapor shutoff and excess
flow valves, if equipped, for signs of damage or
leaks. See Fig. 21.9 or Fig. 21.10.
Inspect the fuel fill fitting for signs of damage or
leaks.
Inspect all lines for signs of leaks or damage,
and check all threaded connections.
5.
Inspect all fuel gauge components for signs of
leaks or damage. Inspect the LNG fuel level
sender cable and wiring, if equipped.
6.
Inspect all coolant hoses for signs of chafing,
kinks, or leaks. The LNG fuel system utilizes
coolant hoses between the engine and the vaporizer; the CNG fuel system utilizes coolant
21.8
Pre- and Post-Trip Inspections and Maintenance
H PRESS UR E
Check the windshield washer reservoir fluid level.
The reservoir is usually located near the righthand frame rail.
2.
After resetting the air intake restriction indicator
during the daily pretrip inspection, check the indicator again with the engine off.
2
1
H IG
1.
RE
LOW PRES S U
CYLINDERS
INSPECT CYLINDERS
EVERY 36 MONTHS
OR 36000 MILES
WHICHEVER OCCURS FIRST
2.1
REGULATOR
INSPECT PRESSURE
RELIEF DEVICE
EVERY 2000 MILES
NATURAL
GAS
VEHICLE
110 PSIG
FILTER
ON
DRAIN HOUSING
EVERY 1500 MILES
REPLACE ELEMENT
EVERY 3000 MILES
3
OPEN VALVE
SLOWLY
M
SH AN
U U
VA T O AL
LV FF
E
3600 PSIG MAX.
SERVICE PRESSURE
4
04/30/2010
1.
2.
3.
4.
Check a go/no-go indicator without graduations to see if the colored bar shows
through the clear window.
f470556
High Pressure Gauge
Low Pressure Gauge
Manual Fuel Shutoff Valve
Fuel Fill Port
Air Intake Restriction Values
Maximum inH2O
Initial inH2O
Engine Make*
Cummins
12
25
Detroit Diesel
10
22
* Turbocharged engines must be checked at full load and governed engine speed.
Table 21.2, Air Intake Restriction Values
Fig. 21.10, CNG Fuel Panel
hoses between the engine and the pressure
regulator inside the fuel panel.
7.
8.
If equipped with an LNG fuel system, check the
fuel tank pressure gauge to ensure that pressure
is within the normal range of 120 to 150 psi (827
to 1034 kPa). If tank pressure exceeds 230 psi
(1586 kPa) and the pressure relief valve does
not open automatically, vent the tank immediately.
Inspect the LNG vaporizer for signs of damage
or leaks. See Fig. 21.11. Inspect the vaporizer
mounting brackets for signs of looseness.
Weekly Post-Trip Inspection
and Maintenance
Engine Compartment Inspection
2.2
If air restriction exceeds the maximum allowable value, operate the vehicle for one
more day, making sure not to run the engine over rated rpm. Refer to the engine
operation manual for more information on
rated rpm for your engine.
2.3
If air restriction exceeds the maximum
value again, replace the air cleaner. For
instructions, refer to Group 09 of the
108SD and 114SD Workshop Manual.
3.
If the vehicle is equipped with an Allison automatic transmission, check the automatic transmission fluid level.
4.
Check for water in the fuel/water separator, if
equipped.
4.1
WARNING
Washer fluids may be flammable and poisonous.
Do not expose washer fluid to an open flame or
any burning material, such as a cigarette. Always
comply with the washer fluid manufacturer’s recommended safety precautions.
21.9
Check an indicator with graduations to see
if air restriction exceeds the value shown
in Table 21.2.
Place a suitable container under the fuel/
water separator. Many states now issue
fines for draining fuel/water separators
onto the ground.
NOTE: A hose may be used to direct water
into the container. Use a hose with a ½-inch
pipe thread on DAVCO models.
4.2
Alliance/Racor Models: Turn the drain plug
counterclockwise to open it. See
Fig. 21.12.
Pre- and Post-Trip Inspections and Maintenance
8
9
5
1
12
10
11
7
06/29/2009
1.
2.
3.
4.
2
3
4
Pressure Relief Device
Fuel Inlet Line
Check Valve
CNG Quick-Connect Port
6
f470536
5.
6.
7.
8.
Coolant Inlet Line
Vaporizer
Fuel Shutoff Solenoid Valve
Coolant Outlet Line
9.
10.
11.
12.
Pressure Gauge
Overpressure Regulator
Pressure Relief Valve
Fuel Outlet Line
Fig. 21.11, LNG Vaporizer Assembly
5.2
Stop draining fluid when fuel begins to
drain out.
Check the steering gear mounting bolts
and pitman arm nut for signs of looseness.
5.3
Alliance/Racor Models: turn the drain plug
clockwise to close it.
Check the drag link nuts for missing cotter
pins.
5.4
Inspect the steering intermediate shaft and
end yokes for excessive looseness or
other damage.
DAVCO Models: Remove the vent cap
and open the drain. See Fig. 21.13.
4.3
4.4
DAVCO Models: close the drain valve.
Install and hand-tighten the vent cap.
5.
Inspect the steering components. See
Fig. 21.14.
5.1
Inspect tie rods, steering arms, and the
drag link for signs of looseness (i.e., shiny
spots or rust tracks).
NOTICE
Do not drive with a drive belt that is visibly worn
or damaged. If it fails, the lack of coolant flow
could rapidly cause damage to engine components.
21.10
Pre- and Post-Trip Inspections and Maintenance
6
5
10
4
3
7
9
2
8
8
7
1
9
10
6
11
02/03/2010
1.
2.
3.
4.
5.
6.
Washers (qty 2)
Nuts (qty 2)
Frame Rail
Fuel Outlet Port
Fuel Inlet Port
Priming Pump
5
f470552
7.
8.
9.
10.
11.
Mounting Head
Mounting Bolts (qty 2)
Filter Element
Sight Bowl
Drain Plug
4
11
Fig. 21.12, Alliance Fuel/Water Separator Assembly and
Installation
6.
3
12
Inspect the serpentine drive belts for signs of
glazing, frayed edges, breaks, cracks, or oil contamination.
2
Monthly Post-Trip Inspection
and Maintenance
Brake Component Inspection
Walk around the vehicle and visually the brake system components for visible damage.
1.
Inspect all visible brake system components for
missing fasteners or signs of looseness, such as
rust tracks.
NOTICE
If the external breather tube or breather cap is
missing or incorrectly installed, road dirt and debris can adversely affect the operation of the
21.11
13
1
05/05/2009
1.
2.
3.
4.
5.
6.
7.
Inlet Port/Check Valve
Lower Housing
Bypass Valve
Filter Element
Spring
Cover O-Ring
Clear Cover
f470530
8.
9.
10.
11.
12.
13.
Vent Cap O-Ring
Vent Cap
Collar
120VAC Pre-Heater
12VDC Pre-Heater
Drain Valve
Fig. 21.13, DAVCO Fuel/Water Separator (Fuel Pro 482
shown)
Pre- and Post-Trip Inspections and Maintenance
Saddle Tank Areas Inspection
WARNING
When draining the air reservoir, do not look into
the air jets or direct them toward anyone. Dirt or
sludge particles may be in the airstream and
could cause injury.
1
1
NOTICE
2
If the water drained from the air reservoirs is
cloudy or oily, it may indicate a problem with the
compressor. If oil is allowed to contaminate the
air dryer, it will not remove the water from the air
brake system, which could adversely affect braking.
1
3
3
10/11/2001
f461916
1. Steering Gear Mounting Bolt
2. Pitman Arm Pinch Bolt Nut
3. Drag Link Nut
1.
Drain the brake system air reservoirs (reservoirs
with automatic drain valves only).
2.
Inspect the batteries.
WARNING
Fig. 21.14, Steering Gear Fasteners
brake chamber. Once inside of the chamber, dirt
and debris can cause the internal parts of the
chamber to deteriorate faster.
2.
Inspect the exterior surfaces of brake chambers
for damage. Make sure that breather holes are
open and free of debris.
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. To prevent possible personal injury, always wash your hands after handling battery parts and related accessories.
NOTE: Do not route air brake lines on top of
anything likely to be stepped on.
3.
Inspect air brake lines for dents, swelling, kinks,
twisting, abrasion, and damage, especially near
moving parts.
4.
Inspect flex air lines for deterioration or signs of
abrasion.
5.
Inspect for cracked, worn, or oil-contaminated
brake linings and brake drums (or rotors).
6.
Check the thickness of the brake linings. Replace brake linings on all brake assemblies on
the axle if any brake linings are worn to less than
approximately 1/4 inch (6.4 mm) at the thinnest
point.
2.1
Remove the battery box cover and inspect
all visible battery cables for loose wiring or
damage. See Fig. 21.15.
2.2
Check that the battery hold-down is secure.
IMPORTANT: Aerodynamic components decrease drag force as a vehicle moves, thereby
improving fuel efficiency. If replacement of an
aerodynamic component is necessary, replacement components must meet or exceed the
drag reduction performance of the originally installed component in order to maintain compliance with greenhouse gas and full efficiency
regulations (GHG14).
3.
Inspect the following aerodynamic components, if
equipped, for structural damage, cracks, or wear.
• Chassis fairings
21.12
Pre- and Post-Trip Inspections and Maintenance
1
2
3
2.1
Make sure the radiator inlet and outlet
hoses are pliable and are not cracking or
ballooning.
2.2
Make sure the heater hoses are pliable
and are not cracking or ballooning.
2.3
Tighten hose clamps as necessary.
IMPORTANT: Do not overtighten hose
clamps, as hose life can be adversely affected.
2.4
Ensure hose support brackets are securely fastened. Make sure hoses are not
located near sources of wear, abrasion, or
high heat.
IMPORTANT: When replacing hoses, install
service-type knitted or braided yarn-reinforced
neoprene hose. Extended-service-life silicone
hoses may also be used. See the Alliance Parts
Catalog at www.alliancebrandparts.com or
contact your Freightliner Dealer.
3.
12/03/2010
1. Back-of-Cab
2. Fuel Tank
f545714
Check the steering wheel for excessive play.
3.1
Start the engine. With the front tires
straight ahead, turn the steering wheel
until motion is observed at the front
wheels.
3.2
Align a reference mark on the steering
wheel to a rule, then slowly turn the steering wheel in the opposite direction until
motion is again detected at the wheels.
3.3
Measure the lash (free play) at the rim of
the steering wheel. Excessive lash exists
if steering wheel movement exceeds 2-1/2
inches (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.
3.4
If there is excessive lash, check the steering system for wear or incorrect adjustment before operating the vehicle.
3. Battery Compartment
Fig. 21.15, Standard Battery Compartment Location
• Roof fairing/deflector
• Side skirts
• Cab extenders
• Battery access cover
Engine Compartment Inspection and
Adjustments
IMPORTANT: If replacement of the hood or
bumper is necessary, the replacement component must meet or exceed the drag reduction
performance of the originally installed item in
order to maintain compliance with greenhouse
gas and full efficiency regulations (GHG14).
1.
Inspect the bumper and hood for structural damage, cracks, or wear.
2.
Inspect the radiator and heater hoses, including
the clamps and support brackets.
21.13
Natural Gas Fuel System Inspection,
If Equipped
1.
Leak test all fuel system components, joints, and
fittings using a methane detector. A bubble solution can be used to pinpoint the exact location of
leaks.
Pre- and Post-Trip Inspections and Maintenance
Replace any leaking or damaged fuel tanks and
fuel lines; repair or replace leaking or damaged
fittings.
2.
Drain the CNG high-pressure fuel filter housing,
if equipped.
2.1
Purge the CNG fuel lines by closing the
CNG fuel cylinder shutoff valves. Start the
engine and let it idle until the fuel lines are
empty and the engine stops.
Gauges on the fuel panel should now read
at or near 0 psi (0 kPa).
2.2
2.3
2.4
7
Close the manual fuel shutoff valve on the
fuel panel.
2
6
5
Remove the two capscrews that secure
the access cover to the fuel panel, then
remove the access cover. See Fig. 21.16.
Save the capscrews for installation.
4
3
2
Slowly open the bleed valve on the manifold to relieve remaining fuel pressure
within the system. See Fig. 21.17.
IMPORTANT: Some pressure may remain in
the fuel system between the solenoid valve
and the engine. Use caution when loosening
fittings, as a small amount of gas may leak
out.
2.5
Put a clean receptacle under the filter assembly.
2.6
Using an 11/16-inch wrench, remove the
drain plug from the filter bowl.
When all liquid has drained, install and
tighten the drain plug on the filter bowl.
2.7
8
1
05/04/2010
1.
2.
3.
4.
5.
6.
7.
8.
f470557
Fuel Panel Access Cover
Capscrews (qty 2)
Wiring Harness
Pressure Relief Valve and Cap
Coolant Outlet Line
Coolant Inlet Line
Fuel Inlet Line (to fuel cylinders)
Fuel Outlet Line (to engine)
Fig. 21.16, CNG Fuel Panel Assembly
Close the bleed valve on the manifold and
open the manual fuel shutoff valve on the
fuel panel.
Open the fuel cylinder shutoff valves.
2.8
Use a methane detector to leak test all
fuel system components between the fuel
cylinders and the solenoid valve. A bubble
solution can be used to pinpoint the exact
location of leaks.
Repair or replace any leaking components.
2.9
Install the access cover on the fuel panel.
21.14
Pre- and Post-Trip Inspections and Maintenance
6
5
7
4
8
3
2
14
1
13
10
12 11
05/04/2010
1.
2.
3.
4.
5.
6.
7.
8.
Coolant Inlet Port
Coolant Outlet Port
Pressure Relief Valve
Pressure Regulator
Wiring Harness
Manifold Bleed Valve
Manifold
Manual Fuel Shutoff
Valve
f470558
9.
10.
11.
12.
13.
14.
Fuel Fill Port
Filter Housing
Filter Bowl
Filter Drain Plug
Solenoid Valve
Fuel Line To Cylinders
Fig. 21.17, CNG Fuel Panel Components
21.15
9
22
Cab Appearance
Cab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dashboard and Instrument Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22.1
22.1
22.1
22.1
22.1
22.2
22.3
Cab Appearance
Cab Washing and Polishing
Care of Fiberglass Parts
IMPORTANT: Carefully read all instructions before using or applying any cleaner or product on
the vehicle or components. Failure to follow
manufacturers’ recommendations can result in
damage to the finish.
Wash unpainted fiberglass air fairings and shields
monthly with a mild detergent, such as dishwashing
liquid. Avoid strong alkaline cleansers.
To protect the finish of your new vehicle, follow these
guidelines carefully.
Care of Chrome Parts
• During the first 30 days, rinse your vehicle fre-
quently with water. If the vehicle is dirty, use a
mild liquid soap. Do not use detergent.
• During the first 30 days, do not use anything
abrasive on your vehicle. Brushes, chemicals,
and cleaners may scratch the finish.
• During the first 120 days, do not wax your
vehicle.
To extend the life of your vehicle’s finish, follow these
guidelines.
• Avoid washing your vehicle in the hot sun.
• Always use water. After the cab is completely
washed, 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. Before waxing, if the finish has become
dull, remove oxidized paint using a cleaner
specifically designed for this purpose. Remove
all road tar and tree sap before waxing.
Freightliner recommends using a high quality
brand of cleaner or cleaner-polish and polishing wax.
• Do not let diesel fuel or antifreeze stand on a
painted surface. If either should occur, rinse
the surface off with water.
Apply a wax specifically designed for fiberglass.
To prevent rust, keep chrome parts clean and protected at all times. This is especially important during
winter driving and in coastal areas where there is
exposure to salt air.
When cleaning chrome parts, use clean water and a
soft cloth or sponge. A mild detergent may also be
used.
Sponge gently, then rinse. If necessary, use a nonabrasive chrome cleaner to remove stubborn rust or
other material. Do not use steel wool.
To help protect the chrome after cleaning, apply a
coat of polishing wax to the surface. Never use wax
on parts that are exposed to high heat, such as exhaust pipes.
Care of Exterior Lights
Clean the headlight lenses by hand only. Use a flannel cloth with mild, non-caustic soap or detergent,
and water.
NOTICE
Do not use a power buffer, paper towels, chemical solvents, or abrasive cleaners on the headlight lens, all of which can remove the UV coating
from the surface, and result in yellowing of the
lens.
Dashboard and Instrument
Panel Care
• To prevent rust, have any nicks or other dam-
age on the finish touched up as soon as possible.
NOTICE
• Park your vehicle in a sheltered area whenever
When cleaning the dashboard, instrument panel,
or gauge lens covers, do not use Armor-All Protectant®, STP Son-of-a-Gun®, window cleaner, or
other equivalent treatments. These cleaners contain vinyl plasticizers which can cause stress
possible.
22.1
Cab Appearance
crazing in the interior plastic panels and can result in cracking of the panels. Some cleaners can
also have an adverse effect on the clear plastic
of instrument panels and gauge lens covers, resulting in a foggy or cloudy appearance. This
type of damage is not covered by vehicle warranty.
To clean the dashboard, instrument panel, and gauge
lens covers, use a cloth dampened with warm soapy
water. Make certain to wring the cloth out well before
cleaning, as excess water will damage the electrical
components.
Vinyl Upholstery Cleaning
To prevent soiling, frequent vacuuming or light brushing to remove dust and dirt is recommended. Harsh
cleaning agents can cause permanent damage to
vinyl upholstery.
To preserve the upholstery and prevent damage,
carefully review the following sections for recommended cleaning procedures. Waxing or refinishing
improves soil resistance and cleanability for all vinyls.
Use any hard wax, such as that used on automobiles.
Ordinary Dirt
Wash the upholstery with warm water and mild soap,
such as saddle or oil soap. Apply soapy water to a
large area and allow to soak for a few minutes, then
rub briskly with a cloth to remove the dirt. Repeat
several times, as necessary.
If dirt is deeply imbedded, use a soft bristle brush
after applying the soap.
If dirt is extremely difficult to remove, use a wallwashing preparation such as those normally found
around the home. Powdered cleaners, such as those
used for sinks and tiles, are abrasive and must be
used with caution as they can scratch the vinyl or
give it a permanent dull appearance.
Chewing Gum
Harden the gum with an ice cube wrapped in a plastic bag, then scrape it off with a dull knife. Remove
any remaining traces of gum with an all-purpose light
oil (peanut butter will also work). Wipe off the gum
and oil substance.
Tars, Asphalts, and Creosote
Each of these items stains vinyl after prolonged contact. Wipe any of these items off immediately and
carefully clean the area using a cloth dampened with
naphtha.
Paint, Shoe Heel Marks
Remove paint immediately. Do not use paint remover
or liquid-type brush cleaner on vinyl. An unprinted
cloth, dampened with naphtha or turpentine may be
used. Use care to prevent contact with parts of the
upholstery that are not vinyl.
Sulfide Stains
Sulfide compounds, such as those found in eggs and
some canned goods, can stain after prolonged contact with vinyl. Remove these stains by placing a
clean, unprinted piece of cloth over the spotted area
and pouring a liberal amount of 6 percent hydrogen
peroxide onto the cloth. Allow the saturated cloth to
remain on the spot for 30 to 60 minutes. For stubborn spots, allow the hydrogen-peroxide saturated
cloth to remain on the area overnight. Use caution to
prevent the solution from seeping into the seams,
where it can weaken the cotton thread.
Nail Polish and Nail Polish Remover
Prolonged contact with these substances causes permanent damage to vinyl. Careful blotting immediately
after contact minimizes damage. Do not spread the
liquid during removal.
Shoe Polish
Most shoe polishes contain dyes which penetrate
vinyl and stain it permanently. Wipe shoe polish off
as quickly as possible using naphtha or lighter fluid.
If staining occurs, try the procedure used for sulfide
stains.
Ball Point Ink
Rub ball point ink immediately with a damp cloth,
using water or rubbing alcohol. If this does not work,
try the procedure used for sulfide stains.
Miscellaneous
If stains do not respond to any of the treatments described above, it is sometimes helpful to expose the
22.2
Cab Appearance
vinyl to direct sunlight for up to 30 hours. Mustard,
ball point ink, certain shoe polishes, and dyes often
bleach out in direct sunlight, leaving the vinyl undamaged.
Velour Upholstery Cleaning
To prevent soiling, frequent vacuuming or light brushing to remove dust and dirt is recommended. Spot
clean with a mild solvent or an upholstery shampoo,
or the foam from a mild detergent. When using a solvent or a dry-cleaning product, follow the instructions
carefully, and clean only in a well-ventilated area.
Avoid any product that contains carbon tetrachloride
or other toxic materials. With either method, pretest a
small area before proceeding. Use a professional
upholstery cleaning service when extensive cleaning
is needed.
Grease and Oil-Based Stains
Dampen a small absorbent cloth with dry-cleaning
solvent or spot remover. Apply the cloth carefully to
the spot from the outer edge to the center. Pat and
blot the spot with a clean, dry cloth. Repeat several
times, as necessary, turning the cloths so that the
stain does not redeposit on the fabric.
Sugar and Water-Based Stains
Apply water-based detergent or cleaner, working in
circular motions. Pat and blot as dry as possible. Repeat, if necessary, before drying thoroughly.
Chewing Gum or Wax
Harden the gum or wax with an ice cube wrapped in
a plastic bag, then scrape it off with a dull knife. Absorb excess wax by placing a thick white blotter over
the wax and heating with a warm (not hot) iron. Remove the remainder by using the procedure for
grease and oil-based stains.
Mildew
Brush the dry fabric with a soft brush. Sponge with
detergent, and blot. If the fabric is colorfast, dilute a
teaspoon of bleach in one quart (one liter) of cool
water. Apply with a swab, directly on the mildew
stain. Dab repeatedly with clear, cool water, and blot
dry.
22.3
23
Headlight Aiming
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2
Headlight Aiming
Preliminary Checks
Checking Headlight Aim
Before checking or adjusting the headlight aim, complete the following inspection:
1.
Park the vehicle on a level surface, 25 ft (7.6 m)
away from, and perpendicular to, a vertical
screen or wall. Shut down the engine and set the
parking brake. Chock the tires.
2.
On each headlight, find the bulb center behind
the headlight lens.
3.
Measure the distance from the ground to the
center of each headlight bulb (Fig. 23.1, Item A).
Note those distances.
4.
On the screen or wall, mark the locations of each
headlight bulb center using the distances found
in step 3. See Fig. 23.1, Items 2 and 3.
5.
Turn on the low-beam headlights.
6.
Check the vertical adjustment of the low beams.
The center of each beam projection should fall
on or near the marks made during step 4. See
Fig. 23.2.
• Check that the hood is closed and latched.
• Remove any large amounts of mud or ice from
the underside of the fenders.
• Check the springs for sagging or broken
leaves.
• Check the suspension for proper functioning of
the leveling mechanism. On cabs with air suspensions, make sure that the height is properly
adjusted.
• Check for damage to the hood and hinge as-
sembly. Repair as necessary.
• With the vehicle unloaded, check that the tires
are inflated to the recommended air pressure.
• Clean the headlight lenses. Use a soft cloth
with mild, non-caustic soap or detergent, and
water.
2
3
A
A
B
B
25 ft
)
(7.6 m
1
10/27/2011
A.
B.
1.
2.
f545850
Measure the distance from the ground to the center of each headlight bulb.
Mark where the center of each headlight projection should appear.
Screen or Wall
3. Center of Left-Hand Headlight Projection
Center of Right-Hand Headlight Projection
Fig. 23.1, Headlight Aiming Screen/Wall
23.1
Headlight Aiming
A
1
2
3
11/03/2011
f545851
1. Low-Beam Angle Upper Limit
2. Ideal Low-Beam Projection
3. Low-Beam Angle Lower Limit
Fig. 23.2, Vertical Low-Beam Headlight Variation Limits
7.
Use Table 23.1 to determine the maximum vertical distance allowable between the marks on the
wall and the center of each low-beam projection.
the various options, the location of adjustment
screws on your vehicle’s headlight assembly
may vary from what is shown here.
If the distance between either projection center
and the mark made on the wall or screen is
greater than the maximum distance given in
Table 23.1, adjust the vertical positioning of that
headlight.
The adjusting screw is located on the upper inboard
corner of the headlight assembly. See Fig. 23.3. Turn
the adjusting screw clockwise to raise the beam and
counterclockwise to lower it, until the beam pattern
meets the acceptable standard.
Adjusting Headlight Aim
NOTE: Freightliner vehicles are offered with
various headlight assembly options. Because of
Distance Between Ground
and Headlight: in (mm)
22–36 (560–900)
36–48 (900–1200)
48–54 (1200–1400)
Vertical Low-Beam Headlight Variation Limits
Desired Variation (Fig. 23.2, Upper Limit (Fig. 23.2, Item
Item 2) : in (mm)
1): in (mm) up
0
3.9 (100)
2 (50) down
2 (50)
2.5 (64) down
1.6 (40)
Lower Limit (Fig. 23.2, Item
3): in (mm) down
3.9 (100)
6 (150)
6.5 (165)
Table 23.1, Vertical Low-Beam Headlight Variation Limits
23.2
Headlight Aiming
05/13/2009
f545526
Fig. 23.3, Headlight Adjusting
23.3
24
In an Emergency
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Filter Replacement, DAVCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24.1
24.1
24.1
24.1
24.2
24.5
24.6
In an Emergency
Hazard Warning Lights
mable substances such as fuel. An explosion or
fire could occur causing serious personal injury.
The hazard warning light flasher (Fig. 24.1) is part of
the multifunction turn signal switch. It is a red rocker
switch located on the top of the multifunction switch
module.
If there is an emergency while driving, cautiously pull
off the road. Turn on the hazard warning lights. Place
the flares and reflector along the side of the road to
alert other drivers that an emergency situation exists.
Emergency Filter
Replacement, DAVCO
4
5
1
2
If the filter cover on the DAVCO fuel/water separator
is broken, 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 information, www.davcotec.com.
3
11/16/2001
WARNING
f820386
Press down on the upper part of the rocker to activate
the flashers.
1. Washer Button
2. Wiper Control Dial
3. Turn Signal Lever
4. Hazard Flasher (red)
5. Multifunction Switch
Module
Fig. 24.1, Hazard Warning Flashers
To activate the hazard warning lights, press down on
the upper part of the rocker (pushing towards the
dash). To deactivate the hazard warning lights, press
down on the lower part of the rocker (towards the
steering wheel).
Fire Extinguisher
A fire extinguisher is located in the cab by the
driver’s door.
Emergency Kit
An optional emergency kit is located in the cab. The
kit includes one or more of the following: a first aid
kit, a reflective vest, a triangular reflector, a flare kit,
and (on vehicles with a DAVCO fuel/water separator)
a spin-on fuel filter element.
Fluid circulated through the fuel/water separator
to heat the fuel may be diesel fuel returned from
the engine, or engine coolant. Drain the fuel/
water separator only when the engine and fluids
have cooled. Draining it when the engine is hot
could cause severe personal injury due to scalding.
If returning fuel is released into the atmosphere,
its vapors can ignite in the presence of any ignition source. Do not expose the fuel to, or work
with the fuel system near, open flame or intense
heat. To do so could cause fire, possibly resulting in serious personal injury or property damage.
1.
Shut down the engine, apply the parking brake,
and chock the tires.
2.
Put a clean receptacle under the fuel/water separator and attach a piece of hose to the drain
valve, to direct fuel into the receptacle.
NOTE: The drain valve on the Fuel Pro 382 has
a 1/2-inch (12.7-mm) opening; use a hose with
a 1/2-inch pipe thread to fit correctly.
3.
Remove the vent cap (Fig. 24.2, Item 4) and
open the drain valve (Fig. 24.2, Item 1) to drain
the fuel to just below the collar level, then close
the drain valve.
4.
Using a DAVCO collar wrench (Fig. 24.3), remove the clear cover and collar.
WARNING
Use extreme care when placing flares in emergency situations that involve exposure to flam-
24.1
In an Emergency
4
3
7.
Ensure that the drain valve is closed.
8.
Remove the filter grommet from the filter stud, if
equipped.
9.
Fill the housing to the top with clean diesel fuel.
10. Install a standard fuel filter element on the filter
stud. If a standard filter element is not available,
install a spin-on fuel filter element (part number
FF105 or equivalent).
5
2
11. Install the cover O-ring, clear cover, and the col-
lar. Hand-tighten the collar.
6
12. Install and hand-tighten the vent cap O-ring and
vent cap.
13. Start the engine. When the lubricating oil
1
05/05/2009
reaches its normal operating pressure, increase
engine speed to high idle for one to two minutes
to purge air from the system.
f470506b
1. Drain Valve
2. Lower Housing
3. Clear Cover
4. Vent Cap
5. Collar
6. Inlet Port/Check Valve
VENT CAP
Fig. 24.2, DAVCO Fuel/Water Separator (Fuel Pro 382
shown)
FOR REMOVAL OF TOP COLLAR ONLY
02/16/2009
Emergency Starting With
Jumper Cables
When using jumper cables, follow the instructions
below.
WARNING
f470277
Fig. 24.3, DAVCO Collar Wrench
NOTE: Broken vent cap and collar warranty
claims will not be accepted if any tool other than
a DAVCO collar wrench, p/n 380134 or 382002,
is used for removal. During installation, the vent
cap and collar are to be hand-tightened only,
not tightened with a wrench.
5.
Remove the filter and dispose of it in an environmentally acceptable manner.
6.
Clean all threads and sealing surfaces very thoroughly. Even a small amount of dirt will prevent
the fuel/water separator from sealing, and an air
leak will result.
Batteries release explosive gas. Do not smoke
when working around batteries. Put out all flames
and remove all sources of sparks or intense heat
in the vicinity of the battery. Do not allow the vehicles to touch each other. Do not lean over the
batteries when making connections, and keep all
other persons away from the batteries. Failure to
follow these precautions could lead to severe
personal injury as a result of an explosion or
acid burns.
NOTICE
Make sure both electrical systems are the same
voltage. Electronic devices on both vehicles can
be damaged when connected to a vehicle with a
different operating voltage.
1.
Apply the parking brakes and turn off all lights
and other electrical devices. Ensure that the vehicles are not touching and both ignition switches
are turned to the OFF position.
24.2
In an Emergency
IMPORTANT: Do not attempt to jump start a
damaged battery.
2.
3.
Remove the battery box cover. See Fig. 24.4 for
the standard battery compartment location.
Connect the positive (+) jumper cable to the
positive terminal or jump start post on the discharged battery. See Fig. 24.6.
POS JUMP
START STUD
3
2
1
2
NEG JUMP
START STUD
3
1
01/07/2011
f545726
1. Frame Rail
2. Negative Jump Start Post
3. Positive Jump Start Post
Fig. 24.5, Possible Jump Start Post Location
(passenger-side engine compartment)
4.
12/03/2010
1. Back-of-Cab
2. Fuel Tank
f545714
3. Battery Compartment
Fig. 24.4, Standard Battery Compartment Location
NOTICE
Always connect the batteries and jumper cables
correctly (positive-to-positive and negative-tonegative). Connecting a charging device backwards (positive-to-negative) can severely damage
the vehicle electrical content and cause nonwarrantable failures.
IMPORTANT: On vehicles equipped with optional jump start posts, connect to these posts
instead of the battery terminals. Jump start
posts may be installed in various locations on
the vehicle. See Fig. 24.5.
24.3
Connect the other end of the positive jumper
cable to the positive terminal or jump start post
on the booster battery providing the charge.
WARNING
Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the
clamps of the other cable. Otherwise, a spark
could occur near a battery, possibly resulting in
severe personal injury from explosion or acid
burns.
5.
Connect the negative (-) jumper cable to the
negative terminal or jump start post on the
booster battery.
6.
Connect the other end of the negative jumper
cable to the negative ground stud on the vehicle
requiring the jump start.
7.
Start the engine of the vehicle providing the jump
start and let the engine run a few minutes to
charge the batteries of the other vehicle.
In an Emergency
4
D
B
3
E
2
+
−
−
+
+
−
−
+
−
+
C
−
+
1
A
01/07/2011
f545725
Disconnect jumper cables in the REVERSE order that they were connected.
A.
B.
1.
2.
3.
4.
Discharged Battery
C. Positive Jumper Cable
E. Booster Battery
Negative Ground Stud
D. Negative Jumper Cable
1st Connection: Positive Jumper Cable to Discharged Battery
2nd Connection: Positive Jumper Cable to Booster Battery
3rd Connection: Negative Jumper Cable to Booster Battery
4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)
Fig. 24.6, Jumper Connections
8.
9.
Attempt to start the engine of the vehicle receiving the jump. Do not operate the starter longer
than 30 seconds, and wait at least two minutes
between starting attempts to allow the starter to
cool.
When the engine starts, let it idle a few minutes.
WARNING
Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the
clamps of the other cable. Otherwise, a spark
could occur near a battery, possibly resulting in
severe personal injury from explosion or acid
burns.
24.4
In an Emergency
10. Disconnect the negative jumper cable from the
studs. This prevents lubricant from leaking out
and will keep contaminants from getting into and
damaging the wheel bearings and axle lubricant.
negative cable stud on the jump started vehicle.
11. Disconnect the negative jumper cable from the
If the driveline(s) were removed, ensure the
U-joint caps are secure so they will not come off.
booster battery.
12. Disconnect the positive cable from the booster
battery.
NOTICE
13. Disconnect the other end of the positive jumper
cable from the jump started vehicle.
14. Install the battery box cover; be sure it is posi-
tioned properly before fastening the latch.
Failure to protect the frame rails from the chains
could cause damage, leading to eventual frame
failure.
4.
Towing
When it is necessary to tow the vehicle, make sure
the instructions below are closely followed to prevent
damage to the vehicle.
WARNING
Do not tow an unbraked vehicle if the combined
weight of both vehicles is more than the sum of
the gross axle weight ratings (GAWR) of the towing vehicle. Otherwise brake capacity will be inadequate, which could result in personal injury or
death.
Front Towing Hookup
1.
Disconnect the batteries at the negative terminals.
Use protection to keep the chains from damaging
the frame.
5.
2.
Remove the driveline from any drive axle that will
have its wheels touching the ground while the
vehicle is towed,
or
remove the drive axle shafts on both sides of the
vehicle from any drive axle that will have its
wheels touching the ground while the vehicle is
towed.
3.
24.5
If the axle shafts were removed, cover the ends
of the hubs with metal plates or plywood cut to fit
the axle opening, and drilled to fit the axle shaft
Remove the bumper end caps and chrome bumper, if equipped.
NOTICE
Do not pass a sling (for example, a rope or chain)
from one tow hook to another to fasten for towing. Known as reeving, this practice is not permissible in most industrial applications of towing
and hoisting. Reeving can overload the hooks
and result in damage to the vehicle.
6.
Attach the towing device. Due to the many variables that exist in towing, positioning the lifting
and towing device is the sole responsibility of the
towing-vehicle operator.
7.
Lift the vehicle and secure the safety chains. If
extra towing clearance is needed, remove the
front wheels.
8.
Connect the clearance lights, taillights, and signal lights. Connect any special towing lights required by local regulations.
NOTICE
Failure to remove the axle shafts or the driveline
when towing the vehicle with the rear wheels on
the ground could result in damage to the transmission and other parts.
If a vehicle with tandem rear axles is to be lifted
and towed, chain the forward rear-axle assembly
to the vehicle frame. This will prevent the forward
rear-axle assembly from dropping and keep its
wheels off the ground while being towed.
WARNING
Failure to chock the tires or connect the tow
truck’s air brake system before releasing the
spring parking brakes could allow the disabled
vehicle to suddenly roll. This could cause property damage or personal injury.
In an Emergency
9.
Chock the tires on the disabled vehicle and connect the towing vehicle’s air brake system to the
vehicle being towed. Then, release the spring
parking brakes and remove the chocks.
Rear Towing Hookup
NOTICE
Using a rear towing hookup on a vehicle
equipped with a roof fairing could cause damage
to the cab structure.
If reverse towing at speeds above 45 mph (70
kph) is necessary, hold down the cab with tension straps looped over the cab shocks and
under the frame rails. Failure to do so could
allow the wind load to lift the cab unexpectedly,
resulting in damage to the air springs and other
components.
1.
2.
3.
If the vehicle is equipped with cab air suspension, and reverse towing at speeds above 45
mph (70 kph) is necessary, hold down the cab as
follows:
1.1
Drain the air from the cab air springs.
1.2
Loop a 2-inch (5-cm) ratchet-style tension
strap (rated 2000 lb [900 kg] minimum
work load) over the top of the cab shock
and under the frame rail. Tighten the strap
for a snug fit. See Fig. 24.7. If the cab is
equipped with two or more shocks, restrain the aftmost shock on each side of
the vehicle.
Place the front tires straight forward and secure
the steering wheel in this position.
Disconnect the battery ground cables.
NOTICE
Failure to protect the frame rails from the chains
could cause damage, leading to eventual frame
failure.
4.
On dual drive axles, using protection to keep the
chains from damaging the vehicle frame, chain
the forward-rear drive axle to the frame.
5.
Attach the towing device.
06/09/2014
f602529
Fig. 24.7, Tension Strap Installed to Hold Down the Cab
NOTE: Due to the many variables that exist in
towing, positioning the lifting and towing device
is the sole responsibility of the towing-vehicle
operator.
6.
Lift the vehicle and secure the safety chains. If
extra clearance is needed, remove the bumper
extension if equipped.
7.
Connect the clearance lights, taillights, and signal lights. Also connect any special towing lights
required by local regulations.
Fire in the Cab
The incidence of fire in trucks is rare, according to
data from the National Highway Traffic Safety Administration. Federal Motor Vehicle Safety Standard
#302 limits the flammability of specified materials
used inside the cab, but despite this, most materials
will burn. The cab of this vehicle contains urethane
foam, which is of concern in this respect.
24.6
In an Emergency
WARNING
Urethane foam is flammable! Do not allow any
flames, sparks, or other heat sources such as
cigarettes or light bulbs to contact urethane
foam. Urethane foam in contact with such heat
sources could cause a serious, rapid fire, which
could result in death, severe burns, or gas poisoning, as well as damage to the vehicle.
In Case of a Cab Fire
As quickly as possible, bring the vehicle to a safe
stop, apply the parking brake, turn off the ignition,
and get out of the vehicle.
24.7
Index
Subject
Page
A
Adjustable Steering Column
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 23.2
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Automatic Slack Adjusters . . . . . . . . . . . . . . . . 12.3
Brake System Conditions . . . . . . . . . . . . . . . . 12.1
Brake System General
Information . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Brake System Operation . . . . . . . . . . . . . . . . . 12.1
Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . 18.1
All Wheel Drive Controls . . . . . . . . . . . . . . . . . . . 5.11
AWD Operation Switch . . . . . . . . . . . . . . . . . . 5.11
AWD Range Switch . . . . . . . . . . . . . . . . . . . . 5.11
Allison Automatic Transmissions . . . . . . . . . . . . . 14.13
General Information, Allison
Transmissions . . . . . . . . . . . . . . . . . . . . . . 14.13
Operation Tips, Allison
Transmissions . . . . . . . . . . . . . . . . . . . . . . 14.13
Auxiliary Braking Applications . . . . . . . . . . . . . . . . 10.3
Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . 10.3
Exhaust Brake, Cummins
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
B
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . 2.4
Climbing Down from Backof-Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Climbing Up to Back-of-Cab . . . . . . . . . . . . . . . . 2.4
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Backrest Tilt, Bostrom Seat . . . . . . . . . . . . . . . . 6.4
Bottom Cushion Tilt, Bostrom
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Fore-and-Aft Seat
Adjustment, Bostrom Seat . . . . . . . . . . . . . . . . 6.4
Height Adjustment, Bostrom
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Isolator, Bostrom Seat . . . . . . . . . . . . . . . . . . . 6.4
Lumbar Support, Bostrom
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Antilock Braking System . . . . . . . . . . . . . . . . . 5.12
Parking Brake Control Valve . . . . . . . . . . . . . . . 5.12
Trailer Air Supply Valve . . . . . . . . . . . . . . . . . . 5.12
Trailer Brake Lever . . . . . . . . . . . . . . . . . . . . . 5.12
C
Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Cab Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
I-1
Subject
Page
Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Cab Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Entering from the Driver’s
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Entering from the
Passenger’s Side . . . . . . . . . . . . . . . . . . . . . 2.3
Exiting from the Driver’s Side . . . . . . . . . . . . . . . 2.2
Exiting from the Passenger’s
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Cab Washing and Polishing . . . . . . . . . . . . . . . . . 22.1
Canadian Motor Vehicle Safety
Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 22.1
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 22.1
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 22.1
Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 23.1
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Daily Pretrip Inspection
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Monthly Post-trip Inspection
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Weekly Post-trip Inspection
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . 7.1
Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . 7.4
Air Conditioning, Optional . . . . . . . . . . . . . . . . . 7.3
Air Selection Switch . . . . . . . . . . . . . . . . . . . . . 7.1
Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Fresh Air Mode . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Recirculation Mode . . . . . . . . . . . . . . . . . . . . . 7.3
Temperature Control Switch . . . . . . . . . . . . . . . . 7.3
Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Clutch General Information . . . . . . . . . . . . . . . 13.5
Clutch Maintenance . . . . . . . . . . . . . . . . . . . . 13.7
Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 13.6
Component GWR Label . . . . . . . . . . . . . . . . . . . . 1.1
Component Information Label . . . . . . . . . . . . . . . . 1.1
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
D
Daily Pretrip Inspection and
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Inspection . . . . . . . . . . . . . . . . . . . . . . .
Engine Compartment
Inspection . . . . . . . . . . . . . . . . . . . . . . . . .
Natural Gas Fuel System
Inspection, If Equipped . . . . . . . . . . . . . . . . .
Saddle Tank Areas
Inspection . . . . . . . . . . . . . . . . . . . . . . . . .
21.1
21.5
21.4
21.8
21.4
Index
Subject
Page
Suspension and Slack
Adjuster Inspection . . . . . . . . . . . . . . . . . . . 21.1
Wheel and Tire Inspection . . . . . . . . . . . . . . . . 21.1
Dashboard and Instrument
Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Diesel Exhaust Fluid and Tank . . . . . . . . . . . . . . . 11.3
DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
DEF Warnings and Engine
Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 11.3
Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . 11.4
Differential Lock, Drive Axles . . . . . . . . . . . . . . . . 15.1
Differential Lock Operation . . . . . . . . . . . . . . . . 15.1
Differential Lock Switch . . . . . . . . . . . . . . . . . . 15.1
Single Drive Axles with
Traction Equalizer . . . . . . . . . . . . . . . . . . . . 15.2
Door Locks and Handles . . . . . . . . . . . . . . . . . . . . 2.1
Driver Message Center . . . . . . . . . . . . . . . . . . . . . 4.7
Driving Screens . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Parked Screens/Menus . . . . . . . . . . . . . . . . . . . 4.7
E
Eaton Fuller 10-Speed RangeShift Transmissions . . . . . . . . . . . . . . . . . . . . . 13.4
General Information, 10Speed Range-Shift
Transmissions . . . . . . . . . . . . . . . . . . . . . . . 13.4
Operation Tips, Eaton Fuller
Range-Shift Transmissions . . . . . . . . . . . . . . 13.4
Eaton Fuller 13-Speed and 18Speed Splitter and RangeShift Transmissions . . . . . . . . . . . . . . . . . . . . . 13.1
General Information, Eaton
Fuller Splitter and RangeShift Transmissions . . . . . . . . . . . . . . . . . . . 13.1
Operation Tips, Eaton Fuller
Splitter and Range-Shift
Transmissions . . . . . . . . . . . . . . . . . . . . . . . 13.2
Eaton Fuller AutoShift
Automated Transmissions . . . . . . . . . . . . . . . . 14.10
General Information,
AutoShift Transmissions . . . . . . . . . . . . . . . 14.10
Operation, AutoShift
Transmissions . . . . . . . . . . . . . . . . . . . . . . 14.10
Eaton Fuller UltraShift DM
Automated Transmissions . . . . . . . . . . . . . . . . . 14.1
General Information,
Ultrashift Transmissions . . . . . . . . . . . . . . . . 14.1
Operation, UltraShift
Transmissions . . . . . . . . . . . . . . . . . . . . . . . 14.2
Ultrashift Diagnostics . . . . . . . . . . . . . . . . . . . 14.5
Eaton Fuller UltraShift PLUS
Automated Transmissions . . . . . . . . . . . . . . . . . 14.6
Auto Neutral . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Subject
Page
Auto Start Gear Selection
and Override . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Automatic Mode (AUTO) . . . . . . . . . . . . . . . . . 14.7
Automatic Traction Control . . . . . . . . . . . . . . . 14.10
Clutch Abuse Protection . . . . . . . . . . . . . . . . . 14.8
Coasting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
Creep Mode . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Engine Overspeed
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Hill Start Aid . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Load-Based Shifting . . . . . . . . . . . . . . . . . . . 14.10
Low (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
Manual Mode (MAN) . . . . . . . . . . . . . . . . . . . . 14.8
Power Down . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
Reverse (R) . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
Shuttle Shifting . . . . . . . . . . . . . . . . . . . . . . . 14.9
Skip Shifting . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
Emergency Filter Replacement,
DAVCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Emergency Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Emergency Starting With
Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 24.2
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Aftertreatment System
Indicators Label . . . . . . . . . . . . . . . . . . . . . . 1.1
Certified Clean Idle Label . . . . . . . . . . . . . . . . . 1.4
EPA Noise Emission Control
Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Vehicle Emission Control
Information Label . . . . . . . . . . . . . . . . . . . . . 1.4
Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . 10.2
California Engine Idle
Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . 10.2
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Cold-Weather Operation . . . . . . . . . . . . . . . . . . 9.3
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . 9.2
Normal Operation . . . . . . . . . . . . . . . . . . . . . . 9.2
Safety and Environmental
Considerations . . . . . . . . . . . . . . . . . . . . . . . 9.2
Engine Protection—Warning
and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Cold-Weather Starting . . . . . . . . . . . . . . . . . . . 9.1
Starting After Extended
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Enhanced Stability Control . . . . . . . . . . . . . . . . . . 12.4
EPA-Regulated Emissions
Aftertreatment System . . . . . . . . . . . . . . . . . . . 11.1
ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 11.3
DPF Maintenance . . . . . . . . . . . . . . . . . . . . . . 11.3
I-2
Index
Subject
Page
Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
F
Federal Motor Vehicle Safety
Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . 17.1
Fontaine and Holland Fifth
Wheels Coupling . . . . . . . . . . . . . . . . . . . . . 17.1
Jost Fifth Wheel Coupling . . . . . . . . . . . . . . . . 17.3
Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . 17.7
Air Slide Operation . . . . . . . . . . . . . . . . . . . . . 17.9
Manual Slide Operation . . . . . . . . . . . . . . . . . . 17.7
Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . 17.4
Air-Actuated Uncoupling . . . . . . . . . . . . . . . . . 17.5
Manual Uncoupling . . . . . . . . . . . . . . . . . . . . . 17.4
Fifth Wheels, General
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Air-Suspension Dump Valve . . . . . . . . . . . . . . . 17.1
Fifth Wheel Lubrication . . . . . . . . . . . . . . . . . . 17.1
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 24.6
In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 24.7
Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Freightliner High-Back Seat . . . . . . . . . . . . . . . . . . 6.2
Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Bottom Cushion Extension . . . . . . . . . . . . . . . . 6.2
Fore/Aft Isolator . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Fore/Aft Seat Slide . . . . . . . . . . . . . . . . . . . . . . 6.2
Front Cushion Height . . . . . . . . . . . . . . . . . . . . 6.3
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 6.2
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 6.2
Rear Cushion Height . . . . . . . . . . . . . . . . . . . . 6.3
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Freightliner SmartShift Shift
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
General Information,
SmartShift Control . . . . . . . . . . . . . . . . . . . . 14.1
G
Greenhouse Gas Emissions
and Fuel Consumption
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
H
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . .
Holland Trailer Coupling . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . .
Trailer Hookup . . . . . . . . . . . . . . . . . . . . . . . .
Trailer Release . . . . . . . . . . . . . . . . . . . . . . .
I-3
24.1
18.1
18.1
18.1
18.1
Subject
Page
Hood Opening and Closing . . . . . . . . . . . . . . . . . .
To Return the Hood . . . . . . . . . . . . . . . . . . . . .
To Tilt the Hood . . . . . . . . . . . . . . . . . . . . . . . .
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5
2.5
2.5
5.6
5.6
5.6
I
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Instrumentation Control Unit . . . . . . . . . . . . . . . . . . 4.1
Audible Alerts . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 4.1
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Air Intake Restriction Gauge . . . . . . . . . . . . . . . 4.8
Coolant Temperature Gauge . . . . . . . . . . . . . . . 4.9
Drive Axle Oil Temperature
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . 4.10
Engine Oil Temperature
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Fuel/Diesel Exhaust Fluid
(DEF) Gauge . . . . . . . . . . . . . . . . . . . . . . . 4.11
Primary and Secondary Air
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 4.11
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Transmission Fluid
Temperature Gauge . . . . . . . . . . . . . . . . . . . 4.12
Turbocharger Boost
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 4.12
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Interaxle Lock, Tandem and
Tridem Axles . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Interaxle Lock Operation . . . . . . . . . . . . . . . . . 15.3
Interaxle Lock Switch . . . . . . . . . . . . . . . . . . . 15.2
L
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior Light Controls . . . . . . . . . . . . . . . . . . .
Interior Light Controls . . . . . . . . . . . . . . . . . . . .
Load Disconnect Switch . . . . . . . . . . . . . . . . . . . .
5.3
5.3
5.5
3.1
M
Major Repair and Replacement
of Natural Gas Components . . . . . . . . . . . . . . . 19.10
Meritor WABCO® Antilock
Braking System . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Automatic Traction Control . . . . . . . . . . . . . . . . 12.4
Trailer ABS Compatibility . . . . . . . . . . . . . . . . . 12.4
Mirrors and Windows . . . . . . . . . . . . . . . . . . . . . . 8.1
Index
Subject
Page
Down View Mirror, Optional . . . . . . . . . . . . . . . . 8.2
Mirror Heat Switch, Optional . . . . . . . . . . . . . . . 8.1
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Power Mirrors, Optional . . . . . . . . . . . . . . . . . . 8.1
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Monthly Post-Trip Inspection
and Maintenance . . . . . . . . . . . . . . . . . . . . . . 21.11
Brake Component Inspection . . . . . . . . . . . . . 21.11
Engine Compartment
Inspection and
Adjustments . . . . . . . . . . . . . . . . . . . . . . . 21.13
Natural Gas Fuel System
Inspection, If Equipped . . . . . . . . . . . . . . . . 21.13
Saddle Tank Areas
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.12
Multifunction Turn Signal Lever
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Turn Signal Controls . . . . . . . . . . . . . . . . . . . . . 5.6
Windshield Wiper/Washer
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
N
National 2000 Series Seat . . . . . . . . . . . . . . . . . . . 6.5
Backrest Tilt, National 2000
Series Seat . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Bottom Cushion Fore-and-Aft
Adjustment, National 2000
Series Seat . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Fore-and-Aft Seat
Adjustment, National 2000
Series Seat . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Height Adjustment, National
2000 Series Seat . . . . . . . . . . . . . . . . . . . . . 6.6
Isolator, National 2000
Series Seat . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Lumbar Support, National
2000 Series Seat . . . . . . . . . . . . . . . . . . . . . 6.6
Rear Cushion Adjustment,
National 2000 Series Seat . . . . . . . . . . . . . . . 6.6
Natural Gas Detection System . . . . . . . . . . . . . . . 19.5
Alarm Procedure . . . . . . . . . . . . . . . . . . . . . . 19.5
Overhead Console . . . . . . . . . . . . . . . . . . . . . 19.7
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7
Natural Gas Fuel Tank Filling
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2
CNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . 19.2
LNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . . 19.3
Natural Gas Vehicles, Engine
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9
Natural Gas Vehicles, General
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Natural Gas Vehicles, Safety
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Subject
Page
In Case of Emergency . . . . . . . . . . . . . . . . . . 19.2
O
Overhead Instrument Panel . . . . . . . . . . . . . . . . . 4.13
P
Periodic Inspections and
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Power Steering System . . . . . . . . . . . . . . . . . . . . 16.1
Steering Wheel Adjustment . . . . . . . . . . . . . . . 16.1
Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . 10.6
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 5.7
Aftertreatment System
Regeneration Switches . . . . . . . . . . . . . . . . . . 5.7
Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Cruise Control Switches . . . . . . . . . . . . . . . . . . 5.8
Engine Brake Switch . . . . . . . . . . . . . . . . . . . . 5.9
Engine Fan Switch . . . . . . . . . . . . . . . . . . . . . . 5.9
Exhaust Brake Switch . . . . . . . . . . . . . . . . . . . . 5.9
Transmission Controls . . . . . . . . . . . . . . . . . . . 5.10
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 23.1
Premier Trailer Couplings . . . . . . . . . . . . . . . . . . 18.2
General Information . . . . . . . . . . . . . . . . . . . . 18.2
Trailer Hookup . . . . . . . . . . . . . . . . . . . . . . . . 18.2
Trailer Release . . . . . . . . . . . . . . . . . . . . . . . 18.3
R
Roll Stability Advisor/Control . . . . . . . . . . . . . . . . .
Hard-Braking Advisor . . . . . . . . . . . . . . . . . . .
Roll Stability Advisor . . . . . . . . . . . . . . . . . . . .
Roll Stability Control . . . . . . . . . . . . . . . . . . . .
Trip/Leg Totals . . . . . . . . . . . . . . . . . . . . . . . .
12.5
12.6
12.5
12.5
12.6
S
Sears Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . .
Armrest Adjustment, Sears
Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . . .
Backrest Tilt, Sears Atlas
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fore-and-Aft Seat
Adjustment, Sears Atlas
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height Adjustment, Sears
Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . . .
Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lumbar Support, Sears Atlas
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
6.5
6.5
6.4
6.4
6.4
6.5
I-4
Index
Subject
Page
Seat Tilt/Extension
Adjustment, Sears Atlas
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 6.6
General Information, Seat
Belts and Tether Belts . . . . . . . . . . . . . . . . . . 6.6
Inspection, Seat Belts and
Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 6.7
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Bench Seats . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Seats, General Information . . . . . . . . . . . . . . . . . . 6.1
Bench Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Suspension Controls . . . . . . . . . . . . . . . . . . . . . . 5.13
Air Suspension Autofill
Override Valve . . . . . . . . . . . . . . . . . . . . . . 5.13
Air Suspension Dump
Control Switch . . . . . . . . . . . . . . . . . . . . . . . 5.13
T
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5
Front Towing Hookup . . . . . . . . . . . . . . . . . . . 24.5
Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 24.6
V
Vehicle Power Distribution . . . . . . . . . . . . . . . . . . . 3.1
Main Powernet Distribution
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Power Distribution Modules . . . . . . . . . . . . . . . . 3.1
Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 22.3
Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 22.3
Grease and Oil-Based Stains . . . . . . . . . . . . . . 22.3
Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Sugar and Water-Based
Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 22.2
Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Nail Polish and Nail Polish
Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 22.2
Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 22.2
W
Warning and Indicator Lights . . . . . . . . . . . . . . . . . 4.2
Engine Protection System . . . . . . . . . . . . . . . . . 4.6
I-5
Subject
Page
Weekly Post-Trip Inspection
and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 21.9
Engine Compartment
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.9

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