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Driver’s Manual

® CASCADIA

Part Number STI 478Publication Number STI-478-6

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

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

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

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

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

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

This vehicle is equipped with an event data recorder(EDR). The main purpose of an EDR is to recorddata in certain crash or near-crash situations, suchas air bag deployment or hitting a road obstacle, thatwill assist in understanding how a vehicle’s systems

performed. The EDR is designed to record data re-lated to vehicle dynamics and safety systems for ap-proximately 60 seconds. This data can help providea better understanding of the circumstances in whichcrashes and injuries occur. Data recorded includesthe following items:

• how various systems in the vehicle were oper-ating

• engine system information

• how far (if at all) the driver was depressing theaccelerator

• if the driver was depressing the brake pedal

• how fast the vehicle was traveling

NOTE: Data is not recorded by the EDR undernormal driving conditions. Personal data suchas name, gender, age, and crash location arenot recorded. However, other parties such aslaw enforcement could combine the EDR datawith the type of personally identifying data rou-tinely acquired during a crash investigation.

To read data recorded by an EDR, special equipmentis required, and access to the vehicle or the EDR isneeded. In addition to the vehicle manufacturer, otherparties that have the special equipment, such as lawenforcement, can read the information if they haveaccess to the vehicle or the EDR.

Emissions and Fuel EfficiencyComplianceThis vehicle must be regularly inspected and main-tained as indicated in the Cascadia MaintenanceManual, and in the Pre- and Post-Trip Inspectionsand Maintenance chapter in this manual, in order tocontinue satisfactory performance and ensure cover-age of the vehicle under the manufacturer’s warranty.Many maintenance procedures ensure that the ve-hicle and engine continue to comply with applicableemissions standards. Maintenance procedures, usingcomponents engineered to comply with greenhousegas emissions and fuel efficiency regulations, may beperformed by an authorized Daimler Trucks NorthAmerica dealer, an independent outlet, or the vehicleowner or operator.

The vehicle owner is responsible for determining thesuitability of replacement components to maintain

Foreword

STI-478-6 (8/15)Part Number STI 478

Printed in U.S.A.

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

Customer Assistance CenterHaving trouble finding service? Call the CustomerAssistance Center at 1-800-385-4357 or 1-800-FTL-HELP. Call night or day, weekdays or weekends, fordealer referral, vehicle information, breakdown coor-dination, or Fleetpack assistance. Our people areknowledgeable, professional, and committed to fol-lowing through to help you keep your truck moving.

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

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

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

Canadian customers who wish to report a safety-related defect to Transport Canada, Defect Investi-gations and Recalls, may telephone the toll-free

hotline 1-800-333-0510, or contact TransportCanada by mail at: Transport Canada, ASFAD,Place de Ville Tower C, 330 Sparks Street, Ot-tawa, Ontario, Canada K1A 0N5.

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

© 2007–2015 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 transmittedin any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per-mission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks NorthAmerica LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer towww.Daimler-TrucksNorthAmerica.comand www.FreightlinerTrucks.com.

Foreword

www.safercar.gov

www.safercar.gov

www.tc.gc.ca/roadsafety

www.tc.gc.ca/roadsafety

http://www.Daimler-TrucksNorthAmerica.com

www.FreightlinerTrucks.com

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Emissions and Fuel Efficiency Compliance,Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Driver Assistance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Seats and Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Engine Starting, Operation, and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111 Optional Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.112 Emissions and Fuel Efficient Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.113 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.114 Manual Transmissions and Hydraulic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.115 Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.116 Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.117 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.118 Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.119 Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.120 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.121 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.122 Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.123 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.124 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.125 Natural Gas Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.126 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1

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

1

Vehicle IdentificationComponent Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Component GWR Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Federal Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Canadian Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

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

The component information label lists the vehiclemodel, identification number, and major componentmodels. It also lists the major assemblies and instal-lations shown on the chassis specification sheet.One copy of the component information label is at-tached to the inside of the glove box; another copy isinside the rear cover of the Owner’s Warranty Infor-mation for North America booklet. An illustration ofthe label is shown in Fig. 1.1.

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

See Fig. 1.2 for a typical component GWR label.

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

Tractors with or without fifth wheels purchased in theU.S. are marked as certified by means of an FMVSScertification label. See Fig. 1.3. This label is attachedto the driver-side B-pillar, as shown in Fig. 1.4.

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

Trucks built without a cargo body that are intendedfor service in the U.S. have an incomplete vehiclecertification label attached by the final-stage manu-facturer. See Fig. 1.5. This label will be attached tothe incomplete vehicle document included with thevehicle, and certifies that the vehicle conforms to allapplicable FMVSS regulations in effect on the date ofcompletion.

Canadian Motor Vehicle SafetyStandard LabelsIn Canada, tractors with fifth wheels are marked ascertified by means of a statement of compliance labelwith the Canadian National Safety Mark attached tothe driver-side door frame B-pillar. See Fig. 1.6.

Trucks built without a cargo body and tractors builtwithout a fifth wheel that are intended for service inCanada have an incomplete vehicle certification labelattached to the driver-side B-pillar. After completionof the vehicle, a complete certification label must beattached by the final-stage manufacturer to certifythat the vehicle conforms to all applicable CanadaMotor Vehicle Safety Standard (CMVSS) regulationsin effect on the date of completion.

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

02/20/2012 f080176

Fig. 1.1, Component Information Label

Vehicle Identification

1.1

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

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

02/20/2012 f080178

Fig. 1.2, Component GWR Label

02/20/2012 f080177

Fig. 1.3, Vehicle Certification Label

02/28/2012 f080182

1

2

1. EPA Noise Emission Control Label2. FMVSS Certification Label

Fig. 1.4, Label Locations

f08018002/28/2012

Fig. 1.5, Incomplete Vehicle Certification Label

f08002410/10/2006

Fig. 1.6, Canadian National Safety Mark


1.2

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

January 1, 2007–December 31,2009

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

January 1, 2010–December 31,2012

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

From March 5, 2012

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

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

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

EPA Noise Emission Control LabelA vehicle noise emission control label (Fig. 1.9) islocated on the driver-side B-pillar as shown inFig. 1.4. It is the owner’s responsibility to maintainthe vehicle so that it conforms to EPA regulations.

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

f080156

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended.

Filter is reaching

Bring vehicle tohighway speeds to

Filter Regeneration

Filter is nowreaching maximumcapacity.

To avoid enginederate, bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked, and a Parked

Service Regeneration Required.Engine Derate To Idle Only.

Filter has exceeded maximumcapacity.

Vehicle must be parked, and aService Regeneration must be

(Solid) (Flashing) (Flashing)

CHECKINDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity.

STOP

allow for an AutomaticRegeneration orperform a Parked

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

Regeneration mustbe performed.Engine will beginderate.

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

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

02/20/2009

WARNING

HEST (High ExhaustSystem Temperature)

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

A regeneration is inprogress.

Flashing

Solid

Regeneration.

Necessary

Fig. 1.7, ATS Indicators, EPA07


1.3

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

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

Certified Clean Idle LabelThe California Air Resources Board (CARB) requiresmodel year 2008 and newer heavy-duty diesel en-gines to be equipped with a non-programmable en-gine shutdown system that automatically shuts downthe engine after five minutes of idling in order to limitemissions of particulate matter and NOx.

DPF Regen Needed

Hot Exhaust

DEF Refill Needed

Diesel Particulate Filter (DPF)regeneration is needed.

If flashing, regenerate as soon aspossible. Engine derate possible.

Hot exhaust can cause fire.

Keep flammables and people awayfrom exhaust.

Diesel Exhaust Fluid (DEF) level islow. Engine derate likely.

Refill tank with certified DEF.

24−01656−000

IMPORTANT

DEF

11/30/2010 f080162

See operator’s manual for complete instructions.

Fig. 1.8, ATS Indicators, EPA10 and Newer

10/06/98 f080026

24−00273−020

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

DATE OF MANUFACTURE 01/96

Fig. 1.9, Vehicle Noise Emission Control Label

f08018102/29/2012

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

REGULATORY CLASS:

EMISSION CONTROL IDENTIFIERS:

DATE OF MANUFACTURE:VEHICLE EMISSION CONTROL INFORMATION

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

Fig. 1.10, Vehicle Emission Control Information Label


1.4

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

CERTIFIEDCLEAN IDLE

02/20/2012 f080179

Fig. 1.11, CARB Clean Idle Label


1.5

2

Vehicle AccessCab Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Cab-to-Sleeper Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Sleeper Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Sleeper Luggage Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Cab Door Locks and HandlesOne common key operates the ignition switch and allof the door locks.

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

To unlock the driver’s door from outside the cab, in-sert the key in the lockset and turn it one-quarter turnclockwise. See Fig. 2.1. To remove the key, turn itcounterclockwise to the original position. Pull out onthe door pull handle to open the door.

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

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

To lock a door from outside the cab, insert the key inthe lockset and turn it in the direction opposite to theunlocking direction (counterclockwise for the driver’sdoor, clockwise for the passenger’s door). Close thedoor if it is open.

To lock either door from inside the cab, push the lockbutton downwards. See Fig. 2.2.

To open the door from the inside, lift up on the doorlever. This will unlatch the door whether or not it islocked.

To unlock the door without unlatching it, pull the lockbutton upwards.

Grab Handles and AccessSteps

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

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

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

10/22/2001 f720397

1

2

3

1. Key2. Lockset

3. Door Pull Handle

Fig. 2.1, Exterior Door Handle

06/22/2006

1

2

3 f720639

1. Lock Button2. Integral Door Upper Grab Handle3. Door Lever

Fig. 2.2, Door Interior

Vehicle Access

2.1

Entering the Driver SideWhen entering the cab from the driver side, use thegrab handle and access steps as follows:

1. Open the driver side door, and place anythingthat you are carrying in the cab.

2. Using both hands, grasp the grab handle that ison the B-pillar, or use your left hand on the inte-gral door lower grab handle. See Fig. 2.3. Reachup as far as is comfortable.

3. Place your right foot on the bottom step, and pullyourself up. Move your left hand to the integraldoor upper grab handle.

4. Place your left foot on the top step.

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

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

Exiting the Driver SideExit the cab from the driver side as follows:

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

1. Grasp the steering wheel with both hands, placeyour left foot on the top step, then stand on thethreshold facing into the cab.

2. Using your right hand, grasp the grab handle,located on the B-pillar.

3. Move your right foot to the bottom step.

4. Move your left hand to the integral door lowergrab handle.

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

Entering the Passenger SideWhen entering the cab from the passenger side, usethe grab handles and access steps as follows:

1. Open the passenger-side door, and place any-thing that you are carrying in the cab.

2. Using your left hand, grasp the grab handlethat’s on the rear of the door opening. SeeFig. 2.4.

3. Using your right hand, grasp the integral doorlower grab handle.

4. Place your right foot on the bottom step, andstep up to the upper step with your left foot.

5. Place your right foot on the top step, and stepup.

6. Move your right hand to the upper grab handleon the windshield post.

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

Exiting the Passenger SideExit the cab from the passenger side as follows:

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

11/30/2006 f602271

1

2

3

4

5

1. Steering Wheel2. B-Pillar Grab Handle3. Bottom Step

4. Top Step5. Integral Door Lower

Grab Handle

Fig. 2.3, Driver-Side Steps and Grab Handle

Vehicle Access

2.2

1. Using both hands, grasp the grab handle thatson the windshield post, and place your right footon the top step while standing up from the seatfacing inward.

2. Place your left foot on the bottom step.

3. Move your left hand to the lower grab handlelocated at the rear edge of the door opening.See Fig. 2.4.

4. Move your right hand to the integral door lowergrab handle.

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

Cab-to-Sleeper AccessTo open the sleeper access on vehicles with vinylsleeper curtains, unzip the sleeper curtains. If de-sired, unsnap the curtains all the way around thesides and top, and remove the curtains.

To open the sleeper access on vehicles with veloursleeper curtains, unfasten the snaps at one side,then push the curtain to the opposite side.

Sleeper DoorThe sleeper door (Fig. 2.5, Ref. 1) is not intended forentry or exit. The door is intended only as a conve-nient means to stow or remove personal belongingsin and from the sleeper area. To open the sleeperdoor from the inside, push down on the lever handlelocated inside the sleeper compartment aft of thedoor, or pull out on the upper lever located inside thecab door opening; see Fig. 2.6. To open the sleeperdoor from outside, open the cab door, then pull outon the upper lever located inside the cab door open-ing. To close the door, pull on the strap attached tothe inside of the door, or push it closed from the out-side, until it latches.

IMPORTANT: The sleeper doors are two-stagelatching. When closing the doors, ensure thatthey are completely latched to prevent windnoise and water intrusion.

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1. Lower Grab Handle2. Upper Grab Handle3. Integral Door Lower Grab Handle4. Top Step

Fig. 2.4, Passenger-Side Steps and Grab Handles

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f602302

1. Sleeper Door2. Luggage Compartment Door

Fig. 2.5, Sleeper Doors

Vehicle Access

2.3

Sleeper Luggage DoorTo open the sleeper luggage door, pull out on thelower lever located inside the cab door opening. SeeFig. 2.6. To close the door, push it closed until itlatches.

Back-of-Cab Access

WARNINGExternal surfaces of the exhaust system remainhot after the engine has been shut down. Whenaccessing the back of the cab or sleeper, do nottouch any part of the exhaust system, or severeburns could occur.

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

Optional grab handles are mounted either on bothcab sidewalls, or on the left sidewall only. SeeFig. 2.7. Steps are mounted either on the fuel tank(s)or on metal brackets. When a deck plate is neces-sary, it is mounted across the top of the frame rails.

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

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

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

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1. Sleeper Door Lever2. Luggage Door Lever

Fig. 2.6, Sleeper Door Levers

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1. Steps2. Grab Handle

3. Deck Plate

Fig. 2.7, Back-of-Cab Access

Vehicle Access

2.4

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

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

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

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

3. Place your other foot on the top step.

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

5. Step onto the deck plate.

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

1. Grasp the sidewall grab handle with both hands.

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

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

4. Move one foot to the bottom step.

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

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

Hood Opening and ClosingA grab handle at the front of the hood provides ahand-hold for hood tilting. Two tilt-assist struts help totilt the hood open, and to return it to the operatingposition. A damper controls the closing rate of thehood and hood straps prevent the hood from over-travel. In the operating position, the hood is securedby a hold-down latch on each side of the hood.

To Tilt the Hood1. Apply the parking brakes.

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

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

3. Using the bumper step and grab handle, slowlytilt the hood until the straps support it. SeeFig. 2.8.

To Return the Hood1. Grasp the grab handle, and lift the hood a just-

over-center position.

2. As the hood goes over center, the hood dampercontrols the rate of descent to the operating posi-tion.

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

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

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Fig. 2.8, Hood Tilting

Vehicle Access

2.5

3

Electrical SystemElectrical Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Emergency Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3Progressive Low Voltage Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

Electrical Power DistributionElectrical power distribution provides battery power tothe electrical and electronic systems. See Fig. 3.1 forpower distribution component locations.

The following components make up the power distri-bution system:

• MEGA Fuse Junction Block (MFJB), EPA07only

• Powertrain Power Distribution Module(PT-PDM)

• Powernet Distribution Box (PNDB), EPA10 andnewer

• Cab Load Disconnect Switch

• Auxiliary PDM

MEGA Fuse Junction Block, EPA07On EPA07 vehicles, the MFJB distributes batterypower to the alternator, SAM cab, SAM chassis, andpowertrain PDM. Battery power may also be routedto an inverter and a trailer PDM. The MFJB housesup to five MEGA fuses, and is located on the leftframe rail in front of the batteries. See Fig. 3.2.

Powernet Distribution Box, EPA10and NewerThe PNDB distributes battery power to the SAM cab,SAM chassis, powertrain PDM, and other keep-alivecircuits.

The PNDB is mounted in the engine compartment onthe frontwall near the steering column. The label onthe PNDB fuse cover identifies typical circuits. SeeFig. 3.3.

Power Distribution ModulesPowertrain PDMThe powertrain PDM contains fuses and relays thatprovide battery and ignition power to the engine, af-tertreatment device, transmission, and otherpowertrain-related circuits. It is mounted in the en-gine compartment, above the driver-side innerfender.

Auxiliary PDMThe optional auxiliary PDM is used when additionalcircuit protection is needed for optional features. Forexample, if a beacon light is added to the Cascadia,it may require an auxiliary PDM. The auxiliary PDMmay contain fuses and relays for these devices. It ismounted in the cab, behind the doghouse cover.

Trailer PDMThe optional trailer PDM, mounted on the frame rail,is used to supply trailer power to the chassis-mounted trailer receptacles. The SAM chassis sup-plies control signals to the relays in the trailer PDM.

SAM CabThe SAM cab is located behind the glove box insidethe vehicle cab. See Fig. 3.4. The SAM cab containsfuses and relays in addition to solid state circuit pro-tection devices that will trip when a circuit is over-loaded.

Refer to Chapter 25 for fuse and relay locations.

SAM ChassisThe SAM Chassis is located in the engine compart-ment on the driver-side frontwall. See Fig. 3.3. TheSAM chassis contains fuses and relays in addition tosolid state circuit protection devices that will tripwhen a circuit is overloaded.

Refer to Chapter 25 for fuse and relay locations.

Circuit Protection FeaturesThe SAM chassis and SAM cab may be equippedwith self-resetting circuit breakers instead of fuses.Self-resetting circuit breakers are tripped when theyreach 170°F (77°C), then self-reset once the tem-perature drops sufficiently. When the circuit overloadis removed, this circuit protection will self-reset.Some of these circuits require the ignition switch tobe cycled off then back on again for the self-reset tooccur.

Some ECU’s are equipped with a self-resetting circuitbreaker removal tool.

WARNINGAlways wear heat-protective gloves when han-dling a self-resetting circuit breakers, which can

Electrical System

3.1

reach extremely high temperatures. Failure to useappropriate heat protection can lead to seriousinjury.

NOTICESelf-resetting circuit breakers can be perma-nently damaged if improperly handled. Use theguidelines below to handle them safely.

• Disconnect the batteries before removing aself-resetting circuit breaker.

• Use a circuit breaker removal tool to remove aself-resetting circuit breaker. See Fig. 3.5. Useof any other tool, including pliers, may damagethe circuit breaker.

• Never attempt to probe a self-resetting circuitbreaker while installed on the SAM Cab orSAM Chassis. Remove the circuit breaker first,or use a non-contact infrared thermometer tomeasure temperature.

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1. SAM Cab2. Powertrain PDM (PT-PDM)3. Powernet Distribution Box (PNDB)4. SAM Chassis5. Main Ground Junction Block

6. MEGA Fuse Junction Block7. Cab Load Disconnect Switch (optional location)8. Cab Load Disconnect Switch (optional location)9. Trailer PDM

Fig. 3.1, Component Locations

Electrical System

3.2

Cab Load Disconnect Switch

WARNINGTurning the cab load disconnect switch (CLDS) tothe off position does not disconnect the connec-tion between the battery and the starter. To workon the vehicle safely, the negative leads must bedisconnected from the battery.

IMPORTANT: The ignition should be turned offbefore turning the CLDS to on or off.

The CLDS is used to avoid excessive draw on thebattery when the vehicle is parked for an extendedperiod of time by disconnecting (or opening) the con-nection between the battery and the most of the ve-hicle electrical system.

The CLDS may be mounted:

• inside the cab on the outboard side of thedriver’s seat;

• at the battery box;

• outboard on the left frame rail.

See Fig. 3.6 for an EPA07 CLDS; see Fig. 3.7 for anEPA10 and newer switch.

If the CLDS is turned to the off position while the ve-hicle is running, the emergency power system willactivate. The powertrain PDM will receive power fromthe emergency power feed, but the batteries will notbe charging. See the Emergency Power Supplyheading below for details.

Emergency Power SupplyThe Cascadia electrical system has an emergencypower circuit that supplies battery power for exteriorlighting. This assists vehicle visibility in the event aMEGA fuse is open circuit. The emergency powercircuit is live even when the CLDS is turned off.

The emergency power supply feature allows for thevehicle to be driven off the highway and for the exte-rior lighting to remain on in the event of a SAM Cabor SAM Chassis failure. The emergency power sup-ply will cause certain exterior lamps to flash (depend-ing on if it is the SAM Cab or SAM Chassis thatfailed), indicating that the vehicle is disabled.

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1. MEGA Fuse Junction Block2. Main Ground Junction Block

Fig. 3.2, EPA07 MEGA Fuse Junction Block

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1. Powertrain PDM (PT-PDM)2. Inline Fuse, Auxiliary PDM3. SAM Chassis4. Powernet Distribution Box (PNDB)

Fig. 3.3, Engine Compartment Power DistributionComponents

Electrical System

3.3

SAM Cab FaultIf the emergency power supply system activates, donot shut down the engine until the vehicle is in a safeposition to do so. It will not be able to be restarteduntil the problem is corrected. If emergency powermode is due to a SAM Cab fault, the gauges will be-come unresponsive but the engine will remain run-ning until it is turned off.

When the ignition is in the ON position, the emer-gency power supply will cause the following lamps toflash:

• dash panel lights

• clearance lights

• front marker lights

• side marker lights

• trailer taillights

• rear stop lights

SAM Chassis FaultThe engine may be able to be restarted when theSAM Chassis fails. When the ignition is in the ONposition, the emergency power supply will cause thefollowing lamps to flash:

• dash panel lights

• identification lights

• front marker lights

• turn-signal indicators in the ICU (alternately)

• side marker lights

• rear turn-signal lights

• trailer taillights

If the ignition switch is turned ON while the load dis-connect switch is in the OFF position, the emergencypower supply feature will activate the followinglamps:

• clearance lights (flashing)

• side marker lamps (flashing)

• low beam headlights

Progressive Low VoltageDisconnectThe progressive low voltage disconnect (PLVD) fea-ture protects the batteries from excessive dischargeby disconnecting certain circuits from battery powersupply. This allows the batteries to maintain accept-able charge to restart the vehicle.

When battery voltage drops below a predeterminedvalue, loads designated as comfort loads (priority

f54494502/07/2007

Fig. 3.4, SAM Cab Location

Electrical System

3.4

level I) are shut down first. Then loads designated ashouse loads (priority level II) are shut down. If neces-sary, basic loads (priority level III) are shut down last.

PLVD allows the driver to continue using criticalloads, while noncritical loads are temporarily unavail-able. Calculations for disconnecting loads are basedon battery voltage, ignition switch status, and enginerpm. Also, a time delay is implemented for the shut-down and reactivation of loads to avoid unnecessarycycling of loads when battery voltage is close toshutdown thresholds.

One minute before the comfort loads or house loadsare shut down, the alarm in the instrument cluster

beeps. No alarm sounds before basic loads are shutdown.

If the interior lights have been shut down by PLVD,pressing one of the interior light switches (ifequipped) brings the interior lights back on.

See Table 3.1 for the type of loads shut down underspecific conditions.

See Table 3.2 for the loads that are designated com-fort, house, and basic load status.

Type of Loads Shut Down Under Specific Conditions

Key Switch PositionEngine On, Voltage less than

12.5 VoltsEngine Off, Voltage less than


12.1 VoltsOff N/A Priority level I, II loads Priority level I, II, and III loads

Accessory N/A Priority Level I loads Priority level I, II loads

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1. Circuit BreakerRemoval Tool

2. Self-Resetting CircuitBreaker

Fig. 3.5, Self-Resetting Circuit Breaker Removal

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Fig. 3.6, Cab Load Disconnect Switch, EPA07

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Fig. 3.7, Cab Load Disconnect Switch, EPA10 andNewer

Electrical System

3.5

Type of Loads Shut Down Under Specific Conditions

Key Switch PositionEngine On, Voltage less than



12.1 VoltsOn Priority level I loads Priority Level I loads Priority level I, II loads

Start N/A N/A N/A

Table 3.1, Type of Loads Shut Down Under Specific Conditions

Designated LoadsType of Load Function

Priority Level I

12V power receptacle 6 (sleeper, refrigerator)Amplifier power, accessoryGeneral sleeper lightFoot well lightReading light 1 (dimmer/theater)Reading light 2 (dimmer/theater)Rear baggage compartment light12V power receptacle 5 (sleeper, cigar), batteryAuxiliary circulation fan-sleeper, battery12V power receptacle 4 (sleeper, cigar), batteryReading light 4 (switched locally), battery

Priority Level II

Heated seats, ignition*

Sleeper HVAC controller, accessory*

Cabin HVAC controller, accessory*

Radio, accessory (clamp 15R)Power feed spare output I, batteryPower feed spare output III, batteryMirror heating, passenger*

Mirror heating, driver*

Power feed spare output IV, batteryPower feed spare output II, batteryFuel/water separator heater element, ignition*

Air dryer (pneumatic, electrically heated), accessory*

Auxiliary circulation fan-windshield, accessory*

Accessory heater powerUtility lightUtility lightDome light rearArea lighting (lower bunk and sleeper work surface),batteryDome light cab, batteryOverhead compartment lights, battery12V power receptacle 3 (sleeper, cigar), batteryStand-alone HVAC, batteryAdvertising light, accessory*

Dome light passengerDome light driver/forward overhead

Electrical System

3.6

Designated LoadsType of Load Function

Priority Level III

CB radio, battery†

Fleet management system, battery†

Trailer power, battery or ignition12V power receptacle 2 (dash, phone), battery12V power receptacle 1 (dash, cigar), battery

* When the vehicle has Optimized Idle, these functions will not operate with the ignition switch in the accessoryposition. Optimized Idle may also turn these functions off to reduce stress on the batteries. Refer to the Opti-mized Idle section in Chapter 11 for more information.† May or may not shut down depending on how an additional parameter is set at the factory or dealership.

Table 3.2, Load Designation

Inverter/ChargerThe optional Freedom HF Inverter/Charger powerssmall appliances and other electric equipment. It islocated in the driver-side luggage compartment. SeeFig. 3.8. The unit has one three-pin GFIC OUT con-nector, one three-pin GFIC IN connector, and two ACpower outlets.

There are three models available for the Cascadia:

• 1000W: 1000 watt, 20-amp

• 1500W: 1500 watt, 40-amp

• 1800W: 1800 watt, 40-amp

DANGERDo not store gasoline, flammable material, or anycomponent with a connection to the fuel systemin the storage compartment with the inverter/charger. The unit contains equipment that mayproduce sparks. Storing flammable or electricalequipment in proximity to the unit could result infire or explosion hazards, which could result inserious injury or death.

The display on the sleeper control panel providesinformation about the operation of the unit. SeeFig. 3.9. Refer to Table 3.3 for details on the displaypanel.

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Fig. 3.8, Inverter/Charger

Electrical System

3.7

Display Panel FunctionsNumber Name Function

1 Power

Press the power button for one second to turn on the unit.

Press and hold the button for five seconds to enter the feature settings mode, thenpress the button to toggle between the following modes:

• Charging Current Setting

• Inverter Mode Setting

• Alarm Setting

• Shutdown Setting

• Factory Setting

Refer to the owner’s manual for more information.2 LED Display The LED display screen shows status information and fault codes.

3 Select

The Select button changes the display or settings.

Press the Select button to cycle through the setting options. Press and hold theSelect button for five seconds to save the setting. Refer to the owner’s manual formore information.

• In "Inverter Mode Setting" press the button to turn the inverter mode ON orOFF.

• With the inverter mode ON, press the button to choose what appears on theLED display screen: Input Voltage, Input Current, or Output Power. Details areprovided below.

NOTE: The unit is in "Inverter Mode" when shore power is not present and theunit is using the battery to power the appliances connected to it.

• In an alarm condition, press and hold the button for two seconds to disable orenable the audible alarm.

• In "Charging Current Setting" mode, press the button to select the chargercurrent.

4 Input Voltage LED In inverter mode, when Input Voltage is selected, the corresponding LED will light upand the display will show the input voltage.

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1. Power2. LED Display3. Select4. Input Voltage LED

5. Input Current LED6. Output Power LED7. Status LED

Fig. 3.9, Inverter/Charger Display Panel (1000W shown)

Electrical System

3.8

Display Panel FunctionsNumber Name Function

5 Input Current LED In inverter mode, when Input Current is selected, the corresponding LED will light upand the display will show the input current.

6 Output Power LED In inverter mode, when Output Power is selected, the corresponding LED will light upand the display will show the output power.

7 Status

The Status indicator displays one of three colored lights that indicates the unit’s modeof operation:

• Green: Utility (Shore Power Mode)

A solid green light indicates that the battery is fully charged.

A flashing green light indicates that the unit is charging the battery.

• Yellow: Battery (Inverter Mode)

A solid yellow light indicates that the unit is using the battery to supply ACpower.

A flashing yellow light indicates that the unit is in inverter mode, but that ACshore power is detected and is transferring to shore power mode within 20seconds.

• Red: Fault Condition

The fault status light indicates a fault condition with the unit. Refer to the owner’smanual for fault code information and troubleshooting procedures.

Table 3.3, Display Panel Functions

For more information about troubleshooting, settings,and other features, refer to the owners manual in-cluded with the inverter/charger.

Electrical System

3.9

4

InstrumentsInstrumentation Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Driver Message Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12Overhead Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24

Instrumentation Control UnitsThe instrumentation control unit (ICU) provides thedriver with engine and vehicle information. It is com-prised of standard and optional gauges, an audiblewarning, a driver message center, and a lightbar con-taining warning and indicator lamps (also known astelltales). Warning and indicator lamps illuminate inred (danger), amber (caution), green (status advi-sory), or blue (high-beam headlights active).

Cascadia vehicles are equipped with an ICU3, ICU4,ICU4M, or ICU4Me. See Fig. 4.1, Fig. 4.2, andFig. 4.3 for typical ICU layouts.

The following headings in this chapter provide addi-tional information and operating instructions for ICUcomponents:

• "Warning and Indicator Lights"

• "Instruments"

• "Driver Message Center"

Ignition SequenceWhen the ignition is turned on, the ICU runs a self-check. See Fig. 4.4. Observing the ignition sequenceis a good way to ensure the ICU is functioning prop-erly.

IMPORTANT: Do not crank the engine until theICU self-check is complete.

NOTE: Air gauges do not complete a sweep oftheir dials during the ignition sequence.

When the ignition is turned on, the following actionsshould occur:

• electronic gauges complete a full sweep oftheir dials

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1. Transmission Temperature Gauge2. Coolant Temperature Gauge3. Engine Oil Pressure Gauge4. Driver Message Center5. Fuel/DEF Level Gauge

6. Primary Air Pressure Gauge7. Secondary Air Pressure Gauge8. Speedometer9. Tachometer

10. High Beam Indicator11. Driver Display Screen12. Mode/Reset Switch13. Satellite Gauges

Fig. 4.1, ICU3 Instrument Cluster (EPA10 shown)

Instruments

4.1

• warning and indicator lamps illuminate, thenare extinguished

• audible alert sounds for approximately fourseconds or until sufficient air pressure buildsup in the primary and secondary air systems

• DEF level indicator illuminates all segmentsgreen, then turns them off one at a time beforeturning the leftmost segment amber and thenred

• Freightliner logo displays on the ICU4Me drivermessage center for two seconds.

• software revision level of the ICU is displayedon the driver message center, followed by anyactive faults

IMPORTANT: If any red or amber warning andindicator lamps do not illuminate during the ICUself-check or do not go out after the self-checkcompletes, take the action outlined in Table 4.1,or take the vehicle to an authorized Freightlinerservice facility as soon as possible.

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

If the ICU receives active fault codes, it displaysthem one after the other until the parking brake isreleased or the ignition is turned off. Once the park-ing brake is completely released, the ICU displaysthe odometer. If there are no active faults, the ICUdisplays the odometer after the self-check completes.

When the self-check is complete on an ICU4M, thefasten seat belt screen displays if the engine is off. Ifthe engine is running, the idle hours screen displays.

Audible AlertsAn audible alert sounds during the ignition sequenceand whenever one of the following conditions exists:

• Engine oil pressure falls below the minimumpreset value.

• Coolant temperature rises above the maximumpreset value.

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NOTE: The ICU4 and ICU4M are nearly identical, with the exception of the driver message center (Item 7).

1. Battery Voltage Gauge2. Lightbar3. Engine Oil Pressure Gauge4. Coolant Temperature Gauge5. Engine Oil Temperature Gauge

6. Turbo Boost Air Pressure Gauge7. Driver Message Center8. Tachometer9. Speedometer10. Primary Air Pressure Gauge

11. Fuel/DEF Level Gauge12. Secondary Air Pressure Gauge13. Pyrometer14. Rear Axle Temperature Gauge

Fig. 4.2, ICU4M Instrument Cluster (EPA10 shown)

Instruments

4.2

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

• Parking brake is set with the vehicle movingfaster than two miles per hour.

• System voltage falls below 11.9 volts.

• Door is open or the headlights are on, with theparking brake off.

• Driver seat belt is not fastened with the parkingbrake off (optional).

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

Warning and Indicator LightsThe ICU lightbar has three or four rows of warningand indicator lights with icon symbols, depending onthe ICU. The positions of the lights may vary for thedifferent ICU’s, but the telltales are standard for allapplications. See Table 4.1 for a listing of standardand commonly used warning and indicator lamps.

06/27/2012 f611164

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4 5 6

7

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10

1. Engine Oil Temperature Gauge2. Front Axle Temperature Gauge3. Rear Axle Temperature Gauge4. Speedometer and Coolant

Temperature Gauge

5. Fuel/DEF Level Gauge6. Tachometer and Engine Oil

Pressure Gauge7. Primary Air Pressure Gauge

8. Secondary Air Pressure Gauge9. Transmission Oil Temperature

Gauge10. Driver Message Center

Fig. 4.3, ICU4Me Instrument Cluster

IGNITION SWITCH

PARKING BRAKERELEASED

IF NO FAULTSWERE DETECTED

IF FAULT DETECTED

APU 190123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

MI

MI

01/18/2012 f040420c

PARKING BRAKERELEASED

TURNED TO ON

ICU PERFORMSSELF−TEST

Fig. 4.4, ICU Ignition Sequence

Instruments

4.3

Warning and indicator lamps illuminate in red (dan-ger), amber (caution), green (status advisory), orblue (high-beam headlights active).

IMPORTANT: Depending upon local jurisdic-tional emissions guidelines, vehicles and/or en-

gines that are domiciled outside of the U.S. andCanada may not be compliant with EPA07,EPA10, or GHG14 regulations. Noncompliantvehicles may not be equipped with all of thelamps shown in Table 4.1.

Common Warning and Indicator LampsLamp Description Color

STOP STOP Engine*

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

Safely bring the vehicle to a stop on the side of the roadand shut down the engine as soon as the red light is seen.If the engine shuts down while the vehicle is in ahazardous location, turn the key to the OFF position fora few seconds, then restart the engine and move thevehicle to a safer location.

Red

High Coolant Temperature Indicates the coolant temperature is above the maximumallowable temperature. Red

Low Air Pressure (EPA07) Indicates air pressure in the primary or secondary reservoirhas dropped below approximately 70 psi (483 kPa). Red

Low Air Pressure (EPA10and Newer)

Indicates air pressure in the primary or secondary reservoirhas dropped below approximately 70 psi (483 kPa). Red

Low Engine Oil Pressure Indicates the engine oil pressure is below the minimumallowable pressure. Red

Transmission Overheat Indicates high transmission temperature. Red

Transmission Fluid Level Indicates low transmission fluid level. Safely bring thevehicle to a stop as soon as possible. Red

BRAKEParking Brake (EPA07)

Indicates the parking brake is engaged, or hydraulic brakefluid pressure is low. An audible alert activates when thevehicle is moving over 2 mph (3 km/h) with the parkingbrake set.

Red

Parking Brake (EPA10and Newer) Indicates the parking brake is engaged. Red

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

Instruments

4.4


Unfastened Seat Belt

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

Red

Check ECAS Indicates Electronically Controlled Air Suspension (ECAS)active fault. Red

CHECK CHECK Engine*

Indicates an engine condition (low oil pressure, low coolantlevel, high coolant temperature, high DPF soot level, oruncontrolled DPF regeneration) that requires correction.Correct the condition as soon as possible. If the conditionworsens, the STOP engine lamp will illuminate.

Amber

High Exhaust SystemTemperature (HEST)*

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

IMPORTANT: When the HEST lamp is illuminated, donot park the vehicle near flammable material.

Solid illumination indicates high exhaust temperatures at theoutlet of the tail pipe when speed is below 5 mph (8 km/h).

Amber

Diesel Particulate Filter(DPF) Status

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

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

Amber

Malfunction IndicatorLamp (MIL)

Indicates an emissions-related fault. See the engineoperation manual for details. Amber

Vehicle ABS

Momentary illumination indicates the vehicle ABS isengaged.

Solid illumination indicates a problem with the vehicle ABS.Repair the ABS immediately to ensure full brakingcapability.

Amber

Trailer ABS

Momentary illumination indicates the trailer ABS is engaged.

Solid illumination indicates a problem with the trailer ABS.Repair the ABS immediately to ensure full brakingcapability.

Amber

NOCHARGE No Charge Indicates the alternator is not properly powering the

electrical system. Amber

Water in Fuel Indicates the fuel may contain water. Drain any watercollected in the fuel/water separators. Amber

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

Instruments

4.5


IDLE

MGMT Optimized Idle Indicates optimized idle is enabled. Amber

Check Transmission Indicates an undesirable transmission condition. Amber

WAIT

TO STARTWait To Start (EPA07/EPA10)

Indicates that the system is preventing the starter fromcranking. This can occur when the ignition switch is turnedto START before the gauge sweep has completed, or if thestarter has overheated.

Turn the ignition switch back to ON, wait for the lamp to goout, then turn the ignition switch to START again.

Amber

START

BLOCKED Start Blocked (GHG14)

Indicates that the system is preventing the starter fromcranking. This can occur when the ignition switch is turnedto START before the gauge sweep has completed, or if thestarter has overheated.

NOTE: Illumination of the Start Blocked lamp does notindicate a problem with the starter.

Turn the ignition switch back to ON, wait for the lamp to goout, then turn the ignition switch to START again.

Amber

WHEELSPIN Wheel Spin

Flashing indicates the ATC system is active, or the ATCbutton has been pressed to allow wheel slip.

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

Amber

Roll Stability

Momentary illumination indicates that a stability event hasoccurred.

On vehicles that are also equipped with ATC, flashingindicates the ATC button has been pressed to allow wheelslip.

Amber

Hill Start Aid (HSA)Override

Indicates the HSA switch has been pressed to override thehill start assist feature. Amber

Outside Normal RideHeight

Indicates the current rear suspension height is not at thenormal ride height. This light will turn off once the vehiclereturns to normal ride height.

Amber

Engine Brake Indicates the engine brake is enabled. Green

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

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

Instruments

4.6


Cruise Control

Indicates the cruise control is enabled.

NOTE: The ICU4Me does not have a green cruise controltelltale.

Green

A Active Brake Assist(GHG14 and newer) Indicates the Active Brake Assist system is not available. Amber

Lane Departure Warning

Indicates that lane departure warning is disabled due tominimum speed, no lane markings, or system not available.

NOTE: Only on vehicles equipped with Detroit Assuranceradar.

Amber

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

* See Fig. 4.5 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

Engine Protection System

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

See Fig. 4.5 for an explanation of the aftertreatmentsystem (ATS) warning indicators, and actions re-quired to avoid further engine protection steps.

The STOP engine lamp illuminates when the engineprotection system is activated in one of two ways. Onsome engines, the engine protection system will der-ate the engine, allowing it to run at lower rpm andslower vehicle speed. Drive the vehicle to a safe lo-cation or to a service facility.

IMPORTANT: Safely bring the vehicle to a stopon the side of the road and shut down the en-gine as soon as the red light is seen. If the en-gine shuts down while the vehicle is in a haz-ardous location, turn the key to the OFF positionfor a few seconds, then restart the engine andmove the vehicle to a safer location.

On other engines, the engine protection system willshut down the engine. It will first derate the engine,then shut it down completely 30 to 60 seconds afterthe indicator illuminates (depending on the criticalfault type) if the condition does not improve. Bringthe vehicle to a stop on the side of the road beforethe engine shuts down.

Some vehicles may have a shutdown-overrideswitch, which may be used to momentarily overridethe shutdown sequence. See Chapter 11 for detailedinformation regarding the shutdown process.

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

To restart the engine, turn the ignition to OFF, leaveit there a few seconds, then turn the ignition toSTART. The engine will run for a short period andshut down again if the condition does not improve.

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

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

Instruments

4.7

Air Intake Restriction GaugeThe air intake restriction gauge indicates the vacuumon the engine side of the air cleaner. On standardinstallations, it is mounted on the air intake duct inthe engine compartment. As an option for easierviewing, the air intake restriction indicator (seeFig. 4.6) can be mounted on the dash, usually on theright-hand control panel.

NOTE: Rain or snow can wet the filter andcause a temporary high reading.

Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with agraduated indicator or a restriction gauge on thedash, check the gauge with the engine off. If the yel-low signal stays locked in the red zone once the en-gine is shut down, or is at or above the valuesshown in Table 4.2, the air cleaner element needs tobe replaced.

Vehicles may be equipped with a go/no-go restrictionindicator without graduations (see Fig. 4.7) instead ofa graduated indicator.

Air Intake Maximum Restriction Values (inH2O)

Engine Make Pre-EPA07Engines

EPA07 andEPA10

Engines

GHG14Engines

Cummins 25 25 25Detroit 20 22 18Mercedes-Benz 22 22 –

Table 4.2, Air Intake Maximum Restriction Values

f080156


Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended.

Filter is reaching


Filter Regeneration


To avoid enginederate, bring vehicle



Vehicle must beparked, and a Parked

Service Regeneration Required.Engine Derate To Idle Only.

Filter has exceeded maximumcapacity.

Vehicle must be parked, and aService Regeneration must be


CHECKINDICATORLAMP(S)



Required Action

capacity.

STOP

allow for an AutomaticRegeneration orperform a Parked

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

Regeneration mustbe performed.Engine will beginderate.

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


02/20/2009

WARNING


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


Flashing

Solid

Regeneration.

Necessary

Fig. 4.5, ATS Warning Lamps

02/12/2015 f090514

Fig. 4.6, Air Intake Restriction Indicator

Instruments

4.8

Application Air Pressure GaugeAn application air pressure gauge registers the airpressure being used to apply the brakes, and shouldbe used for reference only. The gauge will not regis-ter air pressure until the foot brake pedal is de-pressed or the trailer hand brake is applied.

Coolant Temperature Gauge

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

During normal engine operation, the coolant tem-perature gauge should read 175 to 195°F (79 to91°C). If the temperature remains below 160°F(71°C), inspect the cooling system to determine thecause.

If coolant temperature rises above the maximumtemperature listed in Table 4.3, the CHECK enginelamp will illuminate. If the condition does not im-prove, the STOP engine lamp will also illuminate andan audible warning will sound. The engine will thenderate or shut down, depending on the type of en-gine protection system installed.

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

Cummins 225 (107)

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

Detroit 215 (101)Mercedes-Benz 221 (105)

Table 4.3, Maximum Coolant Temperature

Drive Axle Oil Temperature Gauges

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

During normal operation, drive axle oil temperaturegauges should read as follows:

• 160 to 220°F (71 to 104°C) for Detroit™ andMeritor™ drive axles

• 180 to 200°F (82 to 93°C) for Dana Spicer®drive axles

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

Engine Oil Pressure Gauge

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

The engine oil pressure gauge displays the currentengine oil pressure. If engine oil pressure falls belowthe minimum levels shown in Table 4.4, the CHECKengine lamp will illuminate. If the condition does notimprove, the STOP engine lamp will also illuminateand an audible warning will sound. The engine willthen derate or shut down, depending on the type ofengine protection system installed.

04/08/2005 f090431

Fig. 4.7, Manual-Reset Air Restriction Indicator, Go/No-Go

Instruments

4.9

Minimum Oil Pressure*

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)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 varyfrom the listed pressures; observe and record pressures when the engineis new to create a guide for checking engine condition.

Table 4.4, Minimum Engine Oil Pressure

Engine Oil Temperature Gauge

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

During normal operation, the optional engine oil tem-perature gauge should read:

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

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


Fuel Gauge, Pre-EPA10The fuel gauge indicates the level of fuel in the fueltank(s). A single fuel gauge is standard. If equippedwith an optional second fuel tank, each fuel tanklevel is indicated on a separate gauge.

Fuel/Diesel Exhaust Fluid (DEF)Gauge, EPA10 and NewerFor engines that are EPA10-compliant or newer, thefuel and DEF levels are measured in a dual purposefuel/DEF level gauge. See Fig. 4.8.

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

amber when the diesel fuel level registers 1/8th ofcapacity.

The DEF level is indicated in the lightbar on thelower portion of the gauge. There is a low DEF levelwarning lamp that illuminates amber when the DEFlevel reaches 10% of capacity. See Chapter 12 fordetails of the DEF gauge functions.

Primary and Secondary Air PressureGauges

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

Air pressure gauges register the pressure in the pri-mary and secondary air systems. Normal pressure,with the engine running, is 100 to 120 psi (689 to827 kPa) in both systems.

08/21/2009

1/2ULTRA LOW SULFURDIESEL FUEL ONLY

E F

DEF

FE

f611045

1

2

3

4

1. Diesel Fuel Level Indicator2. DEF Level Indicator3. Low DEF Warning Lamp (amber below 10% DEF)4. Low Fuel Warning Lamp (amber at 1/8 tank of fuel)

Fig. 4.8, Fuel/DEF Gauge, EPA10 and Newer

Instruments

4.10

A low-air-pressure warning light and audible alert,connected to both the primary and secondary sys-tems, activate when air pressure in either systemdrops below approximately 70 psi (483 kPa).

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

SpeedometerTwo speedometer options are available. The U.S.version of the speedometer registers speed in bothmiles per hour (mph) and kilometers per hour (km/h),with mph in larger numbers. The metric version ofthe speedometer face reverses this arrangement,with km/h in larger numbers.

TachometerThe tachometer indicates engine speed in revolutionsper minute (rpm) and serves as a guide for shiftingthe transmission and keeping the engine in the ap-propriate rpm range. For low idle and rated rpm, seethe engine identification plate.

Tire Pressure Monitoring System(TPMS)IMPORTANT: The use of temporary resealing orreinflation products containing internal sealers orpropellants in any tire/wheel assembly, may ad-versely affect the operation of the tire sensor(s)and void the warranty.

The TPMS constantly monitors the pressure andtemperature of each tire on the vehicle, and providestire status information to warn the driver about a tire-related problem before it becomes dangerous. Tiresensors mounted on each wheel measure tire pres-sure and temperature every 12 seconds and transmitdata every 3 to 5 minutes. If a tire pressure changeof 3 psi (21 kPa) or greater is detected, the sensorbreaks its regular schedule and transmits tire dataimmediately. The SmarTire™ display is shown inFig. 4.9.

For further information on the TPMS, including op-eration, TPMS warnings, and proper tire removal/installation, see the SmarTire TPMS Owner’sManual.

Transmission Fluid TemperatureGaugeThe transmission fluid temperature gauge indicatesthe transmission lubricant operating temperature.Temperatures vary by application, but the transmis-sion fluid temperature gauge reading should not ex-ceed 250°F (121°C).

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


Turbocharger Boost Pressure GaugeA turbocharger boost pressure gauge indicates thepressure in the intake manifold, in excess of atmos-pheric pressure, being created by the turbocharger.

05/13/2015 f400383

5

2

1

34

1. Warning Lamp2. Display Screen3. Wheel Button

4. Exit Button5. Axle Button

Fig. 4.9, SmarTire Display

Instruments

4.11

VoltmeterThe voltmeter indicates the vehicle charging systemvoltage when the engine is running and the batteryvoltage when the engine is off. By monitoring thevoltmeter, the driver can stay aware of potential bat-tery charging problems and have them fixed beforethe batteries discharge enough to create starting diffi-culties. Cascadia vehicles are equipped with either avoltmeter gauge, or a digital voltmeter readout lo-cated on the bottom line of the dash message center.

The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltageof a fully charged battery is 12.7 to 12.8 volts whenthe engine is off. Battery voltage under 12.0 volts isconsidered a low battery, and a completely dis-charged battery will produce only about 11.0 volts.

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

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

Driver Message CenterICU3/ICU4The driver message center is controlled using themode/reset switch, located on the right side of theICU, and the + and – buttons mounted in the right-hand pod of the steering wheel (Fig. 4.10). SeeFig. 4.1 and Fig. 4.10. Tap the mode/reset switch orthe + switch to advance one screen; press and holdeither switch to select a menu choice or reset thedisplay. When the display resets, an audible chirpsounds.

Four driving screens are accessible when the parkingbrake is off. All screens and menus are accessiblewhen the parking brake is on (parked screens).

Driving ScreensThe following screens are available when the parkingbrake is off (when the vehicle is mobile) and no ac-tive fault codes are found. Use the + and – switcheson the steering wheel, or the mode/reset switch, to

scroll through the screens. To reset any values,press and hold the + switch or the mode/resetswitch. The driving screens appear in the followingorder:

i. Odometer

ii. Trip distance

iii. Trip hours

iv. Outside temperature

Parked Screens/MenusThe following screens and menus are available whenthe parking brake is on (when the vehicle is parked)and no active fault codes are found. Use the + and –switches on the steering wheel, or the mode/resetswitch, to scroll through the driving screens. To resetany values, press and hold the + switch or the mode/reset switch. See Fig. 4.11. The parked screens ap-pear in the following order:

i. Odometer

ii. Trip distance

iii. Trip hours

iv. Outside temperature

v. Temperature alert

vi. Diagnostics

MRKRINT

ENGBRK

−

+

02/06/2007 f462061

NOTE: To reset values in the ICU4M and ICU4Me drivermessage centers, press and hold the + switch.

Fig. 4.10, Steering Wheel-Mounted Switches

Instruments

4.12

vii. Clear screen (on vehicles with less than 255miles on the odometer)

viii. Engine miles/hours

ix. Setup

Temperature AlertWhen the outside temperature drops to 35°F (1.7°C)or less, the ICU displays a caution text at one-second intervals for five seconds, and an audiblealert sounds. Tap the + or – switch on the steeringwheel, or the mode/reset switch, to acknowledge themessage. The audible alert will not sound again un-less the temperature cycles above 37°F (4°C) andback to 35°F (1.7°C) or less. This warning only oc-curs while the ignition is on and the parking brake isreleased.

The temperature alert message allows the driver toenable or disable the ambient temperature warning.

Press and hold the mode/reset switch to toggle be-tween on and off. Release the mode/reset switch,then tap it to select the displayed choice.

DiagnosticsWhen the DIAG screen is displayed, press and holdthe mode/reset switch to access the various diagnos-tic screens. See Fig. 4.12 for a diagram of the diag-nostic screens.

The diagnostic screens are used by trained techni-cians to retrieve fault codes and other diagnostic in-formation pertaining to the vehicle. If active faultcodes display during start-up or at any other time,make a note of the fault code and take the vehicle toan authorized Freightliner service facility

If fault codes are displayed, press and hold themode/reset switch to view the next fault code untilreaching the DIAG screen.

01/30/2012 f040754

123456.7TRIP MI 12.3 VOLTS

Tap

123456.7MI 12.3 VOLTS

Tap

123456.7TRIP HOURS

12.3 VOLTS

ALrt

n

123456.7HOURS

ENGINE

oiL *Lo

SEtUP **MI **HOURS**no

To reset trip miles

Press & Hold

To reset trip hours

Press & Hold

Display serviceinterval screensPress & Hold

Press & Hold

Tap

To toggle ON

*Lo = Oil Level LowHI = Oil Level HighBlank = Oil Level OK− − = No Message

**MI = Miles Interval Mode**HOURS = Hours Interval Mode**no = Service Interval Inactive

dIAGMI HOURS

n

Display diagnostics

Press & Hold

n = Number of Active Fault CodesMI = Miles Interval ModeHOURS = Hours Interval Mode

°t

ENGINE

Tap

Tap

Tap

Tap

Tap

Tap

12.3 VOLTS

56°F

OFF

Odometer

To display totalengine miles/hours

Note: The engine oil level screen displays for Mercedes-Benz engines only (if equipped and enabled).

Fig. 4.11, ICU3 Parked Screens

Instruments

4.13

Engine Miles/HoursWhen the engine miles/hours screen is displayed,press and hold the mode/reset switch to access theengines screen submenu. See Fig. 4.12 for a dia-gram of the engine screens.

SetupThe setup menu allows the driver to manage ICUparameters. The setup screen submenu allows thedriver to enable and change service intervals. SeeFig. 4.13.

If service intervals are enabled and service distanceor time has been exceeded, the text SERVICE

HOUR/MI (KM) will display at start-up to indicate ve-hicle service is required.

For each parameter, press and hold the mode/resetswitch to navigate to the parameter change screen.In each change screen, tap the mode/reset switch totoggle between options.

Use the last screen in the setup menu, RESET EE,to reset the parameters the ICU learns back to thedefault settings. Press and hold the mode/resetswitch to reset the following learned parameters:

• automated transmission display

• seat belt switch learning

f040802

From Temp Alert Screen

Press & Hold

Tap

Press & Hold

Tap

Press & Hold

Tap

n = Number ofActive Fault Codes

dlAG

n

*FAULT

01

*If fault goes inactive,display "noFault 1"

*FAULT

nn

*If fault goes inactive,display "noFault n"

To Setup Screen (or OilLevel Screen, if equipped)

Press & HoldAbS 11 ECU 0

Tap Tap

Press & Hold123456

Tap Tap

Press & HoldFAIL 03 FAIL 00

Tap Tap

SPN SPN

123456

01/31/2012

Fig. 4.12, ICU4 Diagnostic Screens

Instruments

4.14

• engine oil level

• other electronic devices that have been re-moved from the vehicle (e.g. Qualcomm)

ICU4MFunctionsICU4M settings and the driver message center arecontrolled with the + and – switches and the MY

Selection?

To toggle MIHOURSno

NOTE:* Flash screen text**Display active mode

Select NOto disableService Intervals

Press & Hold to reset allService Interval counters

To toggleMI

To toggle

Tap

To toggleON

HRSMI

no

Tap

TapTap

Tap Tap Tap

Tap

Tap

TapTap

Press & Hold

Press & Hold

Press & Hold

Press & Hold

Press & Hold Press & Hold Press & Hold

Press & HoldPress & Hold

Press & Hold

SET UP SELECT*MI

SET UP

WARN°T

*on

LCD LMP

*on

**MI **HOURS**no

RESET**MI **HOURS

*no

SELECT*MI *HOURS

*noSERVICE SERVICE SERVICE

*12345MI

SERVICE

*12345HOURS

SERVICE

RESET

EE

DONE

f04075501/30/2012

OFF

KM

ON OFF

To Odometer

From EngineMiles/Hours Screen

Fig. 4.13, ICU4 Setup Screens

Instruments

4.15

INFO switch, mounted on the dash. See Fig. 4.14.Tap the MY INFO switch to drill down from eachmain screen to the submenus contained within it.Use the + and – switches to scroll through screensand select options. Tap the MY INFO switch again toexit each change screen.

With the parking brake off, only the odometer andalert messages can be displayed. Park the vehicleand set the parking brake to access the parkedscreens and menus.

Alert MessagesThe driver message center displays alert messageswhen certain conditions occur. They are warnings,cautions, or other messages that require the driver’sattention, but not all of them are critical to the opera-tion of the vehicle.

NOTE: If there is more than one alert messageto display, tap the + switch or the MY INFOswitch to access the next message, and so on,until all messages have been viewed.

More important messages take priority over less im-portant messages. The order of priority is:

1. parking brake set (with the vehicle moving)

2. parking brake off (with the door open)

3. low oil pressure or high coolant temperature

4. hard brake warnings (if equipped with roll stabil-ity advisor)

5. low battery voltage

6. ambient temperature below 35°F (1.7°C)

7. turn signal on

8. incoming instant or Qualcomm messages

9. service warnings

10. no datalink activity

Incoming MessageOn vehicles with a Qualcomm onboard communica-tions system, a notification appears on the drivermessage center whenever a message is received.

NOTE: The incoming message screen also dis-plays during the ignition sequence if a messageis available.

This message displays for a preset time period, thenreturns after a preset interval until it is dismissed bythe + and – switches or the MY INFO switch.

Parking Brake OnThis warning message and an audible warning comeon whenever the parking brake is applied and thevehicle is moving faster than 2 mph (3 km/h). SeeFig. 4.15. The screen and audible warning go awayonly when the parking brake is released, or speed isreduced below 2 mph.

Low Oil PressureThis warning message and an audible warning comeon whenever the oil pressure falls below the mini-mum oil pressure, whether the vehicle is idling or inmotion. Tap the + and – switches or the MY INFOswitch to dismiss the message.

If low oil pressure is detected during the ignition se-quence, it displays as an active fault instead of analert message. After 30 seconds, the message dis-plays again.

02/22/2007

MYINFO

f610887a

Fig. 4.14, MY INFO Switch

f601414

WARNINGPARK BRAKE ON

06/21/2007

Fig. 4.15, Parking Brake On Alert Message

Instruments

4.16

High Coolant TempThis message and an audible warning come onwhenever the engine coolant temperature exceedsthe maximum allowable temperature.

If high coolant temperature is detected during theignition sequence, it displays as an active fault in-stead of an alert message. After 30 seconds, themessage displays again.

Low VoltageOn some vehicles, this optional message and an au-dible warning come on whenever a low voltage con-dition is detected.

Turn Signal OnThis warning message and audible warning come onwhenever the turn signal remains on for four minutesor five miles of travel. To dismiss this message, ei-ther turn off the turn signal or tap the + and –switches or the MY INFO switch.

Air TemperatureWhen the outside air temperature drops below 35°F(1.7°C), a warning text is displayed at one-secondintervals for five seconds, and an audible warning willsound. Tap the + and – switches or the MY INFOswitch to acknowledge the warning. The alert mes-sage will not occur again unless the temperaturecycles above 37°F (4°C) and back below 35°F(1.7°C). This warning only occurs while the ignition ison and the parking brake is off.

Service WarningsService warning alerts display during the ignition se-quence and indicate if a service interval has beenreached or exceeded and maintenance is required.The messages may indicate the number of miles(KM) or hours until the next required service or, oncepassed, the number of miles (KM) or hours sincemaintenance should have been performed.

Automated Transmission DisplayThe ICU4M can display current gear information forvehicles with an automated transmission. The lastthree digits at the far right on the lower line of thedriver message center are reserved for this informa-tion.

When a shift request is made by the driver, an up ordown arrow is also displayed, depending on the shiftdirection.

For more information about specific models of auto-mated transmissions, see Chapter 15.

Driving ScreensThe following screens are available when the parkingbrake is off (when the vehicle is mobile).

Tap the MY INFO switch to drill down from eachmain screen to the submenus contained within it.Use the + and – switches to scroll through screensand select options. Tap the MY INFO switch again toexit each change screen. See Fig. 4.16.

i. Fasten seat belt (rpm<100)

ii. Fuel economy (rpm>100)

R

R

R

R

R

+

+

+

+

+

+

−

−

−

−

−

−

−0%III +10.5 MPG 23456.7 MI

TRIP MILES 123456.7TRIP HR 1234:56

TRIP ADVISORIES123 ROLL 456 BRK

LEG MILES 123456.7LEG HR 1234:56

LEG ADVISORIES123 ROLL 456 BRK

FUEL USED 12345.6AVG MPG 12:34

OUTSIDE AIRTEMPERATURE 56F

01/30/2012 f545600a

R = Hold to reset.

PUSH + KEYTO CONFIRM CLEAR

Confirmation screen will displayright after the first hold.

+

My Info

Odometer

Fig. 4.16, ICU4M Driving Screens

Instruments

4.17

iii. Odometer

iv. Trip distance/hours

v. Trip advisory

vi. Leg distance/hours

vii. Leg advisory

viii. Fuel used/average MPG (KM/L)

ix. Outside air temperature

Favorite ScreenThe driver can set a favorite driving screen using theMY INFO switch. Press and hold the lower half of theMY INFO switch for just over one second to set thecurrent screen as the favorite screen. A chirp willsound to verify the screen has been set.

Tap the lower half of the MY INFO switch to accessthe favorite screen. Tap the MY INFO switch again toleave the favorite screen.

NOTE: Only driving screens can be set as thefavorite screen.

Parked Screens/MenusTap the MY INFO switch to drill down from eachmain screen to the submenus contained within it.Use the + and – switches to scroll through screensand select options. Tap the MY INFO switch again toexit each change screen. Press and hold the +switch or the upper half of the MY INFO switch toreset the counters for trip and fuel information.

The following screens are available when the parkingbrake is on (when the vehicle is parked). SeeFig. 4.17.

i. Odometer

ii. Trip information including trip miles/hours, idlehours, average speed, leg miles/hours

iii. Fuel information including fuel used, fueleconomy, idle/PTO fuel usage

iv. Engine information including engine miles/hours,engine/PTO gallons, oil level

v. Diagnostic information

vi. Service information including mileage or time tonext service

vii. Setup information

viii. Vehicle information including Datalink status, ICUserial number, software version

ix. Outside air temperature

x. Fasten seat belt warning

Trip InformationTrip Information displays the trip miles, trip adviso-ries, idle hours, leg miles, and leg advisories, in thatorder.

Fuel InformationFuel information displays total fuel usage since thelast reset, fuel mileage, and fuel consumed whileidling or running the PTO, in that order.

Engine InformationEngine information displays engine mileage andhours, and total fuel consumption, in that order.

Diagnostic InformationIf active fault codes are displayed on the diagnosticinformation screens, make a note of the fault codeand text message, then take the vehicle to an autho-rized Freightliner service facility See Fig. 4.18 for adiagram of the diagnostic information screens.

Service InformationThe Service Information menu displays the next ser-vice interval, expressed in either miles or hours. SeeFig. 4.18. Service intervals can also be deactivated.For programming service intervals, see Setup Infor-mation, below.

NOTE: If the vehicle has exceeded the serviceinterval, the miles(km)/hours remaining screenis replaced by the service was due screen, fol-lowed by the number of miles(km)/hours sincethe service was due.

Setup InformationThe Setup Information menu allows the driver to pro-gram various features of the ICU4M. See Fig. 4.19.

The setup features include:

1. Service intervals (OFF/MILES/HOURS)

2. Outside temperature warning (ON/OFF)

3. Target MPG

Instruments

4.18

4. LCD lamp (ON/OFF)

5. Driver message center brightness

6. Language (English/French/Spanish)

7. Units of measurement (English/Metric)

8. Driver select (ON/OFF)

9. Reset parameters to original settings

Vehicle Information ScreensThe vehicle information screens display hardwareand software information, including the Freightlinerpart number and switch ID of the ICU. See Fig. 4.20.

ICU4MeFunctionsICU4Me settings and the driver message center arecontrolled using the ICU4Me control switch locatedon the dash, and the + and – switches mounted inthe right-hand pod of the steering wheel. SeeFig. 4.21 and Fig. 4.10.

The driver message center is divided into four sec-tions. The odometer and cruise control status fieldare displayed along the bottom of the message cen-ter. When cruise control is active, the cruise controlstatus field displays relevant cruise control icons andthe set speed. If the vehicle is equipped with amanual transmission, time and temperature are dis-played in the top left corner of the driver messagecenter. The message field displays the drivingscreens and alert messages. See Fig. 4.22.

If the vehicle is equipped with an automated trans-mission, the gear display is located in the top leftcorner of the driver message center. Time and tem-perature are displayed in the message field, unlessan alert message is active or a driving screen hasbeen selected. The odometer and cruise control sta-tus field are displayed along the bottom of the mes-sage center. See Fig. 4.23. For information abouttransmission display options, see Chapter 15.

IDLE HOURS 1234:5612.3 GAL 123456.7 MI

R

R R

R

R R R

+

+

+

−

−

−

− −

−−

−

−−

− − −

TRIPINFORMATION

FUELINFORMATION

ENGINEINFORMATION

TRIP MILES 123456.7TRIP HR 1234:56

TRIP ADVISORIES123 ROLL 456 BRK

IDLE HOURS 1234:56AVG MPH 12.3

LEG MILES 123456.7LEG HR 1234:56

LEG ADVISORIES123 ROLL 456 BRK

FUEL USED 12345.6AVG MPG 12:34

IDLE GALLONS 12345.6PTO GAL 12345.6

ENG MILES 1234567.8ENG HOUR 1234:56

ENG GALLONS 123456.7PTO GAL 123456.7

OIL LVL*Lo

f545600b

−

01/30/2012

−

85

ENGINE

PER*Lo ENGINE

R = Hold to reset.



+

My Info

Odometer

To Diagnostic Information Screen

Fig. 4.17, ICU4M Idle Hours, Trip Information, Fuel Information, and Engine Information Screens

Instruments

4.19

Alert MessagesAlert messages are displayed in the message field tonotify the driver when certain conditions occur. Theyinclude warnings, cautions, and other messages thatrequire the driver’s attention. Not all alert messagesare critical to the operation of the vehicle. More im-portant messages take priority over less importantmessages.

NOTE: All alert messages follow the formatshown in Fig. 4.24.

Press the + switch to acknowledge alert messagesand revert to the previously displayed driving screen.The following alert messages will repeat intermittentlyuntil the condition is eliminated:

• turn signal on

• low voltage

• no datalink

• low transmission air pressure (Detroit transmis-sions only)

Driving ScreensWith the parking brake off, only the driving screensare available. Use the + and – switches on the steer-ing wheel to scroll through the driving screens; seeFig. 4.25. To reset any values, press and hold the +switch.

• Temperature

• MPG information

• Trip information

• Leg information

• Gauge display (if selected)

DIAGNOSTICINFORMATION

ACTIVE FAULTS

3

2 HIST DASH FAULTSLAST CLR 123456.7

+

SA(text) SA# SPN#

SPN(text) FMI#

LAST OCCUR 123456.71234 TIMES

FIRST OCCUR 123456.71234 TIMES

faults when odometer is < 254 MI.

MILES TONEXT SERVICE

INTERVAL IS SETTO MILES

HOLD + TO CLEARDASH FAULTS

ALL FAULTSCLEARED

R

+

SERVICEINFORMATION

SERVICE WAS DUEMILES AGO

SA(text) SA## SPN####

SPN(text) FMI##

2 Sec Timeout

This will also clear other vehicle ECU’s inactive

If overdue:

R = Hold to reset.



−−−

−

−

+−−

+

−

−

+

−− −

+

+

1234512345 12345

f54560101/30/2012

My Info

From Engine Information Screen

To Setup Screen

Fig. 4.18, ICU4M Diagnostic Information and Service Information Screens

Instruments

4.20

• Predictive Cruise Control (optional) • Enter parked menus

01/30/2012

SETUPINFORMATION

+

−

+

−

+

−

+

−

+

−

+

−

+

−

+

−

+

−

+

−

+

+

+

+

+

+

+

+

−

−

−

−

−

−

−

−

−

+

PUSH KEY TO

Note: If parking brake is released while in stationary screens,the display will return to the bar graph screen.

* = Indicates flashing text

= My Info

Press to toggle between selections

Miles or Hours

Press to set service interval

Press to toggle On Off



Press to toggle Yes No

Press to increase target MPG

Press to decrease target MPG

Press to increase brightness

Press to decrease brightness



Off

SERVICE INTERVAL

PUSH KEY TOCHANGE SERV MI

PUSH KEY TOCHANGE TEMP WARN

PUSH KEY TOCHANGE TARGET MPG

PUSH KEY TO

PUSH KEY TO

PUSH KEY TO

PUSH KEY TO

PUSH KEY TO

PUSH KEY TO

INTERVAL *2000 MILES− LESS MORE +

TEMPERATURE WARNING− OFF * ON +

LCD LAMP− OFF * ON +

TARGET MPG *8.5− LESS MORE +

CHANGE LCD LAMP

CHANGE BRIGHTNESS

CHANGE LANGUAGE

DISPLAY BRIGHTNESS− DARK LIGHT +

LANGUAGE: *ENGLISHFRENCH / SPNISH

CHANGE UNITS

CHANGE DRIVER SEL

RESET PARAMETERS

UNITS*ENGLISH / METRIC

DRIVER SELECT− OFF * ON +

RESET PARAMETERS− *NO YES +

f544963a

OFF/*MILES/HOURS

CHANGE SERVICE

Vehicle InformationScreen

+

−

Fig. 4.19, ICU4M Setup Information Screens

Instruments

4.21

Parked Screens/MenusPark the vehicle and set the parking brake to accessthe parked menus and submenus. See Fig. 4.26. To

reset values in any of the menus, press and hold the+ switch.

• Trip information

• Fuel information

• Engine information

• Diagnostics

• Service information

• Settings

• ICU Information

A small numerical fraction is displayed in the upperright-hand corner of each screen to indicate the num-ber of available screens or options to scroll through.See Fig. 4.27. Press the upper half of the ICU4Mecontrol switch to select a menu choice. Press thelower half of the control switch to back out of a se-lected menu or submenu. Use the + switch to scrollup, and the – switch to scroll down.

When navigating the parked menus, the left side ofthe driver message center displays a "breadcrumbmenu" to show the order of menus and submenus

+

− −

VEHICLEINFORMATION

DASH# 123−12345−123SW VER 1.0

Setup Information

Outside Air Temp03/30/2010 f040803

Fig. 4.20, ICU4M Vehicle Information Screens

f61117304/03/2012

MenuBack

Fig. 4.21, ICU4Me Control Switch

06/26/2012 f611166

5555555 mi

1/7NW

77° F

Trip MPG: 5.6

0 155

1 2

34

10

65 mph

1. Temperature and Compass2. Message Field3. Cruise Control Status Field4. Odometer

Fig. 4.22, Driver Message Center Without Gear Display,ICU4Me

1/7NW

77 °F

06/26/2012 f611165

10A econ

5555555 mi

1 2

34

65 mph

1. Gear Display2. Temperature and Compass3. Cruise Control Status Field4. Odometer

Fig. 4.23, Driver Message Center with Gear Display,ICU4Me

Park Brake On!

06/12/2012 f611192

10A econ

5555555 mi

Fig. 4.24, Parking Brake Alert Message

Instruments

4.22

that have been selected during the current naviga-tion.

Trip InformationThe ICU can record data for one trip segment andone leg segment. When trip information is reset, allthe leg information is reset as well.

Fuel InformationUsing this menu, the driver can view the total fuelused since the last reset, the total idle gallons usedsince the last reset, and the average MPG since thelast reset.

Engine InformationUsing this menu, the driver can view engine miles,engine hours, gallons used, PTO hours, and PTO

Time &Temperature

MPGInformation

+

−

−

TripInformation

Enter toStationary

Menu

−

+GaugeDisplayScreens

LegInformation

PredictiveCruise

Control (opt)

+

+

−

+

−

+

−

06/21/2012 f040823

−

+

(if selected)

Use the + and – switches on the steering wheel tonavigate through the driving screens.

Fig. 4.25, Driving Screen Navigation, ICU4Me

+

−

−

+

−

+

−

+

+

−

−

+

06/26/2012 f040824

Trip Info

Fuel Info

Engine Info Diagnostics Service

Settings

ICU Info

Use the + and – switches on the steering wheel tonavigate through the parked menus.

Fig. 4.26, Parked Menus, ICU4Me

1/3Miles:Gallons:

Menu

MENUBACK

Avg. MPG:Trip Info

Trip

123456.7123456.7

123.4

1/2TripLeg

Menu

MENUBACK

Trip Info

1/7Trip InfoFuel Info

Menu

Engine Info

MENUBACK

Indicates when to pressthe MENU BACK switch

Indicates when to pressthe ENTER switch

06/21/2012 f611193

Fig. 4.27, Parked Menu Navigation, ICU4Me

Instruments

4.23

gallons. Engine oil level is optional for Detroit en-gines. The information contained in the Engine Infor-mation screens cannot be reset.

DiagnosticsActive and historical faults are displayed in the diag-nostics menu. See Fig. 4.28. If there are any activefaults, the total number of faults is displayed in pa-renthesis next to the affected controller. To view spe-cific active faults, press the upper half of the ICU4Mecontrol switch on the dash. Press the upper half ofthe ICU4Me control switch to toggle between the textdescription and the failure code for each selectedfault.

Service InformationUsing this menu, the driver can enable, disable, andset service intervals for engine miles or enginehours. After enabling service intervals, select intervalunit (miles or hours), and the interval duration.

SettingsThe settings menu contains the controls for the fol-lowing settings:

• Display (includes brightness, contrast, displaylight, and night mode settings)

• Gauge select

• Language

• Self-test

• Temperature warning enable/disable

• Units

The Gauge Select submenu allows the driver to se-lect certain gauge values for display in the messagefield while driving. See Fig. 4.29. Use the + and –switches on the steering wheel to scroll through thelist of available gauges, then press the upper half ofthe ICU4Me control switch to select a desired gauge.The ICU4Me control switch can also be used to un-check boxes if necessary.

ICU InformationThe ICU Information screen displays the part num-bers for the instrument cluster and software.

Overhead Instrument PanelThe optional overhead instrument panel may hold acitizen’s band (C/B) radio and any switches that cannot be accommodated on the driver’s or auxiliarydash panels.

The underside of the overhead console also holdsthe sun visors and the optional dome/reading light

1/3Accelerator PedalProblem Detected

Diagnostics

MENUBACK

Active

Engine (3)

1/3ABS (1)Engine (3)

MENUBACK

1/2Active (12)Historic (0)

MENUBACK

Indicates when to pressthe MENU BACK switch

Indicates when to pressthe ENTER switch

05/30/2012 f611194

Menu

Diagnostics

MSF (1)

Menu

Diagnostics

Active

Fig. 4.28, Diagnostics Menu Navigation, ICU4Me

06/26/2012 f611195

1/6Axle TempAir Pressure

Engine Oil Temp

Menu

Settings

Gauge Disp. x

Fig. 4.29, Selecting Gauges to Display, ICU4Me

Instruments

4.24

asssembly. See Chapter 5 for more information onthe dome/reading light assembly.

Instruments

4.25

5

Driver ControlsIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11Dash-Mounted Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14Windshield Wiper/Washer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15Suspension/Trailer Connection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20Adjustable Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20

Ignition Switch and KeyThe ignition switch is located on the left-hand dash,below the headlight switch. See Fig. 5.1.

The ignition switch has four positions: OFF, ACC (ac-cessory), ON, and START. See Fig. 5.2.

In the OFF position, the ignition switch is vertical.The key can be inserted and removed only in theOFF position.

The following functions are operable when the igni-tion switch is in the OFF position (regardless ofwhether the key is inserted):

• low-beam headlights

• taillights

• brake lights

• road lights

• dome lights

• clearance lights

• hazard warning lights

• utility lights

• baggage compartment lights

• spotlights

• electric horn

• clock

• refrigerator

• CB radio

• power mirrors

• power receptacle

• fuel heater

• electric oil pan heater

• electric or diesel-fired engine coolant pre-heater

Turn the key counterclockwise to reach the ACC po-sition. In addition to all the functions that are oper-able in the OFF position, the following functions areoperable when the switch is in the ACC position:

• radio/stereo system

• heater and A/C fan

• mirror defog

• windshield fan

• ether start system

• air dryer

• backup lights

Turn the key clockwise past the OFF position toreach the ON position. With the switch in the ON po-sition, all electrical systems become operable and

04/30/2007

1

f610916

2

1. Headlight Switch 2. Ignition Switch

Fig. 5.1, Left-Hand Dash

07/19/2006 f610805

Fig. 5.2, Ignition Switch

Driver Controls

5.1

the warning and indicator lamps illuminate. Wait forthree seconds before starting the engine.

The SAM Cab vehicle controller automatically cyclesall exterior lights off and then on when the head-lamps are on and the park brake is released, or set.This rapid flash of the exterior lights is a self-test todetect any bulb that is not operational. Drivers maynotice all lights flash simultaneously during this pro-cess. This is the normal operating sequence. A faultcode is set for any bulb that is out.

IMPORTANT: Do not crank the engine until theICU self-check is complete.

Turn the key clockwise past the ON position to reachthe START position to start the engine. Release thekey the moment the engine starts. Do not operatethe starter longer than thirty seconds, then allow thestarter to cool between attempts. If the starter over-heats, the starter protection system will prevent op-eration of the starter until it has cooled. Release thekey the moment the engine starts.

The ignition key also locks and unlocks the cabdoors, the baggage door(s) and if equipped, the bunkdoor(s).

Lighting ControlsIMPORTANT: Unless otherwise noted below,press the upper half of the switch to activate thedesired light(s). Press the lower half of theswitch to turn the light(s) off.

Exterior Lighting ControlsExterior light controls are listed here in alphabeticalorder. See Fig. 5.3 for exterior light locations.

Auxiliary High Beam LightsAuxiliary high-beam lights may be located in the frontbumper. To activate the auxiliary high beam lights,press the upper part of the dash switch. The auxiliaryhigh beam lights will illuminate only when the high-beam headlights are on. They will switch off tempo-rarily when the low-beam headlights are on, until thehigh beams are on again. Press the lower half of theswitch to deactivate it. See Fig. 5.4.

Backup LightsBackup lights activate only when the vehicle is in re-verse, and are designed to be used while backing upat night.

Daytime Running LightsThe daytime running lights (DRL), if equipped, areautomatically activated when the ignition is switchedon and the parking brake is released. The DRL turnoff when the engine falls below 400 rpm, the parkingbrake is applied, or the headlights are turned on.

Daytime running lights are mandatory for vehiclesdomiciled in Canada. Vehicles domiciled in any otherlocation may have an optional override switch(Fig. 5.4, ref. 2). This is a momentary switch that en-ables the driver to deactivate the DRL. Press theupper half of the switch briefly to activate or deacti-vate the DRL.

Fog LightsFog lights are designed to reduce glare in foggy con-ditions. The low-beam headlights must be on in orderto turn the fog lights on. Pull the headlight switch out-ward to activate the fog lights.

Hazard Warning LightsThe hazard warning light switch is located on thedash in what is referred to as the master module.See Fig. 5.5. The hazard lights can be activated re-gardless of the ignition switch position.

To activate the hazard lights, press the center of theswitch once. The switch will blink at the same ratethat the hazard lights flash. Press the switch again toturn them off. All the turn signals on the vehicle andtrailer, as well as the turn signal indicators in theICU, flash simultaneously when the hazard lights areactivated.

HeadlightsThe headlight switch is a rotary switch located to theleft of the steering column, above the ignition switch.See Fig. 5.6.

If the Follow Me Home feature is activated, the low-beam headlights will remain on for nine secondsafter the vehicle is parked, if the headlights were onprior to engine shutdown. This feature provides tem-porary lighting in the path of the headlights whilewalking to a building or other destination. If a vehicle

Driver Controls

5.2

door is opened or closed while this feature is active,the timer will add an additional 10 seconds of light-ing. This feature can be temporarily disabled by turn-ing the ignition switch on, or by cycling the headlightswitch from the off position to one of the other twopositions.

High-Beam HeadlightsTo activate the high-beam headlights, press the turnsignal lever forward towards the windshield while the

low-beam headlights are on. Return the turn-signallever back to its neutral position to deactivate thehigh beams, and return to low beam headlights.

When the high-beam headlights are on, a blue lightilluminates on the instrument cluster. For vehicleswith fog lights, switching on the high beams willswitch off the fog lights. The headlight low beamsremain on continuously during high-beam operation.

02/03/2012 f544971

12

3 4

6

7

7

8

89

10

5

1. High-Beam Headlight2. Fog Light, or Auxiliary High-Beam Light3. Low-Beam Headlight4. Marker Light5. Turn Signal

6. Side Turn Signal and Marker Light7. Clearance Light8. Stop Light, Taillight, and Turn Signal9. Back-Up Light10. Identification Light

Fig. 5.3, Exterior Lights

Driver Controls

5.3

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

Marker LightsTurn the headlight switch clockwise to past the offposition. See Fig. 5.6.

Marker InterruptThe marker interrupt switch, located in the right-handswitch pod of the steering wheel, temporarily flashesthe marker lights. See Fig. 5.7.

AUXHIGH

DRLOVRD

UTLYLAMP

FOOTWELL

DOME

DOMEREARDOME

REARDOME

LWRLAMP

LWRLAMP

01/05/2012 f611155

1 2 3 4 5 6

7 8 9 10 11

1. Auxiliary High Beam Light Switch2. DRL Override Switch3. Utility Light Switch4. Cab Foot Well Light Switch5. Panel Lights Switch6. Rear Cab Dome Light Switch

7. Rear Cab Dome Light Switch(mounted in sleeper)

8. Sleeper Rear Dome Light Switch,Driver Side

9. Sleeper Rear Dome Light Switch,Passenger Side

10. Sleeper Reading Light Switch,Driver Side

11. Sleeper Reading Light Switch,Passenger Side

Fig. 5.4, Dash-Mounted and Sleeper-Control Light Switches

03/20/2007 1 f6108552

1. Hazard WarningSwitch

2. Panel Lights DimmerSwitch

Fig. 5.5, Master Module

Driver Controls

5.4

SpotlightThe spotlight switch is located on the pivoting handleof the spotlight. There may be a single spotlight as-sembly mounted above the driver’s door, or oneabove each door.

Turn SignalsThe turn-signal lever is on the left side of the steer-ing column. See Fig. 5.8.

NOTE: The optional self-canceling turn signallever will automatically return to the neutral posi-tion when the steering wheel returns to thestraight-ahead position after a turn.

Move the turn signal lever downward to turn the left-turn signal on; move it upward to turn the right-turnsignal on. To manually cancel the signal, move thelever to the neutral position.

When a turn signal is activated, a green indicatorlight flashes on the instrument cluster.

Turn-Tip FeatureThe turn-tip feature is advantageous in lane changesituations when the steering wheel does not travel farenough to cancel a conventional turn signal request.Pushing the turn-signal lever halfway to the normalturning position to activate the turn-tip feature. Thesignal will flash for a few seconds, then cancel. Acti-vation of the turn-tip feature is immediately canceledwhen a request for the turn signal in the oppositedirection is made.

Utility LightsUtility lights can be swivel-mounted on upper half ofthe cab, mounted on the exhaust support, or flush-mounted on the back of the cab or sleeper. Press theupper half of the switch to activate it. Press the lower

f61080601/05/2012

1

2 3

4

1. Fog Lights (optional)—Activate by pulling the switchout when the marker lights or headlights are on.

2. Off3. Marker Lights4. Headlights

Fig. 5.6, Headlight Switch

05/24/2007 f462049

ON/OFF

ACCRES

CNCL

DEC/SET

MRKRINT

ENGBRK

Fig. 5.7, Steering Wheel-Mounted Controls

07/19/2006 f820427

1

2

1. Wiper Control Dial 2. High-Beam Icon

Fig. 5.8, Multifunction Turn Signal Lever

Driver Controls

5.5

half of the switch to turn it off. When activated, a redindicator light in the switch is illuminated. SeeFig. 5.4.

Interior Lighting ControlsInterior light controls are listed here in alphabeticalorder.

The interior lights include panel lights, dome lights,red map lights, clear reading lights, and courtesylights. Vehicles come pre-set from the factory withtheater lighting, which ramps up lights from lowpower to full power when activated.

Sleepers have rear dome lights, bunk reading lights,sleeper floor lights, and baggage compartment lights.

Baggage Compartment LightsBaggage compartment lights are located on the un-derside of the lower bunk, on both sides. Both lightsturn on when either baggage compartment door isopened to illuminate the baggage compartment. Thelights also come on when the lower bunk is raised.

Foot Well LightsWhen the driver or passenger doors are opened, redlights illuminate both foot wells. These lights can alsobe activated with the foot well light switch. SeeFig. 5.4. Press the upper half of the switch to turnthe foot well lights on, press the lower half of theswitch to turn them off.

Overhead Console LightsThe overhead console includes a clear reading light,a clear dome light, and a red map light. See Fig. 5.9.The dome lights illuminate when a door opens, thenstay on for a short time after both doors are closed.Press the lens of the reading light, dome light, ormap light to activate each one independently of theothers.

Panel LightsThe panel lights illuminate when the headlights areturned on. To adjust the brightness of the panellights, use the panel lights switch, usually located inthe master module next to the hazard flasher switch.See Fig. 5.4. The panel lights brighten and dim in5% increments, depending on whether the upper halfor the lower half of the switch is pressed. When the

headlights are turned on, the panel lights setting willdefault to the intensity that was last set.

Rear Dome LightA rear cab dome light is located on the roof, betweenthe bunk and the cab on sleeper vehicles. SeeFig. 5.10. The rear cab dome light will activate withthe dome lights when a door is opened, then stay onfor a short time after both doors are closed.

Use the dash-mounted switch or the switch in thesleeper panel to activate the rear cab dome light.See Fig. 5.4.

11/21/2006 f544907

12

3

1. Clear Reading Lamp2. Clear Dome Lamp

3. Red Map Lamp

Fig. 5.9, Overhead Console Lights

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Fig. 5.10, Rear Cab Dome Light

Driver Controls

5.6

Sleeper Dome LightTwo dome lights are mounted on the sleeper roof,close to the outside walls.

There are two switches in the sleeper that control thesleeper dome lights. The passenger-side switch willactivate both dome lights. The driver-side switch op-erates the driver-side light only. Press the upper halfof the switch to turn the sleeper dome light on, pressthe lower half of the switch to turn it off.

Sleeper Foot Well LightsThe sleeper foot well switch is located in the lowerswitch module in the sleeper. It looks identical to thecab foot well switch. See Fig. 5.4. When the switchis activated, two lights illuminate the sleeper floor.

Sleeper Reading LightsClear reading lights are mounted above the lowerbunk in the rear corners of the sleeper. There aretwo switches in the sleeper control panel for thereading lights. To turn a reading light on, press theupper half of the switch. Press the lower half of theswitch to turn it off. See Fig. 5.4.

The reading lights can also be activated by pressingthe lens.

Horn ControlsAir HornAir horn(s) may be mounted on the roof of day cabs,or under the driver-side floor for sleeper cabs. Theair horn is controlled by a wire lanyard that hangsdown inboard by the driver’s door. See Fig. 5.11.Pull downward on the lanyard to sound the air horn.

Electric HornThe button for the electric horn on a vehicle withoutan airbag is located in the center of the steeringwheel. See Fig. 5.12. To sound the horn, press downon the button.

The electric horn on a vehicle with an airbag is acti-vated by pressing down on the top of the steeringwheel center pad. See Fig. 5.13.

The horn will sound for the duration that the button ispressed, up to 60 seconds. The electric horn will op-erate regardless of the position of the ignition key.

Powertrain ControlsAftertreatment System RegenSwitchesNOTE: See Chapter 12 for detailed informationabout the operation of the regeneration (regen)switches and the aftertreatment system (ATS).

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1

1. Lanyard

Fig. 5.11, Air Horn Control

02/05/2007

1

f544961

1. Horn Button

Fig. 5.12, Steering Wheel, No Airbag

Driver Controls

5.7

IMPORTANT: Depending upon local jurisdic-tional emissions guidelines, vehicles that aredomiciled outside of the U.S. and Canada maynot have engines and/or emissions aftertreat-ment systems that are compliant with EPA07,EPA10, or GHG14 regulations.

The regen request switch, located on the dash, isused to initiate a parked regen. See Fig. 5.14. Toaccess the regen request switch, lift the guard andpress the yellow button.

Some vehicles may be equipped with a regen inhibitswitch. See Fig. 5.14. To stop a regen in progress orprevent the start of a regen, press the lower half ofthe switch. Regen will be delayed until the switch isno longer active.

Axle SwitchesSome vehicles are equipped with an interaxle differ-ential lock switch and/or a switch for each driver-controlled differential lock (DCDL). See Fig. 5.15. Formore information about differential locks and usingthem for traction control, see Chapter 16.

Engine Brake SwitchThe Hi/Med/Lo engine brake 3-position switch con-trols the amount of engine braking. See Fig. 5.16.Press the lower third of the switch for low, center formedium, and upper third for high.

01/13/2012 f462236

Press down on the top of the steering wheel center padto activate the horn.

Fig. 5.13, Steering Wheel With Airbag

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NORGEN

12

1. Regen RequestSwitch

2. Regen Inhibit Switch

Fig. 5.14, Regen Request and Inhibit Switches

1

2

3

4

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1. Interaxle Differential Lock Switch2. Fifth Wheel Slide Switch3. Driver-Controlled Differential Lock (DCDL) Switch4. Air Suspension Dump Control Switch

Fig. 5.15, Axle and Suspension Switches

Driver Controls

5.8

There is also an engine brake switch located in theright-hand switch pod on the steering wheel. SeeFig. 5.7. Press the ENG BRK switch once to engageor disengage the engine brake. Refer to Chapter 13for instructions on using the engine brake.

Engine Fan SwitchThe engine cooling fan can be turned on by the en-gine fan switch.

To turn the engine fan on, press the upper half of theswitch. The fan will continue to operate for a setamount of time and then turn off unless the coolanttemperature is high enough to continue fan opera-tion. To turn the fan off before the set time periodends, press the lower half of the switch. SeeFig. 5.17.

Hill Start Aid Override SwitchSome vehicles are equipped with a Hill Start Aid(HSA) feature to prevent the vehicle from rollingwhile on steep grades and to allow for a controlledlaunch. HSA is "on" by default. It can be turned offby pressing and releasing the HSA override switchon the dash (see Fig. 5.18).

PTO SwitchTo activate the PTO function, press the upper half ofthe switch. Press the lower half of the switch to de-activate the PTO function. See Fig. 5.19.

WARNINGTo avoid injury, do not install a PTO that is notDetroit Diesel approved onto a Detroit™ Trans-mission. Use of a non-Detroit Diesel approvedPTO with a Detroit Transmission could result inunintended operation which could lead to severepersonal injury.

Transmission ControlsDetroit™ Automated Transmissions

NOTE: See Chapter 15 for complete Detroitautomated transmission operating instructions.

Vehicles with Detroit transmissions use the multifunc-tion control shown in Fig. 5.20. This control moves intwo directions and has two switches. It is used torequest manual shifts, change shift mode, set enginebrake levels, and control specialty engine brake func-tions during cruise control operation.

ENGBRK

f61090505/02/2007

HI

LO

Fig. 5.16, Engine Brake Switch

ENGFAN

f61089902/26/2007

Fig. 5.17, Engine Fan Switch

HSAOVRD

f61118604/30/2012

Fig. 5.18, Hill Start Aid Override Switch

Driver Controls

5.9

Eaton Automated Transmissions

NOTE: See Chapter 15 for complete automatedtransmission operating instructions.

The SmartShift electronic transmission control is in-stalled with the Eaton® Fuller® UltraShift™ andEaton Fuller AutoShift™ transmissions. The Smart-Shift control is operated by the fingers of the driver’sright hand, allowing both hands to remain on thesteering wheel.

A two-position driving mode slide switch is mountedon the body of the control lever just before thepaddle widens out. The slide switch allows the driverto choose automatic (AUTO) or manual (MAN) mode.See Fig. 5.21.

Manual Transmissions

NOTE: See Chapter 14 for complete manualtransmission operating instructions.

If so equipped, the transmission range control andsplitter valves are attached to the gear shift knob.

The range-preselection lever allows the selection ofthe low or high range for each transmission ratio. It isused once during an upshift sequence and once dur-ing a downshift sequence.

Dependent on the transmission model, some ratioscan be split using the splitter-control button.

Allison Automatic TransmissionsAutomatic transmissions have up to six forwardspeeds and one reverse speed. These transmissionshave electronic shift controls that can be programmed to allow the use of different geared

speeds. See Fig. 5.22.

f61089402/23/2007

PTO

Fig. 5.19, PTO Switch

B

2

3

1

( + )

( − )

4

05/30/2012 f270163a

A

C

A. Front ViewB. Shift RequestsC. Four positions for engine brake settings1. Engine Brake Symbol2. D/N/R Switch3. Mode Switch4. Gear Shift Symbol

Fig. 5.20, Detroit Multifunction Control

Driver Controls

5.10

Cruise Control

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow-covered, slippery, orroads with a loose driving surface. Failure to fol-low this precaution could cause a collision orloss of vehicle control, possibly resulting in per-sonal injury or property damage.

NOTICEWhen the cruise control is engaged, do not at-tempt to shift gears without using the clutchpedal. Failure to follow this precaution will resultin a temporarily uncontrolled increase in enginespeed. Transmission damage and gear strippingcould result.

IMPORTANT: On vehicles equipped withVORAD Collision Warning System with Smart-Cruise, see Chapter 6 before operating thecruise control.

NOTE: If the vehicle is equipped with a Detroitmultifunction control, setting the cruise controlwith the engine brake on will activate DescentControl Mode. Moving the lever to the top posi-tion will resume the set cruise speed. Movingthe lever down to engage the engine brake afterthe cruise control has been set will activate De-celeration Mode. See "Descent Control and De-celeration Modes, Detroit™ Automated Transmis-sions" in this chapter.

The cruise control is operated by four buttonsmounted in the left-hand button pod of the steeringwheel. See Fig. 5.7.

• ON/OFF Button—Press to turn cruise controlon or off. When cruise control is on, a greentelltale illuminates in the ICU. The speedmemory will be retained until the cruise controlis disabled with the ON/OFF button, or the igni-tion is turned off.

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12

3 4

5 6

8

9

10

1112

f270120

7

To upshift manually, pull the lever back (towards thedriver). To downshift manually, push the lever forward(away from the driver).1. SmartShift Control Lever2. Slide Switch (forward driving mode switch)3. MAN Mode (of slide switch)4. AUTO Mode (of slide switch)5. Upshift Direction6. Reverse Position (of selector switch)7. Selector Switch8. Neutral Lock Button9. Neutral Position (of selector switch)10. Drive Position (of selector switch)11. Low Position (of selector switch)12. Downshift Direction

Fig. 5.21, SmartShift Control (Eaton Fuller UltraShiftand AutoShift transmissions)

10/31/94 f600369a

1

2

1. Indicator Panel 2. Mode ID

Fig. 5.22, Allison Push-Button Shift Selector

Driver Controls

5.11

• DEC/SET Button—Press to set the cruisespeed while the vehicle is traveling at the de-sired speed. Press and hold to decrease theset cruise speed.

• CNCL Button—Press to pause the cruise con-trol, while retaining the speed setting inmemory. The cruise control can also be disen-gaged, while retaining the speed memory, bydepressing the brake or clutch pedals.

• ACC/RES Button—Press to resume the setspeed. Press and hold to accelerate the setcruise speed.

1. To cruise at a particular speed:

1.1 Press the ON/OFF button to turn cruisecontrol on.

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

NOTE: Cruise control is cancelled if thebrake or clutch pedal is depressed, or ve-hicle speed drops below the minimum cruisecontrol speed.

1.3 Press the DEC/SET button to set the de-sired speed.

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

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

• Press the CNCL button.

• Depress the brake pedal.

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

3. To resume a preselected cruise speed:

3.1 Ensure cruise control is on.

3.2 Press the ACC/RES button. Cruise willreturn to the last set speed.

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

4. To increase cruise speed, press the ACC/RESbutton until the vehicle accelerates to the desiredspeed.

5. To decrease cruise speed, press the DEC/SETbutton until the vehicle decelerates to the desiredspeed.

Run Smart Predictive Cruise™

Predictive Cruise Control (PCC) is an optional fuelsavings application that adjusts vehicle speed predic-tively, based on the approaching road. Using 3D digi-tal map technology and GPS, PCC evaluates the up-coming road grade about a mile in advance todetermine the most fuel-efficient vehicle speed. Ve-hicles equipped with PCC have a sticker on thedash. See Fig. 5.23.

The 3D digital map database contains profile infor-mation for over 200,000 highway miles (322,000 km)in the 48 contiguous United States. PCC will vary theset cruise speed by up to 6% depending on the ap-proaching road grade. If the engine brake is enabled,PCC will automatically engage the engine brakewhen actual vehicle speed exceeds the cruise setspeed by 6%. This is different from conventionalcruise control, which maintains the speed set by thedriver.

WARNINGApply the brakes and downshift as necessarywhen driving on downhill grades. PCC does notadequately control vehicle speed on steep down-hill grades. Failure to use normal braking tech-niques when PCC is active could result in per-sonal injury and vehicle damage.

IMPORTANT: PCC adjusts the vehicle set speedto achieve maximum fuel economy, but it does

04/15/2009 f100149

Fig. 5.23, Run Smart Predictive Cruise Control Sticker

Driver Controls

5.12

not account for traffic flows or surrounding ve-hicles.

Driver interaction with PCC is the same as conven-tional cruise control, using the standard cruise controlbuttons. In the event of a problem with PCC, or whendriving on a road with no profile information avail-able, the system reverts to conventional cruisecontrol.

Cruise Control ("CC") LimiterOn vehicles equipped with a CC Limiter (or CCBand) switch (see Fig. 5.24 or Fig. 5.25), the cruisecontrol limiter allows the vehicle to exceed the setcruise control speed before engine braking is ap-plied. The CC limiter switch provides more flexibilityto the existing cruise control limit function, allowingthe driver to tune the cruise function to better suitdriving preferences and conditions. To select a limit,use the three-position CC Limiter switch on the dash.See Table 5.1 for switch settings.

CC Limiter Switch SettingsPosition Approximate Overrun Setting

Top in 3 mph (5 km/h)Middle 6 mph (9 km/h)

Bottom in Unlimited

Table 5.1, CC Limiter Switch Settings

Descent Control and DecelerationModes, Detroit™ AutomatedTransmissionsOn vehicles equipped with a Detroit multifunctioncontrol (Fig. 5.26), the functions of the lever posi-tions for engine brake control change when cruisecontrol is set. Two distinct modes can be activated:

• Descent Control Mode—engine braking keepsthe speed below cruise set speed; throttle isnot automatically applied.

• Deceleration Mode—engine braking activatesto reduce vehicle speed (with no lower limit) ata constant rate.

Descent Control ModeDescent Control Mode keeps the vehicle speedbelow the set cruise speed on a downhill.

To activate Descent Control Mode, set the cruisecontrol speed with the engine brake on (Fig. 5.26,positions 1, 2, or 3). In this mode, all three levels ofengine braking will be employed to to keep thespeed below the set cruise speed. This mode will notkeep the speed above the lower limit of the setspeed, so it is possible to eventually coast to a stop,unless the lever is moved to "engine brake off" (posi-tion 0), or throttle is applied. After throttle application,the Descent Control Mode is resumed.

Moving the lever to "engine brake off" (position 0)cancels Descent Control Mode and resumes cruisespeed. To reactivate Descent Control Mode, reset thecruise control speed with the lever in position 1, 2, or3.

Deceleration ModeDeceleration Mode reduces the vehicle speed at aconstant rate.

With the cruise control speed set, activate Decelera-tion Mode by moving the lever to engine brake on

CCLIMIT

f61120302/19/2013

Fig. 5.24, CC Limiter Switch

CCBAND

f61119105/08/2012

Fig. 5.25, CC Band Switch

Driver Controls

5.13

(Fig. 5.27, position 1, 2, or 3). This mode engagesone of the engine brake levels, depending on thelever position. The vehicle will decelerate at a con-stant rate until the vehicle comes to a stop, unlessthrottle applied to override the deceleration, or thelever is moved to "engine brake off" (position 0).

Moving the lever to position 0 resumes the previouslyset cruise control speed.

Dash-Mounted Brake ControlsNOTE: See Chapter 13 for detailed informationabout brake systems.

Parking Brake Control Valve

NOTICEDo not step on the service brake pedal while theparking brakes are applied. To do so can causedamage to the brake mechanisms.

The yellow diamond-shaped knob operates the park-ing brake valve. See Fig. 5.28. Pull the knob out toapply both the tractor and the trailer spring parkingbrakes. Push the knob in to release the tractor springparking brakes. Before the spring parking brakes canbe released, the air pressure in either air brake sys-tem must be at least 65 psi (447 kPa).

If the trailer is not equipped with spring parkingbrakes, pull the parking brake valve out to apply thetractor parking brakes and the trailer service brakes.

Trailer Air Supply ValveThe red octagonal-shaped knob operates the trailerair supply valve, which charges the trailer air supplysystem and releases the trailer spring parkingbrakes. See Fig. 5.28.

After the vehicle and its air hoses are connected to atrailer and the pressure in the air system is at least65 psi (447 kPa), push the trailer air supply valveknob in (and leave it in) to charge the trailer air sup-ply system and release the trailer spring parkingbrakes. Pull the trailer air supply valve out before

0

1

2

3

02/19/2013 f270164a

0. Resume cruise control set speed.1, 2, 3. Descent Control maintains set speed.

Fig. 5.26, Descent Control Mode Positions, DetroitMultifunction Control

0

1

2

3

02/19/2013 f270164a

0. Resume cruise controlset speed.

1. Low

2. Medium3. High

Fig. 5.27, Deceleration Mode Positions, DetroitMultifunction Control

f610291

1 2

03/10/99

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

Fig. 5.28, Brake Valve Control Knobs

Driver Controls

5.14

disconnecting a trailer or when operating a vehiclewithout a trailer.

Trailer Brake LeverThe trailer brake lever is used to apply the trailer ser-vice brakes without applying the truck or tractor ser-vice brakes. It is usually mounted on the right-handcontrol panel. See Fig. 5.29. The valve can be par-tially or fully applied, but in any partially on position itwill be overridden by a full application of the servicebrake pedal. Move the lever down to apply the trailerbrakes; move the lever up to release the trailerbrakes. The lever will automatically return to the upposition when it is released.

Antilock Braking SystemThe Meritor™ WABCO® Antilock Braking System(ABS) passively monitors vehicle wheel speed at alltimes, and controls wheel speed during emergencystops or wheel lock situations.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS will control allwheels to provide steering control and a reducedbraking distance.

The ABS is designed to communicate with a trailerABS, if they are compatible. Compatibility will resultin the illumination of the trailer ABS lamp during ve-hicle start-up and fault detection. The trailer ABSlamp will not illuminate unless a compatible trailer isconnected to the tractor.

Vehicles with ABS may have Automatic Traction Con-trol (ATC). On these vehicles, the ATC system auto-matically limits wheel spin during reduced-tractionsituations. In normal braking applications, the stan-dard air brake system is in effect.

ATC includes a deep snow and mud option to in-crease available traction on extra-soft surfaces likesnow, mud, or gravel. A switch labeled ATC will belocated on the dash. See Fig. 5.30. Press the switchto temporarily allow more drive wheel spin. The acti-vation of the deep snow and mud option is indicatedby a flashing WHEEL SPIN lamp. Press the switchagain to cycle the system back to normal operation.

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

Windshield Wiper/WasherControlsThe multifunction turn signal lever is attached to theleft-hand side of the steering column, just below thesteering wheel. See Fig. 5.8.

NOTICEDo not attempt to manually move the windshieldwiper arms. Wiper motor damage will occur if thearms are forcibly moved.

10/17/2001 f610591

Fig. 5.29, Trailer Brake Lever

f61090706/15/2007

ATC

Fig. 5.30, ATC Switch

Driver Controls

5.15

The wipers are operated by a rotary switch in thewiper control dial, which is on the end of the turn sig-nal lever. There are five intermittent settings, markedon the dial by lines of increasing length, and twosteady speed settings: LO and HI.

Turn the wipers on by rotating the control dial coun-terclockwise. Rotate the control dial further to in-crease the speed of the wipers through the variousintermittent settings, then to LO and HI.

Rotate the control dial clockwise to slow the wipersdown. Rotate the control dial clockwise as far as itwill go to turn the wipers off.

The windshield washer button is located at the endof the turn signal lever. Momentarily press the wind-shield washer button to initiate a single wipe withoutactivating the washer pump. The wipers will swipeone full cycle and return to the inactive position.

To operate the windshield washers, press and holdthe button in. After a short delay, the washer willpump windshield washer fluid onto the windshield foras long as the washer button is pressed. The wind-shield wipers will turn on at low speed while thewasher button is pressed. After the button is re-leased, the wipers will continue to operate for one toseveral wipe cycles, depending on how long thewash button was pressed initially.

Suspension/Trailer ConnectionControlsAir Suspension Dump Control Switch

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

The air suspension height control switch may beused to aid in connecting or disconnecting from atrailer. See Fig. 5.15. When the switch is set toLOWER, the air-suspension dump valve deflates theair springs to lower the rear of the vehicle. In theAUTO position, the automatic ride-control valves op-erate for normal driving.

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

A red LED in the switch is illuminated when the sus-pension is deflated.

ECAS Dash SwitchesVehicles with Electronically Controlled Air Suspension(ECAS) may be equipped with either dash switchesor a remote control unit, not both. See Figure 5.31and Table 5.2.

LOAD XFER (Load Transfer)This switch controls the ECAS Manual Load Transferfunction by adjusting suspension air pressure. Usethis function to minimize wheel slippage in road con-ditions where traction may be a concern.

The ECAS Load Transfer feature applies the maxi-mum available vehicle load on the drive axle, up tothe maximum allowable limit, determined by thegross axle weight rating (GAWR). In bobtail or with aloaded trailer less than the GAWR, the tag axle sup-ports a negligible load while the drive axle supportsnearly the full weight. Above the GAWR, the driveaxle is loaded with approximately the maximum al-lowable load and the tag supports the remainder.

Load transfer mode can be deactivated by holding upon the dash switch for 4 seconds. Load transfer

f61127811/19/2014

12

LOADXFER

1. Load Transfer 2. Suspension Height

Fig. 5.31, ECAS Dash Switches

Driver Controls

5.16

mode will automatically deactivate when the vehiclereaches 45 mph (72 kmh).

For vehicles equipped with the ICU4Me, when LoadTransfer mode is active, "Load Transfer" will displayin the message field of the driver message center.See Figure 5.32.

Suspension HeightIf the suspension is at normal height:

• each up press increases the suspension heightan increment, unless the suspension is atmaximum height

• a down press lowers the suspension to its low-est set-point (usually axle stops)

If the suspension is below normal height:

• an up press increases the suspension height tonormal ride height

• a down press does nothing; the suspension isalready at its lowest point

If the suspension is above normal height:

• each up press increases the suspension heightan increment, unless the suspension is atmaximum height

• a down press lowers the suspension to normalride height

On vehicles equipped with the ICU4Me, messagesabout the ride height status will display in the mes-sage field of the driver message center. See Figure5.33.

If the suspension is outside normal ride height(amber lamp on), the ECAS system will automaticallyreturn the suspension to normal ride height whenvehicle speed reaches or exceeds a set speed (usu-ally set to 5 mph).

ECAS Standby Mode, Dash SwitchOnce the key is turned off, the ECAS will enterStandby mode, remaining powered and adjusting tolevel and load changes for 1 hour. To cancel Standbymode on vehicles with ECAS dash switches, turn thekey from OFF to ON to OFF in less than 1.5 sec-onds. Confirm the deactivation of standby mode bypressing the suspension height switch, which shouldnot adjust the suspension.

ECAS Remote Control UnitSome vehicles equipped with Electronically Con-trolled Air Suspension (ECAS) have a remote controlunit to lower and raise the rear suspension. SeeTable 5.2 for keys and functions.

If the suspension is outside normal ride height(amber lamp on), the ECAS system will automaticallyreturn the suspension to normal ride height whenvehicle speed reaches or exceeds a set speed (usu-ally set to 5 mph).

Messages about the ride height status will display inthe message field of the driver message center.

02/04/2015 f611291

Fig. 5.32, Load Transfer Notification, ICU4Me Only

02/04/2015 f611287

Fig. 5.33, Example of Ride Height Message, ICU4MeOnly

Driver Controls

5.17

ECAS Remote Control Keys and Functions

08/16/2013 f611211

Key Function

Remote Control On/Off. The middlelight will remain lit while the remote is

active.

Memory keys. Pressing the Stop keyand a memory key simultaneously willstore the current height. Once stored,

pressing the key will adjust thevehicle to the stored height.

Normal height key. This key willreturn the vehicle to normal ride

height.

Lift and lower keys. These keys willraise or lower the rear suspension

height.

The Stop key. Pressing the Stop keywill interrupt and stop all adjustments

being made by the remote control.When the key is off, holding the Stopkey for 2 seconds will cancel the 1

hour Standby mode.

Table 5.2, ECAS Remote Control Keys and Functions

ECAS Standby Mode, Remote ControlOnce the key is turned off, the ECAS will enterStandby mode, remaining powered and adjusting tolevel and load changes for 1 hour. To cancel Standbymode on vehicles with a remote control, turn on theremote control then hold the STOP key on the re-mote for 2 seconds. Confirm the deactivation of

standby mode by attempting to turn the remote onand adjust the suspension, which should not bepossible.

Fifth Wheel Slide Control Switch

NOTICEDo not activate the fifth wheel slide control valvewhile the vehicle is in motion. To do so couldcause damage to the fifth wheel member, thekingpin, the cab or trailer, and ultimately to thedrivetrain.

The fifth wheel air slide switch permits repositioningof the sliding fifth wheel from inside the cab. SeeFig. 5.34. Moving the air slide control valve switch tothe lock position deactivates the control valve andlocks the fifth wheel to the baseplate. Moving theswitch to the unlock position activates the controlvalve and unlocks the fifth wheel slide mechanism,allowing changes to the total length of the tractor-trailer and changes to axle loads to comply with vary-ing jurisdictional laws. For detailed operating instruc-tions for fifth wheel slide, coupling, and uncouplingprocedures, refer to Chapter 18.

Trailer Auxiliary SwitchTrailers that are equipped with pneumatic brakes andused in North America or South America are gener-ally equipped with power for the trailer lights. Theconnection is passed from the vehicle to the trailer

07/22/2011 f545806

Fig. 5.34, Fifth Wheel Slide Control Switch

Driver Controls

5.18

via the primary receptacle, controlled by a dashswitch.

Press the top of the switch to activate the trailer aux-iliary function. Press the bottom of the switch to turntrailer auxiliary function off. See Fig. 5.35.

Climate ControlsNOTE: See Chapter 8 for detailed climate con-trol panel operating instructions.

Cab Climate ControlThe climate control panel allows you to control theheating, ventilating, defrosting, and air conditioning(A/C) functions. The cab climate control panel hasthree switches to control the functions of the cabtemperature system; see Fig. 5.36:

• fan switch with recirculation button

• temperature control switch with A/C button

• air selection switch (with bunk-override buttonon sleeper cab only)

The fan switch controls the fan speed, and forcesfresh or recirculated air through the air outlets. Toincrease airflow, turn the switch clockwise to a highernumber. To decrease airflow, turn the switch counter-clockwise to a lower number.

Recirculation mode limits the amount of outside airthat enters the cab. Press the recirculation button toprevent dusty or smoky air from entering the cab.

NOTE: To prevent the buildup of odors and/oroxygen depletion inside the cab, the system

switches from full recirculation mode to partialrecirculation mode after 20 minutes.

The temperature control switch is used to select thedesired temperature. Turn the switch clockwise to thered area for warm air. Turn the switch counterclock-wise to the blue area for cool air.

The A/C cools and dehumidifies the air inside thecab. Press the A/C button, located in the center ofthe temperature control switch, to turn the A/C onand off.

The air selection switch allows the control of air flowthrough the face outlets, the floor outlets, the defrost(windshield) outlets, or a combination of these out-lets. See Fig. 5.37.

Bunk-Override ButtonThe bunk-override button is located in the center ofthe cab air-selection switch (sleeper-cabs only). SeeFig. 5.37.

Press the bunk-override button to make the cab con-trols override the settings on the sleeper temperaturecontrol panel; the sleeper temperature will mimic thecab settings. An amber LED in the button is illumi-nated when the bunk-override mode is activated.When the override switch is not activated, the cabclimate control panel can be adjusted without affect-ing the sleeper settings.

TRLRAUX

f61088802/23/2007

Fig. 5.35, Trailer Auxiliary Switch

0

24

8

6

07/20/2006 f831701

1 2 3

1. Fan Switch with Recirculation Button2. Temperature Control Switch with Air Conditioning

Button3. Air Selection Switch with Bunk-Override Button

Fig. 5.36, Cab Climate Control Panel

Driver Controls

5.19

Sleeper Climate ControlThe sleeper temperature can be controlled from thesleeper climate control panel or from the cab climatecontrol panel if the bunk-override button is activated.

The fan switch controls the sleeper temperature fanspeed. To increase airflow, turn the switch clockwiseto a higher number. To decrease the airflow, turn theswitch counterclockwise to a lower number. SeeFig. 5.38.

The temperature control switch is used to select thedesired temperature in the sleeper. Turn the switchclockwise to the red area for warm air. Turn theswitch counterclockwise to the blue area for cool air.

Press the button in the center of the temperaturecontrol switch to activate the A/C.

Cancel bunk-override mode, if activated, by changingthe sleeper fan speed or temperature setting. Thesystem will then operate from the sleeper controls.

Seat ControlsNOTE: See Chapter 7 for detailed informationabout seat controls and adjustments.

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

The following is a description of adjustments that canbe made to various seats. Not all seats have all ofthe adjustments listed below. See Fig. 5.39.

• Backrest tilt

• Lumbar support

• Isolator

• Height adjustment

• Bottom cushion angle (fore-and-aft bottomcushion height)

• Fore-and-aft seat slide (seat track adjustment)

• Seat tilt

• Headrest adjustment

Adjustable Steering ColumnControlsTo adjust the steering column, depress the foot pedallocated below the steering column. See Fig. 5.40. Tiltthe steering column to the desired angle. Telescope

06/08/2007 f610948

1

2

3

45

6

7

8

9

10

1. Face Mode2. Selection Between Face Mode and Bi-Level Mode3. Bi-Level Mode4. Selection Between Bi-Level Mode and Floor Mode5. Floor Mode6. Selection Between Floor Mode and Defog Mode7. Defog Mode8. Selection Between Defog Mode and Defrost Mode9. Defrost Mode10. Bunk-Override Button (on sleeper-cabs only)

Fig. 5.37, Air Selection Switch With Bunk-OverrideButton

06/08/2007 f610949

1 2

3

1. Fan Switch2. Temperature Control

3. Air ConditioningButton

Fig. 5.38, Sleeper Climate Control Panel

Driver Controls

5.20

the steering column closer or further away by push-ing or pulling it. Release the foot pedal to lock thesteering column in place.

10/26/2000 f910149a

1

2

3 4

56 7

8

1. Backrest Tilt2. Lumbar Support3. Isolator Feature4. Height Adjustment

5. Bottom Cushion Angle (fore-and-aft cushion height)

6. Fore-and-Aft Seat Slide (seattrack adjustment)

7. Seat Tilt8. Upper Backrest Adjustment

Fig. 5.39, General Seat Adjustments

Driver Controls

5.21

07/19/2006 f610799

1

2

3

4

5

1. Multifunction TurnSignal Switch

2. Headlight Switch3. Ignition Switch

4. Tilt Steering ColumnLever

5. Steering Wheel

Fig. 5.40, Steering Column and Left Panel Controls

Driver Controls

5.22

6

Driver Assistance FeaturesVORAD VS-400 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1OnGuard™ Collision Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7Detroit Assurance Radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11Lane Departure Warning (LDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17Roll Stability System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18Enhanced Stability Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20Detroit Connect Tablet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21

VORAD VS-400 System

WARNINGThe VORAD VS-400 System is intended solely asan aid for an alert and conscientious professionaldriver. It is not intended to be relied upon to op-erate a vehicle. Use the system in conjunctionwith rearview mirrors and other instruments tosafely operate the vehicle. Operate a vehicleequipped with the VS-400 System in the samesafe manner as if the CWS were not present.

The VS-400 System is not a substitute for safe,normal driving procedures, nor will it compen-sate for any driver impairment such as drugs,alcohol, or fatigue.

The VS-400 System may provide little or no warn-ing of hazards such as pedestrians, animals, on-coming vehicles, or cross traffic.

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

The VORAD VS-400 system is an on-board radarsystem that monitors traffic conditions, warning thedriver of potentially hazardous driving situations.

The collision warning system (CWS) tracks objectsahead of the vehicle, warning the driver with visualand audible indicators whenever following distancesbecome unsafe.

SmartCruise® adjusts the vehicle’s cruise speed inorder to match the speed of traffic ahead, allowingthe driver to maintain a safe following distance whilecruise control is engaged.

The optional side object detection system warns ofunsafe lane changes by detecting vehicles that maybe difficult to see in adjacent lanes.

The VORAD VS-400 system performs in fog, rain,snow, dust, smoke, and darkness. The VS-400 sys-tem becomes active whenever the ignition key isswitched to ON.

Driver Interface UnitThe driver interface unit (DIU) provides visual andaudible alerts, along with system status information.The DIU also provides an interface for changing sys-tem settings. Menu selections are made by pressing

the up and down arrow buttons, and the OK button.See Fig. 6.1.

The following warning and indicator lights illuminateon the DIU:

• Red: illuminates with the collision alert

• Yellow: illuminates with 3-, 2-, and 1-secondfollowing distance alerts

• Orange: illuminates when a system failure oc-curs

• Blue: illuminates when information is available

Immediately after the ignition switch is turned to ON,the DIU initializes a self-test routine. During the ini-tialization, the VORAD screen displays and all lampsilluminate for approximately three seconds, alongwith a power-up tone. When the initialization is com-plete, the DIU displays the VS-400 system configura-tion screen. See Fig. 6.2.

Menu Selections

IMPORTANT: The display of a menu item isoverridden whenever conditions require an alertor collision warning to be displayed.

After initialization, the menu screen is displayed.Scroll to the desired menu item by pressing an arrowbutton, then press the OK button to select the item.See Fig. 6.3. If the driver does not make a selectionwithin 30 seconds, or the vehicle begins to move, theDIU reverts to the system status display.

TM

f610919a

1

2

3

45

6

7

OK

02/03/2012

1. Fault Indicator2. Info Indicator3. Following Distance

Lights

4. Ambient Light Sensor5. Collision Alert Lights6. User Interface Keypad7. Graphic Display

Fig. 6.1, Driver Interface Unit (DIU)

Driver Assistance Features

6.1

The display of any menu item is overridden when-ever conditions require an alert or collision warningto be displayed.

Demo (vehicle must be stationary)When the vehicle is stationary and Demo mode isselected, the DIU will demonstrate the meaning of allLED and screen displays, including alert messagesand sound warnings. Scroll through the demo

screens by pressing the down arrow. Pressing anyother key exits Demo mode.

VolumeThe minimum adjustable volume is 50% of the maxi-mum volume. If the DIU volume is not adjustable, thedisplay screen shows a grayed bar graph whenevervolume adjustment is selected. See Fig. 6.4. Aftereach ignition switch cycle, the volume will defaultback to 100%.

NOTE: Headway and collision alert tones maybe suppressed when the brake is applied if thesystem is configured to do so.

SmartCruise Headway RangeHeadway range adjustment is only available withSmartCruise. Headway range is adjustable between3.25 and 2.25 seconds. The headway range settingwill default to 3.25 seconds after each ignition powercycle.

If headway range adjustment is disabled, only the3.25 sec screen is displayed. See Fig. 6.5 for thevarious headway range screens. Press the OK but-ton to exit the menu.

VORAD startedCollision WarnSmartCruise

f610921a

VORAD startedCollision Warn

A

B

OK

OK

02/03/2012

TM

TM

A. Configured for CWS onlyB. Configured for CWS and SmartCruise

Fig. 6.2, System Configuration Screens

f610922a

System Status

VolumeDemo

02/03/2012

OK

TM

Fig. 6.3, Menu Screen

f610925a

A

B

Volume

Volume

OK

OK

02/03/2012

TM

TM

A. Adjustable VolumeB. Non-Adjustable Volume

Fig. 6.4, Volume Screen


6.2

NOTE: If the headway range is adjusted tothree seconds or below and SmartCruise is ac-tive, the 3-second collision warning headwayalert will not display. All other alerts are notsuppressed.

BrightnessUse the up and down arrows to change the DIUbacklight and warning LED brightness. Press the OKbutton to exit the brightness screen.

The ambient light sensor reading determines if theDIU is in daytime or nighttime mode. Menu-adjustedbrightness is applied only to the mode the DIU is inat the time of adjustment. The previous brightnesssettings are repeated after each ignition cycle. How-ever, the graphic display and the warning LED bright-ness range are constrained such that they are al-ways visible regardless of how low the brightness is

adjusted in all driving conditions. Press the OK but-ton to exit the menu.

Unit Adjustment ScreenThe unit adjustment screen allows the driver to selecteither km/h or mph units for display of SmartCruiseset speed. Press OK to exit the mph selectionscreen.

System StatusSystem status shows the status of each system, indi-cating if the system is operating normally. If a systemis not operating normally, the system displays Failedbeside the system name. Failed indicates that a faultis preventing the system from operating and it cannotbe used until the fault is corrected or acknowledged.

Depending on the VS-400 system installed, one ofthe screens shown in Fig. 6.6 will appear unless asystem fault is active. Press OK to exit the systemstatus menu.

DiagnosticsThe DIU displays fault codes currently active whenthis screen is selected and the vehicle is stationary.

f610927a

C

3.25 sec

SmartCruiseRange

A

SmartCruiseRange

2.25 sec

B

3.25 sec

SmartCruiseRange

fixed

OK

OK

OK

02/03/2012

TM

TM

TM

A. Minimum headway adjustmentB. Maximum headway adjustmentC. Headway range disabled

Fig. 6.5, Headway Range Screen

f610923a

A

B

Coll ision warnSmartCruise

VORAD statusOKOK

Press OK for Menu

Coll ision warn

VORAD statusOK

Press OK for Menu

OK

OK

02/03/2012

TM

TM

A. Status display for CWS and SmartCruiseconfiguration

B. Status display for CWS configuration

Fig. 6.6, System Status Screens


6.3

See Fig. 6.7. Contact an authorized Freightliner ser-vice center if fault codes display.

Collision Warning SystemThe CWS may require a warm-up period of up toone minute if the outside air temperature is below32°F (0°C). The DIU will display a warm-up messageuntil the system reaches operating temperature. SeeFig. 6.8.

The alerts given by the VS-400 system are based onthe distance to the object ahead, whenever vehiclespeed is 10 mph (16 km/h) or faster. The VS-400CWS identifies and tracks the nearest object in thelane of travel. This object is classified by the range,and assigned a message described under the follow-ing headings.

Object DetectedWhen a vehicle is detected in the same lane of travelwithin 350 ft (107 m) but farther than a 3-second fol-lowing distance, the DIU will display OBJECT DE-TECTED. See Fig. 6.9.

3-Second Headway AlertWhen a vehicle is detected to be within a 3-secondfollowing distance, a single yellow indicator will illumi-nate and the DIU will display 3 seconds. SeeFig. 6.10.

f610929a

DIU DIAGNOSTICSSPN: 00886 FMI:012

OKOK

02/03/2012

TM

Fig. 6.7, DIU Diagnostic Screen

f610924a

A

B

Do not useRadar Warming Up

Radar Warming Up

SmartCruise

Please wait

OK

OK

02/03/2012

TM

TM

A. CWS withSmartCruise

B. CWS Only

Fig. 6.8, CWS Warm-Up Screens

f610930a

Object Detected OK

02/03/2012

TM

Fig. 6.9, Object Detected Alert

f610931a

3 seconds OK

02/03/2012

TM

Fig. 6.10, 3-Second Alert


6.4

2-Second Headway AlertWhen the following distance to the object ahead inthe same lane of travel decreases to within two sec-onds, a second yellow indicator will illuminate, theDIU will display 2 seconds, and a single tone willsound. See Fig. 6.11.

1-Second Headway AlertWhen the following distance to the object ahead inthe same lane of travel decreases to within one sec-ond, a third yellow indicator will illuminate, the DIUwill display 1 sec, and two tones will sound. SeeFig. 6.12.

Collision Alert: ½-Second HeadwayWhen the following distance to the object ahead inthe same lane of travel decreases to 0.5 second, thered indicators all illuminate across of the DIU, theDIU will display COLLISION ALERT, and a tone willsound repeatedly. See Fig. 6.13.

SmartCruiseWhen approaching slower moving traffic with the ve-hicle’s cruise control engaged, SmartCruise adaptsthe engine cruise speed to that of the closest vehicleahead, allowing the vehicle to maintain a safe follow-ing distance without disengaging the cruise control.The DIU will display the SmartCruise status screenindicating the vehicle’s current set cruise speed.

Once the speed of traffic ahead increases beyondthe adapted engine cruise speed, the original cruisecontrol set speed re-engages.

When SmartCruise is engaged, depressing the accel-erator pedal will override the SmartCruise and willcause the vehicle to accelerate. Depressing thebrake or clutch pedals will deactivate SmartCruise.

When approaching a slow moving or stopped vehicleahead, SmartCruise will attempt to maintain the mini-mum following distance by reducing the enginecruise speed and engaging the engine brake, if nec-essary. If SmartCruise is unable to maintain the mini-mum following distance, the driver will be alerted bythe CWS headway alerts until the driver takes controlor conditions clear.

Side Object DetectionThe optional side object detection system may beinstalled on one or both sides of the vehicle. Theradar sensor(s) are located on the side of the ve-hicle, while the sensor display unit is mounted on theA-pillar. See Fig. 6.14.

The side sensor display unit uses two lights to dis-play the status of the side sensor(s). The yellow lightindicates the system is active, but no objects are de-tected. The red light indicates that the side sensordetects an object. If the vehicles turn signal is active

f610932a

seconds2

OK

02/03/2012

TM


f610933a

sec1

OK

02/03/2012

TM


f610934a

COLLISIONALERT

OK

02/03/2012

TM

Fig. 6.13, Collision Alert


6.5

and the sensor detects an object alongside the ve-hicle, an audible warning tone will sound.

Special Road SituationsCertain road situations may affect the system’s abilityto detect objects. These situations include the effectsof curves, dips, and hills which can provide an unex-pected result.

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

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

• When approaching a curve, alarms may soundand lights illuminate, because of an object offthe road directly in line with your vehicle. Thiswill not occur when the brakes are applied.

• When approaching a roadway descending to alower elevation, elevated obstacles such asoverpasses and overhead signs may be de-tected.

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

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

• The side sensor only detects objects within itsfield of view, next to the tractor. A vehicle be-hind the field of view will not be detected.

• The side sensor range is set to detectaverage-sized vehicles 2 to 10 feet (0.5 to 3meters) away in the adjacent lane.

• The radar beam will detect near range cut-insof approximately 30 feet (9 meters) or less,depending on the angle of entrance into thelane in front of your vehicle.

• A continuous fixed object on the right side ofthe vehicle such as a guard rail, wall, tunnel, orbridge may cause the side sensor alert light tostay on.

WARNINGHeavy rain or water spray at the side sensor maycause both the yellow and red lights on the sidesensor display to illuminate at the same time.Under these conditions the system is temporarilyunable to provide adequate warnings.


MaintenanceKeep the antenna and side sensor free of buildup ofmud, dirt, ice, or other debris that might reduce thesystem’s range.

Failure Display Mode/Fault CodesThe VS-400 performs internal diagnostics at power-up, then continuously monitors system componentsthereafter.

If a failure is detected, depending on what featuresare affected, the DIU displays a screen similar toFig. 6.15, blinks the orange fault light, and sounds atone. Press the OK button to acknowledge the fault.

After the fault has been acknowledged, the DIU willattempt to return to normal operations. The orangeLED is continuously illuminated while the fault per-sists. If the fault disappears, the VS-400 transmits a

f610935b02/06/2012

1

4

3

2

1. Volume Adjust2. Red LED–Object Detected3. Ambient Light Sensor4. Yellow–No Object Detected

Fig. 6.14, Side Sensor Display Unit


6.6

message to indicate that the fault status haschanged to a previously active fault.

In the event the CWS antenna becomes blockedwhile the vehicle is moving (e.g., snow, mud, ice,tampering, etc.), the system sounds a tone and dis-plays the fault screen shown in Fig. 6.16.

Contact an authorized Freightliner dealer to reviewand clear previously active fault codes.

OnGuard™ Collision SafetySystemMeritor WABCO OnGuard is a forward-looking radar-based safety system. The system includes forwardcollision warning, adaptive cruise control (ACC), andcollision mitigation.

OnGuard equipped vehicles have antilock brakes(ABS) and automatic traction control (ATC), and ei-ther roll stability control (RSC) or electronic stabilitycontrol (ESC). These systems work together to en-hance control of the vehicle. Depending on the situa-

tion, any of these features may apply throttle control,engine brakes, and/or service brakes, as needed.

The front-looking antenna assembly transmits radarsignals to, and receives them back from, objectsahead of the vehicle. To be detected, vehicles mustbe within the radar field of view and provide a sur-face area that can reflect the radar. The distance,speed, and angle of the vehicle ahead is calculated,and the driver is warned of potentially dangeroussituations. The system also warns of stationary ob-jects to alert the driver of potential obstructionsahead in their lane.

WARNINGThe Meritor WABCO OnGuard™ Collision SafetySystem is intended solely as an aid for an alertand conscientious professional driver. It is notintended to be relied upon to operate a vehicle.Use the system in conjunction with rearview mir-rors and other instruments to safely operate thevehicle. Operate a vehicle equipped with the On-Guard in the same safe manner as if the CWSwere not present.

The OnGuard Collision Safety System is not asubstitute for safe, normal driving procedures,nor will it compensate for any driver impairmentsuch as drugs, alcohol, or fatigue.


System LimitationsThe OnGuard Collision Safety System may providelittle or no warning of hazards such as pedestrians,animals, oncoming vehicles, or cross traffic.

OnGuard CMS only brakes for lead vehicles locateddirectly in front of your vehicle, and does not operatewhen vehicle speed is less than 15 mph (25 km/h).

Due to these limitations, the system:

• will not react and alert the operator to objectscrossing in front of the vehicle or oncomingtraffic;

• should not be relied on to track lead vehicleswhen traveling through a severe curve in theroad. Because of this, ACC is not recom-mended for use on winding roads;

f610936a

VORAD faultCollision warn FAILED

OK

OK

02/03/2012

TM

Fig. 6.15, VORAD Fault Display

f610937a

VORAD faultRadar Blocked

OK

OK

02/03/2012

TM

Fig. 6.16, Antenna Blocked Display


6.7

• will alert, but not actively brake, on stationaryobjects;

• should not be relied upon to track smaller ob-jects like motorcycles, mopeds, bicycles, orpedestrians;

• should not be relied on to alert drivers to ve-hicles in an adjacent lane.

OnGuard Display UnitThe OnGuard system controls are located in the dis-play unit. The display provides visual and audiblewarnings and messages, as well as verification ofcorrect system operation and faults. Menu selectionsare made by pressing the up and down arrows, andthe MODE button. See Fig. 6.17 and Fig. 6.18.

The display unit includes:

• an internal speaker

• a graphic display

• buttons to scroll and select options

• day/night display mode (second-generationonly)

Collision Warning System (CWS)The CWS generates audible and visual alerts whenthe following distance may result in a collision. The

OnGuard display unit shows a graphic of the condi-tion, enhanced by a screen color relevant to the in-tensity of the situation. See Table 6.1. If a potentialrear-end collision is imminent, OnGuard’s activebraking automatically applies the engine and servicebrakes to slow the vehicle. The active braking appli-cation is intended only to provide early braking; thedriver is still required to recognize and react to alldriving situations.

OnGuard Display Screen Background ColorsScreen Color Description

Blue General operation; no lead vehiclesdetected.

Green Lead vehicle detected.

Yellow Following distance alert, accompaniedby an audible alert.

RedCollision warning, stationary objectwarning. Accompanied with audiblealert.

Amber Data Error

Table 6.1, OnGuard Display Screen BackgroundColors

IMPORTANT: CMS and active braking are notoperational at vehicle speeds below 15 mph (25km/h).

The CWS cannot be disengaged or turned off, and isalways active at vehicle speeds above 15 mph (25km/h).

08/30/2011 f545826

Fig. 6.17, OnGuard Display Unit, First Generation

10/31/2014 f611277

12

3

4

1. Mode2. Day/Night Mode

3. Up4. Down

Fig. 6.18, OnGuard Display Unit, Second Generation


6.8

StandbyWhen no lead vehicle is detected, the display showsthat the CMS is on and the radar is searching. SeeFig. 6.19.

A Vehicle is DetectedWhen a lead vehicle is detected in the lane ahead,the display shows that the CMS is on and the radaris tracking a lead vehicle at the speed shown. SeeFig. 6.20.

If the following distance between the vehicle and thelead vehicle is too close, the CMS will emit an au-dible alert and the display background will turn yel-low. The alert will end when the vehicle speed dropsbelow the lead vehicle speed and the following dis-tance is increased.

Collision WarningWhen a lead vehicle is detected traveling slower thanyour vehicle, or the gap between them becomes tooclose, the CMS warns of an impending collision byemitting an urgent audible alert and displaying thecollision warning symbol with a red background. SeeFig. 6.21.

Adaptive Cruise Control (ACC)ACC works in conjunction with conventional cruisecontrol to maintain a minimum following distancewhen a lead vehicle is being tracked. The minimumfollowing distance is maintained by automatically de-celerating the vehicle using throttle, engine, and ser-vice brakes without driver intervention. When thelead vehicle is no longer being tracked, the set cruisecontrol speed resumes automatically.

StandbyWhen no lead vehicle is detected, OnGuard ACCoperates similarly to conventional cruise control. Thecruise control set speed is shown on the OnGuarddisplay unit. See Fig. 6.22.

Lead Vehicle DetectedWhen a lead vehicle is detected in the lane ahead,the display shows that ACC is on and the radar istracking it. See Fig. 6.23.

If the driver uses the accelerator pedal to overridethe cruise control and approach a vehicle too closely,

CMS12/18/2014 f611143c

Fig. 6.19, CMS Standby (blue)

CMS

12/18/2014 f611143b

55 MPH

230FT

Fig. 6.20, CMS Lead Vehicle Detected (green)

12/18/2014 f611144a

CMS 15 MPH

15 FT

Fig. 6.21, CMS Collision Warning (red)

10/31/2014 f611145

Set: 60 MPH

Fig. 6.22, ACC Standby (blue)


6.9

the ACC will emit an audible alert and the displaybackground will turn yellow. The alert will end whenvehicle speed drops below the lead vehicle’s speedand the following distance is increased.

NOTE: The following distance alert does notoperate at speeds below 15 mph (25 km/h).

Collision WarningIf the lead vehicle is traveling slower than the driver’svehicle, the CMS warns of an impending collision byemitting an urgent audible alert and displaying thecollision warning symbol with a red background. SeeFig. 6.24.

The braking control will activate and slow the vehicle.The driver must also initiate braking.

Error ScreensIMPORTANT: The OnGuard collision safety sys-tem is not operational when an error screen isdisplayed. If a fault occurs or OnGuard fails toproperly track a vehicle, take the vehicle in for

service as soon as possible. Standard cruisecontrol will not function with an active OnGuardsystem fault.

If a system fault is detected, the OnGuard displayunit will immediately display an error screen asshown in Fig. 6.25. The first error code transmittedwill be displayed first; additional faults (if any) can beviewed using the up or down buttons. The displaydoes not show stored fault codes.

Refer to the OnGuard Collision Safety System Main-tenance Manual MM-0951 for a full list of faults(www.meritorwabco.com).

Additional FeaturesPress the MODE button to access the OnGuard dis-play unit additional features from the CMS or ACCmain operating screen. Press the up and down ar-rows to scroll through each menu, then press theMODE button to select the value to be changed. Inedit mode, press the up or down arrows to change avalue setting, then press the MODE button to savethe setting. Pressing MODE in each feature screenadvances the display to the next feature.

The Display Control menu allows adjustment of thealarm volume, LCD brightness, LCD contrast, andU.S./metric unit conversion. See Fig. 6.26.

The component test menu provides verification ofsystem component operation and acts as a valuableOnGuard system diagnostic tool. The header will dis-play either COMPONENT TEST or ACC FUNCTION,depending on the software release version of the On-Guard system. The component test screen shown inFig. 6.27 provides access to the following compo-nents (press the up or down arrows to scroll throughthe menu):

10/31/2014 f611146

Set: 60 MPH 55 MPH

230 FT

Fig. 6.23, ACC Lead Vehicle Detected (green)

10/31/2014 f611147

Set: 60 MPH 15 MPH

15 FT

Fig. 6.24, ACC Collision Warning (red)

10/31/2014 f611148

ACC1 Link Error

DATA ERROR

Fig. 6.25, OnGuard Error Screen (amber)


6.10

www.meritorwabco.com

• brake pedal position

• EBS brake switch

• CCVS brake switch

• clutch switch

• park brake switch

• accelerator pedal position

• driveline engaged

• cruise control enable

• cruise control set speed switch

• cruise control coast switch

• cruise control resume switch

• cruise control accelerate switch

• cruise control pause switch

Detroit Assurance RadarDetroit Assurance is a driver safety system on ve-hicles equipped with a Detroit engine and DT12 or a

manual transmission. The system uses a bumper-mounted radar and an optional windshield-mountedcamera to communicate information to the vehicles’sbrakes, engine, and transmission. The system cantrack forward-facing vehicles and objects up to 600feet (200 meters), and will sound a warning andapply the brakes, if necessary.

Driver Message CenterThe driver message center displays warnings andthe status of Adaptive Cruise Control (ACC) and/orLane Departure Warning. Refer to "Adaptive CruiseControl" and "Lane Departure Warning" for more in-formation.

To show distance, speed, and lane markings, scrollto the ACC menu using the + and – switchesmounted in the right-hand pod of the steering wheel.Refer to Chapter 4 for more information on drivermessage center controls.

Adaptive Cruise Control (ACC)

WARNINGThe Detroit Assurance system is intended solelyas an aid for an alert and conscientious profes-sional driver. It is not intended to be relied uponto operate a vehicle. Use the system in conjunc-tion with rearview mirrors and other instrumentsto safely operate the vehicle. Operate a vehicleequipped with the Detroit Assurance system as ifthe vehicle were not equipped with a collisionwarning system.

The Detroit Assurance system is not a substitutefor safe, normal driving procedures, nor will itcompensate for any driver impairment such asdrugs, alcohol, or fatigue.

The Detroit Assurance system will not warn ofhazards such as pedestrians, animals, oncomingvehicles, or cross traffic.


Safety InformationAdaptive cruise control (ACC) may not detect narrowvehicles driving in front like motorcycles, or vehiclesdriving in a different lane.

10/31/2014 f611149

DISPLAY CONTROL

Alarm Volume

Alarm Tone

10

4

LCD Intensity 9

Fig. 6.26, Display Control Menu

10/31/2014 f611151

COMPONENT TEST

CCVS Brake Switch

Brake Pedal Position

ON

37%

ON

EBS Brake Switch

Fig. 6.27, Component Test Menu


6.11

In particular, be aware of the following situations:

• cornering, entering, and exiting bends;

• vehicles driving in a different lane;

• vehicles changing lanes;

• vehicles exiting the road;

• overtaking;

• winding stretches of road; and

• obstacles and stationary vehicles.

Adaptive cruise control does not compensate for inat-tentive driving, weather, or traffic conditions. Theadaptive cruise control is only an aid. The driver isresponsible for maintaining a safe distance from thevehicle in front, maintaining a safe vehicle speed,and braking, and remaining in a lane.

If adaptive cruise control does not detect a vehicledriving in front, the system will accelerate to the setspeed.

OverviewSee Fig. 6.28 and Table 6.2 for a description ofcruise control steering wheel switches.

Steering Wheel ControlsDescription Function

ON/OFF Turns adaptive cruise control on or off.

DEC/SET

Sets the cruise speed while the vehicleis traveling at the desired speed.Pressing and and holding decreases theset cruise speed.

ACC/RESResumes the set speed. Pressing andholding accelerates the set cruisespeed.

CNCL Cancels the set speed.

Table 6.2, Steering Wheel Controls

When a vehicle in front is detected, the driver mes-sage center displays the speed of the detected ve-hicle and the distance to the detected vehicle. SeeFig. 6.29.

Functions and Activation ConditionsACC controls speed, and the distance from a vehicledetected in front.

If there is no vehicle in front, ACC operates in thesame way as cruise control when the vehicle is trav-eling above 10 mph (15 km/h).

If ACC detects a vehicle in front driving at a slowerspeed, the brakes are applied, the engine is der-rated, the engine brakes are used, and the vehicle isslowed to maintain the minimum following distance. Ifthe vehicle in front is no longer detected, the vehiclewill accelerate to the set speed. The ACC will alsoslow the vehicle if it exceeds the set speed (on adownhill grade, for example).

ACC cannot be activated, or is automatically deacti-vated, if:

• the vehicle is traveling slower than 10 mph (15km/h);

01/15/2015 f462049b

ON/OFF

ACCRES

CNCL

DEC/SET

Fig. 6.28, Steering Wheel Cruise Control Switches

02/04/2015 f611281

Fig. 6.29, Adaptive Cruise Control Screen


6.12

• the transmission is in neutral for more than 5seconds;

• reverse gear is selected;

• ABS is deactivated;

• there is a malfunction in the brake system orthe electronic management system; or

• the distance sensor initialization is not yet com-plete.

Activating Adaptive Cruise ControlPress the ON/OFF switch on the steering wheel toactivate cruise control.

If the brake pedal is pressed, ACC is deactivatedautomatically.

Setting the SpeedDrive at the desired speed, then press the DEC/SETswitch. Cruise control will be activated and the setspeed stored.

If cruise control is deactivated, the stored speed canbe activated again by pressing the ACC/RES switch.The driver message center will show the cruise con-trol symbol and display the set speed. Cruise controlwill automatically brake or accelerate the vehicle tomaintain the set speed.

Increasing or Reducing SpeedThe speed setting can only be set by when driving.

Press DEC/SET to set the cruise speed while thevehicle is traveling at the desired speed. Press andhold to decrease the set cruise speed.

Setting the Distance to the Vehicle in FrontThe optional headway switch can be used to set thedistance to the vehicle in front. See Fig. 6.30. Theminimum distance for ACC can be set to 5 levels.

IMPORTANT: Make sure that the minimum dis-tance is maintained to the vehicle in front re-quired by law. Adjust the specified minimum dis-tance to the vehicle in front if necessary.

Press + or – on the headway switch to increase ordecrease the specified minimum distance. The drivermessage center will show the selected minimum dis-tance. The setting will be stored automatically.

Collision WarningsA warning appears in the driver message center anda double warning tone sounds in the event of a po-tential collision. See Fig. 6.31. The event screen isdisplayed for as long as the hazardous situationpersists.

If a collision warning appears in the driver messagecenter when the vehicle is in motion, pay attention tothe traffic situation and reduce vehicle speed usingthe service brake. If the accelerator pedal is pressed,or a turn is indicated, the collision avoidance systemis suppressed.

Overtaking

NOTE: It is possible to exceed the set speedwhen overtaking.

The set speed can be exceeded using the accelera-tor pedal. When the accelerator pedal is released,the set speed will be resumed.

Deactivating the SystemPress the ON/OFF switch, or, press the brake pedalto deactivate cruise control.

HDWY−

f61128301/15/2015

HDWY+

Fig. 6.30, Headway Switch

01/15/2015 f611282

Fig. 6.31, Collision Warning Event Screen


6.13

NOTE: The speed remains stored when ACC isdeactivated.

Active Brake Assist (ABA)Safety Information

WARNINGActive brake assist is intended only as an aid fora conscientious and alert driver. ABA does nottake road and weather conditions into account,nor the prevailing traffic situation. The driver isresponsible for keeping a safe distance to thevehicle in front, for the vehicle speed, braking ingood time, and remaining in lane. The drivershould always adapt driving style to suit prevail-ing road and weather conditions.

ABA is not a substitute for safe driving proce-dures.


IMPORTANT: Do not mount any attachments infront of the distance sensor. Do not paint or affixitems over the distance sensor cover. If attach-ments are mounted in front of the distance sen-sor, such as a crash guard, they can impair theoperation of the distance sensor.

ABA can minimize the risk of a front-end collisionwith a moving vehicle, a stationary vehicle, or a sta-tionary object. If ABA detects the risk of a front-endcollision, it issues an audible and visual warning. Ifthe risk persists, ABA automatically initiates partialbraking of the vehicle. If the driver does not react tothe warnings and partial brake application, ABA auto-matically initiates a full brake application.

ABA may not detect narrow vehicles driving in frontlike motorcycles, or vehicles driving on a differentline.

ABA does not automatically adapt to road and trafficconditions. Brake the vehicle using the service brakeif:

• an event window with the Warning symbol ap-pears in the driver message center;

• an intermittent warning tone sounds; or

• an intermittent warning tone sounds and auto-matic partial braking was initiated.

If no visual and/or acoustic warning is issued in acritical situation:

• ABA has not recognized the danger of the situ-ation;

• ABA is suppressed; or

• ABA has failed.

ABA-triggered emergency braking can be deactivatedif the driver presses the accelerator pedal beyond thepressure point (kickdown).

IMPORTANT: Adaptive cruise control may warnthe driver before active brake assist if there is arisk of collision.

Activating/Deactivating Active BrakeAssistThe ABA system cannot be turned off. However, ABAis suppressed when the driver:

• uses the turn signal during an audible warning;

• presses the brake pedal; or

• rapidly depresses the accelerator.

If there is a system error, the indicator lamp will illu-minate. See Fig. 6.32.

Collision Warning and EmergencyBrakingIf there is a risk of collision and ABA issues a warn-ing, the radio and/or hands-free systems like DetroitConnect are automatically muted.

f611286a01/28/2015

A

Fig. 6.32, ABA Indicator Lamp


6.14

• Preliminary Warning (ACC): A warning ap-pears in the driver message center with analert that the forward vehicle is too close.

• Warning (ABA): An alert appears in the drivermessage center, the radio is muted, and abuzzer is activated.

• Partial Braking (ABA): An alert appears in thedriver message center, and an intermittentwarning tone sounds. In addition, ABA slowsthe vehicle with automatic partial braking. ABAbrakes the vehicle with around 50% of the ve-hicle’s maximum braking power.

• Emergency braking (ABA): If the driver doesnot react to the collision warnings or partialbrake application, ABA automatically initiatesemergency braking (full brake application). Thewarning message appears in the driver mes-sage center, and a continuous warning tonesounds.

CAUTIONAfter emergency braking, the "Emergency Brak-ing Finished" message appears in the event win-

dow in the driver message center. The vehicle isheld by the service brake for another 5 secondsto prevent it from rolling away. If an emergencybraking maneuver has been performed, removethe vehicle from the area of danger as soon aspossible while paying attention to the traffic situ-ation. Stop the engine and apply the parkingbrake to prevent the vehicle from rolling away.Make sure that the vehicle is in proper operatingorder and that the load is secured properly.

The driver can interrupt emergency braking by press-ing the accelerator pedal beyond the point of resis-tance (kickdown).

Driving SituationsSee Table 6.3 for a description of adaptive cruisecontrol and active brake assist limitations in specificdriving conditions.

Active Brake Assist LimitationsCondition Visual Description

Cornering, enteringand exiting bends

12/18/2014 f040840a

The ability of ABA and ACC to detect vehicles on bends islimited. ABA and ACC may unexpectedly issue warnings orbrake the vehicle. ACC may also accelerate the vehicleunexpectedly.

Driving in a differentlane, and stationaryvehicles

12/18/2014 f040835a

The ability of ABA and ACC to detect vehicles driving in adifferent lane, or stationary vehicles is limited. ABA andACC may unexpectedly issue warnings or brake the vehicle.ACC may accelerate unexpectedly.


6.15


Other vehicleschanging lane

12/18/2014 f040836a

The ability of ABA and ACC to detect vehicles pulling intoyour lane is limited. The distance to the vehicle in frontentering your lane may then be too short. ABA and ACCmay unexpectedly issue warnings or brake the vehicle. ACCmay also accelerate the vehicle unexpectedly.

12/18/2014 f040841a

The ability of ABA and ACC to detect vehicles pulling intoyour lane without maintaining a safe distance is limited.They do not detect vehicles until they are within thesystem’s detection range. ACC may accelerateunexpectedly. Brake the vehicle. This will increase thedistance to the vehicle in front.

Vehicles turning off

12/18/2014 f040843a

The ability of ABA and ACC to detect vehicles turning off islimited. ABA and ACC may unexpectedly issue warnings orbrake your vehicle.

Overtaking

12/18/2014 f040838a

When passing, ABA and ACC may unexpectedly issuewarnings or brake your vehicle if the vehicle is too close tothe vehicle in front, and is in the same lane.

Winding stretches ofroad

12/18/2014 f040844a

On winding stretches of road, ABA and ACC cannot detectwhich lane the vehicle in front is driving in. ABA and ACCmay unexpectedly issue warnings or brake your vehicle.ACC may also accelerate the vehicle unexpectedly.

Obstacles andstationary vehicles

12/18/2014 f040837a

ABA and ACC cannot detect obstacles or stationaryvehicles in front of the detected vehicle. ABA and ACC mayunexpectedly issue warnings or brake your vehicle. ACCmay also accelerate the vehicle unexpectedly.


6.16


Stationary objects

12/18/2014 f040842a

ABA can also unexpectedly issue warnings and brake thevehicle if it detects stationary objects like:

• vehicles which have broken down

• signs

• bridges

Table 6.3, Active Brake Assist Limitations

Lane Departure Warning (LDW)

WARNINGThe optional lane departure warning system isintended only as an aid for a conscientious andalert driver. The system may not indicate lane de-partures under certain conditions. Read the infor-mation in this manual to understand the circum-stances under which this system may notprovide adequate lane departure warnings. Donot rely solely on the system to safely operatethe vehicle. The system does not warn of all pos-sible hazards. For example, the system cannotprevent an accident if the driver is impaired ornot driving safely.

The lane departure warning system is not a sub-stitute for safe driving procedures.


Safety NotesThe system may be impaired or may not operate inthe following situations:

• when there is low visibility due to insufficientroad illumination, or due to snow, rain, fog orheavy spray

• when there is glare due to oncoming traffic,direct sunlight, or reflections from wet road sur-faces

• when the windshield in the area of the camerais dirty, misted up, damaged or covered by asticker

• when no lane markings or several varied lanemarkings are present, such as in a construc-tion zone

• when the lane markings are worn, dark or cov-ered, for example by dirt or snow

• when the distance from the vehicle in front istoo small and this prevents the lane markingsfrom being detected

• when the lane markings change rapidly, whenlanes branch off, or when they cross or merge

• when lanes are very narrow or winding

• when shade conditions on the road surfacechange greatly

The driver must adapt their driving style to currentconditions. Lane departure warning cannot take theroad and weather conditions into account, nor theprevailing traffic situation. The driver is responsiblefor the distance to the vehicle in front, for vehiclespeed, braking in good time and remaining in lane.

Functions and Activation ConditionsLane departure warning monitors the area in front ofthe vehicle with a camera that is on the top of thewindshield. When lane departure warning is activatedand it detects lane markings on the road surface, itwarns the driver that they may be leaving the laneunintentionally.

Lane departure warning issues warnings if the speedis above approximately 37 mph (60 km/h).

When driving over lane markings unintentionally, thevolume of audio equipment like the radio and/orhands-free systems is reduced, and a direction-related "rumble-strip noise" sounds from the left orright overhead speaker.


6.17

NOTE: The Detroit Assurance LDW system isdesigned to warn the driver as the vehiclecrosses the outer boundary of the lane marking.This may differ from other LDW systems whichissue a warning as the driver approaches theinside of the lane marking. If the system warnsat, or just beyond the outer edge of the lanemarking, the system is performing as designed.If the warning does not occur, or occurs after anexcessive lane departure, the system may notbe operating properly.

Lane departure warning does not issue a warning if:

• the turn signals are switched on;

• there is braking or acceleration; or

• a driving safety system such as ABA, StabilityControl, or ACC intervenes.

Lane departure warning will issue a warning if a turnsignal has been switched on for more than 1 minute.

Activating or DeactivatingWhen the engine is turned on, LDW is automaticallyactivated. Pressing the lane alert switch will deacti-vate LDW for a minimum of 15 minutes. SeeFig. 6.33.

LDW is not active if:

• the driver presses the lane alert switch; or

• the system is searching for a lane.

If there is a system error, the LDW indicator lamp willilluminate. See Fig. 6.34.

Cleaning the Distance Sensor and theCameraTo avoid malfunctions, clean the cover of the dis-tance sensor regularly.

Regularly clean the area of the windshield used bythe camera to avoid incorrect lane detection.

If the area of the windshield is damaged, the functionof the lane departure warning could be restricted. Ifthis happens, the windshield must be replaced.

Make sure that the windshield is always kept cleanand unobstructed in the area of the camera. Thedriver can switch on the windshield wiper to cleanthe windshield, for example, or remove snow and icefrom the windshield.

Roll Stability SystemThe roll stability system may include the roll stabilityadvisor (RSA) only, or it may also include the roll sta-bility control (RSC).

A decal (Fig. 6.35) on the auxiliary dash panel, andan amber-colored dash indicator light (Fig. 6.36), in-dicate that the vehicle is equipped with roll stabilitysystem components.

Roll Stability AdvisorIMPORTANT: This is not an advance warningsystem. The roll stability advisor displays a mes-sage only after the driving maneuver is com-pleted.

The roll stability system uses a lateral-accelerationsensor that monitors rollover risk. Shortly after acurve, lane change, or other driving maneuver that

LANEALERT

f61128401/15/2015

Fig. 6.33, Lane Alert Switch

f611285a01/28/2015

Fig. 6.34, LDW Indicator Lamp


6.18

results in a rollover-risk detection, a dash warninglight illuminates, an audible tone sounds, and a driveradvisory message is displayed in the driver messagecenter. The purpose is to advise the driver that theprevious maneuver produced a rollover risk.

The roll stability advisor displays different text mes-sages depending on the severity of the risk of eachoccurrence of risky driving. From the highest risklevel to the lowest risk level, the system will soundan audible alert, and display a message, as shown inFig. 6.37.

NOTE: The system will calculate and recom-mend a speed reduction value. It may be differ-ent than the values shown here.

Bring the vehicle to an authorized service facility if asystem failure message is displayed.

Roll Stability Control

WARNINGThe Roll Stability Control system is intended onlyas an aid for a conscientious and alert driver.Carefully read the information in this manual to

understand this system and its limitations. TheRoll Stability Control system is not a substitutefor safe driving procedures. Failure to drive

lamp indicates tractionOR roll control event.Follow instructions indriver’s manual.

24−01204−000

07/11/2003 f080125

SAFETY INSTRUCTIONS

Fig. 6.35, Roll Stability Decal

06/26/2003 f602128

Fig. 6.36, Roll Stability Indicator Lamp

Message to Display

4 1

MessageMSG

No.

System Fault1WARNING

RAC SYSTEM FAIL

ACTIVE SLOWING

ROLLOVER RISK

4 NoneRSC2

VERY HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

19.6 10RSA Level 33

HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

14 5RSA Level 24

ROLLOVER RISK

DETECTED

REDUCE SPEED

AT LEAST 11 KPH

or in metric

REDUCE SPEED

AT LEAST 7 MPH

8.4 2RSA Level 15

HARD BRAKING WITH

ABS ACTIVATED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 36

HARD BRAKING

DETECTED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 27

LOSS OF TRACTION

ABS ACTIVATED

ROAD SURFACE

MAY BE POOR

14 0.5HBED Level 18

07/25/2008 f040769

DisplayTime:

Seconds

BuzzerTime:

Seconds

Fig. 6.37, Roll Stability and Hard-Braking Warnings


6.19

safely, and use the system properly, could resultin personal injury and/or death and propertydamage.

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

The dash indicator light illuminates whenever the rollstability control system intervenes.

Hard-Braking AdvisorThe hard-braking advisor uses the information fromthe ABS wheel speed sensors to determine whenbraking is severe enough to produce lockup at oneor more wheels on the tractor, and/or very rapid ve-hicle deceleration. Shortly after a hard-braking eventoccurs, an advisory message is displayed in thedriver message center, indicating that the brakingbehavior was too aggressive for the current road sur-face conditions. This system is not a replacement fora driver’s good judgment. Sometimes it is necessaryto brake hard.

From the highest risk level to the lowest risk level,the system will sound an audible alert, and display amessage, as shown in Fig. 6.37.

Trip/Leg TotalsThe driver message center records the number ofmessages received, and displays the number ofmessages as counts. Roll stability advisor (RSA) andhard-braking event data (HBED) counts can beviewed in the trip advisory screen, and the leg advi-sory screen.

Counts can be reset using the + key on the steeringwheel. Clearing RSA and HBED leg counts will alsoreset the leg miles and leg hours. Clearing RSA andHBED trip counts will also reset trip miles, trip hours,leg miles, leg hours, and leg advisory counts. In ad-dition, resetting leg miles will clear leg counts. Clear-ing trip miles will reset miles, hours, and counts inboth the leg and trip screens.

The TRIP and LEG advisor screens count both theroll stability advisories (ROLL) and hard-brakingevents (BRK). For example, if during a TRIP, thedriver message center recorded the events inTable 6.4, the message center would display asshown in Fig. 6.38.

RSA/HBED CountMessage Received Message Counts

RSA Level 3 2RSA Level 2 3RSA Level 1 7

HBED Level 3 5HBED Level 2 1HBED Level 1 8

Table 6.4, RSA/HBED Count

If the count reaches more than 9 occurrences an up-arrow symbol will appear, to indicate to the driverthat the count has exceeded 9 counts. SeeFig. 6.39.

Enhanced Stability Control

WARNINGEnhance Stability Control (ESC) is intended onlyas an aid for a conscientious and alert driver.Carefully read the information in this manual tounderstand this system and its limitations. ESCis not a substitute for safe driving procedures.

07/25/2008

TRIP ADVISORIES

237 ROLL 518 BRK

f040770A B C D E F

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. 6.38, Trip Advisor Message Screen

07/25/2008

TRIP ADVISORIES

23 ROLL 518 BRK

f040771A

A. RSA Lev. 1 has more than 9 counts.

Fig. 6.39, Trip Advisor Message Screen (more than 9counts)


6.20

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

ESC offers the full capability of RSC (shown above)with the added capability of complete directional sta-bility (yaw control) in oversteer and understeer condi-tions to reduce the likelihood of drift-out or jackknife.The system determines where the driver is attempt-ing to steer the vehicle and how much brake demandis required in order to more precisely control the ve-hicle in an emergency situation.

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

When the system detects that the vehicle is at risk ofoversteering or understeering, it applies individualtractor wheel end brakes and trailer brakes, activatesthe engine retarder (if equipped), and/or cuts enginepower, depending on the severity. As a result, thedriver has full control over the vehicle until the sys-tem detects a potential risk and intervenes accord-ingly. ESC operates automatically; the driver doesnot monitor or activate the system.

Detroit Connect TabletThe Detroit Connect on-board tablet is an optionalfeature that tracks hours of service, posts driveralerts, documents pre- and post-trip vehicle inspec-tions, and provides advanced navigation. SeeFig. 6.40.

The tablet operates in conjunction with Virtual Tech-nician to provide communication between drivers andfleet managers.

Refer to Zonar® user documentation for more infor-mation.

11/19/2014 f546116

Fig. 6.40, Detroit Connect Tablet


6.21

7

Seats and RestraintsSeats, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Cascadia 2.0 High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Cascadia High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Sears Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Steering Wheel Air Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8RollTek Rollover Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

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

Due to the high degree of adjustability of mid- andhigh-back air suspension seats, it is possible to com-bine the seat back recline adjustment and the seatslide adjustment so that the seat back contacts theback wall. Use care when adjusting the seat to pre-vent damage to the seat and the cab interior.

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

The following is a description of adjustments that canbe made to various Freightliner-installed seats. Notall seats have all of the adjustments listed below.See Fig. 7.1.

• Backrest Tilt enables the backrest to pivot for-ward or backward.

• Lumbar Support changes the shape of thebackrest to give more or less support to theoccupant’s lumbar (lower back) area. This ad-justment is either mechanical or air controlled,depending on the seat model.

• Fore/Aft Isolator feature reduces the amount ofroad shock by isolating the occupant from themotion of the vehicle, and allowing the upperseat to move in a simple pendulum motion. Alockout feature is used whenever the isolator isnot desired.

• Height Adjustment moves the entire seat up ordown. The adjustment is either manually- orair-controlled, depending on the seat model.

• Bottom Cushion Angle (fore-and-aft bottomcushion height) enables the occupant to raiseor lower the front or back of the bottom cush-ion. This adjustment is easier to perform whenall weight is removed from the seat.

• Fore/Aft Seat Slide (seat track adjustment)moves the entire seat forward or backward onits track.

10/26/2000 f910149a

1

2

3 4

56 7

8

1. Backrest Tilt2. Lumbar Support3. Fore/Aft Isolator4. Height Adjustment

5. Bottom Cushion Tilt (fore-and-aftcushion height)

6. Fore/Aft Seat Slide (seat trackadjustment)

7. Seat Tilt8. Headrest Adjustment

Fig. 7.1, General Seat Adjustments

Seats and Restraints

7.1

• Seat Tilt allows the seat assembly (back andbottom cushions) to tilt forward or backward.

• Headrest Adjustment changes the angle of theupper part of the backrest to provide head andupper back support.

Cascadia 2.0 High-Back SeatSee Fig. 7.2 for seat adjustment controls. Not allmodels of the Cascadia 2.0 Hi-Back seat have all theadjustments listed below.

ReclinePull the recline handle to adjust the backrest tilt.

Seat Heating/VentilationUse the forward switch to turn the seat heater andventilation ON or OFF. To turn on the heat, push thetop of the switch. To turn on the ventilation, push thebottom of the switch. To turn off the heat or ventila-tion, move the switch to the middle position. To ad-just the heat or ventilation, Use the rear button toadjust seat heating or ventilation. Three settings areavailable: low, medium, and high. See Fig. 7.3.

NOTICEDo not install seat covers on seats with heatingand ventilation. Do not cover the seat with blan-kets, clothing, or pillows. Blocking the air flowthrough the cushions can overheat and damagethe seat.

IMPORTANT: Turn off seat heating/ventilationwhen the seat is unoccupied.

Lumbar SupportPress the forward button to adjust lower lumbar sup-port, the middle button to adjust upper lumbar sup-port, and the rear button to adjust side support.

Height AdjustmentPull or push the lever to adjust seat height.

Shock Absorber AdjustmentMove the lever down to increase damping on roughroads, or up to decrease damping on flat roads.

Fore/Aft IsolatorRotate the isolator knob to the left to lock the isola-tor, or to the right to allow movement.

05/11/2012 f910682

12

34

567

89

10

1. Recline Handle2. Heat/Ventilation Adjustment Switch3. Heat/Ventilation ON/OFF Switch4. Lumbar and Side Support Switches5. Height Adjustment Lever6. Shock Absorber Adjustment Lever7. Fore/Aft Isolator Lever8. Bottom Cushion Extension Lever9. Seat Fore/Aft Slide Lever10. Seat Tilt Lever

Fig. 7.2, Cascadia 2.0 Hi-Back Seat


7.2

Bottom Cushion ExtensionPull the lever to move the seat cushion forwards orbackwards. The cushion moves 2-3/8 inches (60mm) in 3/8-inch (10-mm) increments.

Seat Fore/Aft SlideLift the lever to slide the seat forward or backward.Release the lever to lock the seat in position.

Seat TiltPull the lever and lean back to tilt the seat back-wards. Three positions are available.

Armrest AngleTo adjust the armrest angle, tilt the armrest to thehighest position, then down to the lowest position,then to the desired position.

Cascadia High-Back SeatSee Fig. 7.4 for seat adjustment controls.

Backrest TiltTo tilt the backrest, lean forward slightly to removepressure from the cushion, then turn the knob for-ward or rearward to achieve the desired position.

Lumbar SupportTo adjust the lumbar support, use the lumbar supportswitches on the side of the seat.

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

Bottom Cushion ExtensionTo adjust the fore-and-aft position of the seat cush-ion, remove your weight from the seat, then lift upand pull forward on the cushion adjustment handle.To return the cushion to the aft position, lift up andpush rearward.

Fore/Aft Seat SlideTo adjust the fore-and-aft position of the entire seat,move the fore-and-aft seat adjustment lever to theleft and slide the seat forward or backward to thedesired position. Move the lever back to its originalposition to lock the seat in place.

Fore/Aft IsolatorTo engage the isolator, turn the isolator knob rear-ward to the unlocked position. Turn the isolator knobforward to the locked position when the isolator fea-ture is not desired.

Shock AbsorberTo adjust the amount of damping the shock absorberprovides, move the lever up to increase damping;move the lever down to decrease damping.

Front Cushion HeightTo adjust the height of the front of the cushion, re-move your weight from the seat, then turn the adjust-ment knob toward the front of the seat (clockwise) toincrease cushion height. To lower the cushion height,turn the adjustment knob toward the rear of the seat(counterclockwise).

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

05/08/2012 f910683

1

2

3

4 5

1. Ventilation ON2. Heat/Ventilation OFF3. Heat ON4. Heat/Ventilation ON/OFF Switch5. Heat/Ventilation Adjustment Switch

Fig. 7.3, Cascadia 2.0 Hi-Back Seat Heat/VentilationControls


7.3

HeaterTo turn on the heat option, press the button. To turnoff the heat option, press the button again. If the ve-hicle has Optimized Idle, seat heating will not oper-ate with the key in accessory mode. Optimized Idlemay also turn seat heating off to reduce stress onthe batteries. Refer to Chapter 11 for more informa-tion.

Sears Atlas SeatSee Fig. 7.5 for seat adjustment controls.

Backrest TiltPull upward on the recliner handle, move the back-rest to the desired position and release the handle.

Lumbar SupportRear rocker switch: Push forward to inflate the lowerlumbar bag; push rearward to deflate the bag. Centerrocker switch: Push forward to inflate the upper lum-bar bag; push rearward to deflate the bag.

Fore/Aft Seat SlideTo adjust the fore-and-aft position of the entire seat,squeeze the fore/aft slide lock against the adjustmentbail, and lift the bail up. See Fig. 7.6. Slide the seat

f910576

5

4

78

9

10

6

07/18/2007

1

2

3

1. Rear Cushion Height AdjustmentKnob

2. Fore/Aft Isolator3. Front Cushion Height Adjustment

Knob

4. Bottom Cushion Extension Handle5. Fore/Aft Seat Slide Lever6. Backrest Tilt Knob7. Heater Button

8. Shock Absorber Lever9. Height Adjustment Switch10 Lumbar Support Switches

Fig. 7.4, Cascadia Hi Back Seat


7.4

forward or backward to the desired position. Releasethe bail and fore/aft slide lock, to its original position,to lock the seat in place.

Bottom Cushion TiltLift the handle upward and move the seat cushion tothe desired position. Three positions are available.

Armrest AngleRotate the control knob, located on the underside ofthe armrest, to set the desired angle of the armrest.

IsolatorPosition the handle to the left to allow isolationmovement. Position the handle to the right to lock-out isolation movement.

Suspension Inflation/DeflationPush forward on the gray rocker switch to inflate andraise the suspension; push rearward to deflate andlower the suspension.

Seat ExtensionRotate the handle upward to disengage, then movethe seat cushion to the desired position and releasethe lever. Three positions are available.

Seat Belts and Tether BeltsSeat belt assemblies are designed to secure personsin the vehicle to help reduce the chance of injury, orthe amount of injury, resulting from accidents or sud-den stops. For this reason, Daimler Trucks NorthAmerica LLC (DTNA) urges that the driver and allpassengers, regardless of age or physical condition,use seat belts when riding in the vehicle.

10/15/2007 f910597

12

34

5

6

7

1. Isolator Lever2. Fore/Aft Seat Slide

Lever3. Bottom Cushion Tilt

Handle4. Seat Extension Lever

5. Backrest Tilt Lever6. Lumbar Support

Switches7. Suspension Inflation/

Deflation Switch

Fig. 7.5, Sears Atlas Seat

10/15/2007 f910599

A

B

A. Squeeze the fore-and-aft slide lock against theadjustment bail.

B. Lift up the adjustment bail.

Fig. 7.6, Fore/Aft Slide Adjustment, Sears Atlas Seat


7.5

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

Seat belt assemblies in DTNA vehicles meet FederalMotor Vehicle Safety Standard 209, "Type 1" and"Type 2" requirements.

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

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

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

Seat Belt Inspection

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

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

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

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

3. Check the seat belt and tether belt connectionpoints and tighten any that are loose.

Seat Belt Operation

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

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

When engaged and used properly, the Komfort Latch(Fig. 7.7) and the Sliding Komfort Latch (Fig. 7.8)introduce a small amount of slack into the seat belt,resulting in a more comfortable ride.

1. Slowly pull the link end of the seat belt out of theretractor and pull it across your lap (from out-board to inboard) far enough to engage thebuckle. If the retractor locks too soon, allow thebelt to retract slightly, then slowly pull it outagain. See Fig. 7.9.

2. Fasten the seat belt by pushing the latch into thebuckle. Listen for an audible click.

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

4. Snug the seat belt to your waist.


7.6

WARNINGBefore activating the Komfort Latch or the Slid-ing Komfort Latch, make sure the amount of

slack in the shoulder strap is set as describedbelow. Excess slack in the shoulder strap re-duces the effectiveness of the seat belt, and in-creases the risk of injury or death in an accident.

5. Position the shoulder strap diagonally acrossyour chest with the adjustable D-loop bracket (ifequipped). The shoulder strap must be centeredon your shoulder and chest, away from your faceand neck. See Fig. 7.10. If desired, engage theKomfort Latch or Sliding Komfort Latch as fol-lows.

If equipped with a Sliding Komfort Latch, makesure that the shoulder strap is snug against yourchest. Without loosening the shoulder strap,push the Sliding Komfort Latch switch to the"ON" position. See Fig. 7.8. To activate the latchlean forward until you hear a click. This will allow

03/11/2010 f910620

A B

A. Disengaged B. Engaged

Fig. 7.7, Komfort Latch

11/18/2010 f910621a

Fig. 7.8, Sliding Komfort Latch

07/02/2007 f910578

1

2

1. Latch 2. Buckle

Fig. 7.9, Three-Point Seat Belt Operation


7.7

for approximately 1 inch (2.5 cm) of slack be-tween your chest and the shoulder harness.Once engaged, the latch will allow you to leanforward about 5 inches (13 cm) without having toreset the latch. Leaning forward more than 5inches (13 cm) will disengage the Sliding Kom-fort Latch, requiring it to be reset.

If equipped with a Komfort Latch, pull on theshoulder strap to lessen the pressure of the strapon your shoulder and chest. Allow no more than1 inch (2.5 cm) of slack between your chest andthe shoulder harness. More slack can signifi-cantly reduce the seat belt effectiveness in anaccident or a sudden stop. While holding the beltslack, press the Komfort Latch lever up, clamp-ing the seat belt webbing (Fig. 7.11 andFig. 7.12).

6. Unbuckle the seat belt and release the KomfortLatch or the Sliding Komfort Latch as follows.

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

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

NOTE: Neither the Komfort Latch nor the SlidingKomfort Latch need to be manually released inan emergency situation. Each will release by

itself under rough road or other abnormal condi-tions. Make sure the seat belt is completely re-tracted when it is not in use.

Steering Wheel Air BagOperationNOTE: Only vehicles with the letters "SRS"molded into the steering wheel center pad areequipped with a steering wheel air bag.

The air bag, when used with seat belts, provides ad-ditional protection to the driver in severe frontal colli-sions. Steering wheel air bags are designed to inflateonly in severe frontal collisions. The driver and the

08/09/2010 f910634A B C

A. Correct—Belt is centered on your shoulder andchest, 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. 7.10, Proper Shoulder Strap Fit

A

01/06/95 f910048a

A. 1 Inch (2.5 cm) Maximum

Fig. 7.11, Adjusting Shoulder Harness Clearance,Komfort Latch

11/02/95 f910144

Fig. 7.12, Locking the Komfort Latch


7.8

passenger should always wear seat belts. The steer-ing wheel air bag will activate during a collision evenif the seat belts are not fastened, but the system isdesigned to provide protection to the occupant onlywhen the seat belts are fastened.

WARNINGKeep all heavy objects in the cab secured. Do notplace objects on the steering wheel or betweenyou and the steering wheel. Any such objectsmay cause harm during an accident. Keep yourhands on the sides and lower portion of thesteering wheel. Failure to follow these instruc-tions may result in death or personal injury.

For maximum protection in a collision, always be in anormal seated position with your back against theseat back and your head upright. Fasten your seatbelt and ensure that it is properly positioned on yourbody as described under the "Seat Belt Operation"heading. Since the air bag inflates with considerablespeed and force, a proper seat position will helpkeep you a safe distance from the inflating air bag.

Inspection and Service

WARNINGDo not attempt to service or modify the air bagsystem. Unintentional or improper air bag deploy-ment could cause severe bodily injury or death.Contact an authorized Freightliner service facilityfor all service and maintenance.

The air bag system contains components thatuse combustible chemicals. Do not cut, drill,braze, solder, weld, strike, or probe the air bagcomponents. Keep all liquids and chemicalsaway from air bag components.

The surface of the deployed air bag may containsmall amounts of sodium hydroxide (which is aby-product of the gas generant combustion) andmetallic sodium. Sodium hydroxide may be irri-tating to the skin and eyes. Immediately washyour hands and exposed skin areas with a mildsoap and water. Flush your eyes immediately ifexposed to sodium hydroxide.

The operational readiness of the air bag system isindicated by the supplemental restraint system (SRS)indicator on the dash. The SRS indicator illuminates

for several seconds when the ignition is turned on,and then it goes off. The indicator will remain on ifthere is a problem with the air bag system. The ve-hicle should be serviced if the SRS indicator doesnot illuminate when the ignition is turned on, or if theSRS indicator remains on.

The air bag module may contain perchlorate mate-rial; for information, see www.dtsc.ca.gov/hazardouswaste/perchlorate. Special handling mayapply; follow appropriate rules and regulations whendisposing of materials.

For all service and maintenance, contact an autho-rized Freightliner service facility.

RollTek Rollover ProtectionSystemIdentificationOnly seats with the RollTek module under the seatand the molded side-roll air bag cover on the upperside of the seat back are equipped with the RollTekrollover protection system; see Fig. 7.13. RollTekmay be installed in one of the following configura-tions:

• driver seat only or driver and passenger seats

• driver seat only, with an optional steeringwheel frontal air bag

• driver and passenger seats, with an optionalsteering wheel frontal air bag

OperationThe RollTek system, when used with seat belts, pro-vides additional protection to the driver and passen-ger (if equipped with a passenger-side system) inrollover accidents. The RollTek system provides asignificant increase in seat stability during a rollover.Vehicles equipped with RollTek rollover protectionhave a sensor mounted in the seat base that acti-vates the side-roll air bag and seat pull-down deviceduring a rollover.

When the RollTek module senses a rollover, themodule triggers gas cylinders mounted in the base ofthe seat. The gas cylinders activate the powercinches that then tighten the lap and shoulder beltsagainst the occupant of the seat and lower the seatsuspension, moving the occupant down and awayfrom the steering wheel and ceiling. The side-roll air


7.9

www.dtsc.ca.gov/hazardouswaste/perchlorate


bag deploys from the outboard side of the seat asthe seat is pulled down to its lowest position. SeeFig. 7.14.

WARNINGAlways use the seat belts when operating the ve-hicle. Failure to do so can result in severe per-sonal injury or death. Do not place infants andchildren in seats equipped with the RollTek sys-tem. The RollTek system is designed for adultsonly. Doing so could result in severe bodily in-jury or death. Keep all heavy objects in the cabsecured. Do not place objects on the seat back

or block the side-roll air bag. Objects that blockthe side-roll air bag may prevent proper inflationand could result in serious injury or death.

The RollTek system will activate during a rollovereven if the seat belts are not fastened, but theRollTek system is only designed to provide protectionto the occupant when the seat belts are fastened.

For vehicles with the RollTek system(s) only, de-vice(s) deploy as follows:

• Rollover Crash—occupant seat belt pretension-ing, seat pretensioning, and side-roll air bag atthe proper time

• Frontal Crash—no devices deployed

10/15/2007 f9105981

2

1. RollTek Module2. Side-Roll Air Bag Cover

Fig. 7.13, RollTek Protection System Components

07/03/2007

A

B

f910579

A. Side-roll air bag contained in seat.B. Side-roll air bag deployed.

Fig. 7.14, Side-Roll Air Bag


7.10

For vehicles with the RollTek system(s) and frontalsteering wheel air bag, device(s) deploy as follows:

• Rollover Crash—occupant seat belt pretension-ing, seat pretensioning, and side-roll air bag atthe proper time

• Frontal Crash—steering wheel air bag, occu-pant seat belt pretensioning, seat pretension-ing, and the side-roll air bag at the proper time

Inspection and Service

WARNINGKeep hands and tools away from the scissorpoints under the seats.

The RollTek system contains components thatuse combustible chemicals. Do not cut, drill,braze, solder, weld, strike, or probe any part ofthe RollTek system. Keep all liquids and chemi-cals away from the RollTek components.

Do not attempt to service or modify the RollTeksystem. Unintentional or improper deployment ofthe RollTek system could cause severe bodilyinjury or death. Contact an authorized Freight-liner service facility for all service and mainte-nance.

IMPORTANT: The RollTek system must be re-placed after being activated. Damaged seatbelts and tethers, or seat belts and tethers thatwere worn in an accident, must be replaced,and their anchoring points must be checked.

The operational readiness of the RollTek system isindicated by the supplemental restraint system (SRS)indicator on the dash. The SRS indicator illuminatesfor several seconds when the ignition is turned on,and then it goes off. The indicator will remain on ifthere is a problem with the air bag or RollTek sys-tem. The vehicle must be serviced if the SRS indica-tor does not illuminate when the ignition is turned on,or if the SRS indicator remains on.

The air bag module may contain perchlorate mate-rial; for information, see www.dtsc.ca.gov/hazardouswaste/perchlorate. Special handling mayapply; follow appropriate rules and regulations whendisposing of materials.

For all service and maintenance, contact an autho-rized Freightliner service facility.


7.11



8

Climate ControlCab Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Sleeper Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2ParkSmart™ HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

Cab Climate Control PanelThe standard cab climate control panel has a fanswitch with a recirculation button, temperature controlswitch with an A/C button, and a mode controlswitch. See Fig. 8.1. Sleeper cabs are also equippedwith a bunk override button.

Fan SwitchThe fan switch activates the fan, which forces freshair or recirculated air through the air outlets. The fanswitch has eight fan speed settings and an OFF po-sition. See Fig. 8.2.

To operate the fan switch, turn the fan switch clock-wise to increase airflow; turn the fan switch counter-clockwise to decrease airflow.

There is a two-second delay between the time theengine is started and the blower is operational. It cantake an additional four seconds for the blower toreach high speed. The blower motor performs a self-test immediately after the engine is started, whichcauses the delay. If the vehicle has Optimized Idle,the fan will not operate with the key in accessorymode. Optimized Idle may also turn the fan off toreduce stress on the batteries. Refer to Chapter 11for more information.

RecirculationRecirculation mode limits the amount of outside airentering the cab. Press the recirculation button toprevent dusty or smoky air from entering the cab.See Fig. 8.2. Recirculation mode can also decreasethe time required to cool or heat the cab interior dur-ing extreme outside temperature conditions. Whenthe recirculation mode is turned on, the amber indi-cator on the recirculation button will illuminate.

The recirculation button will not work when the modecontrol switch is in either defog or defrost modes.

NOTE: To prevent the buildup of odors or oxy-gen depletion inside the cab, the systemswitches from full recirculation mode to partialrecirculation mode after 20 minutes. In ex-tremely dusty or smoky conditions, the partialrecirculation mode can be overridden by press-ing the recirculation button twice to obtain fullrecirculation mode. This resets the 20-minutetimer.

Temperature Control SwitchThe temperature control switch is used to select thedesired temperature in the cab. Turn the switchcounterclockwise for cool air, or clockwise for hot air.See Fig. 8.3.

Air Conditioning ButtonThe air conditioner (A/C) cools and dehumidifies theair inside the cab. Press the A/C button, located inthe center of the temperature control switch, to turnthe air conditioner on and off. See Fig. 8.3.

A/C will be automatically disabled when:

0

24

8

6

07/20/2006 f831701

1 2 3

1. Fan Switch2. Temperature Control Switch3. Mode Control Switch

Fig. 8.1, Cab Climate Control Panel

06/08/2007 f610946

1

1. Recirculation Button

Fig. 8.2, Fan Switch

Climate Control

8.1

• outside air temperature is low enough to makethe A/C ineffective;

• engine is running at extremely low rpm;

• conditions exist that result in the climate con-trol system going into protection mode.

Mode Control SwitchThe mode control switch allows the driver to controlthe flow of air through the face outlets, the floor out-lets, the defrost (windshield) outlets, or a combinationof these outlets. See Fig. 8.4.

• Face Mode: Directs all airflow through the faceor instrument panel outlets.

• Bi-Level Mode: Directs the airflow equally tothe face outlets and the floor outlets.

• Floor Mode: Directs all airflow through the flooroutlets.

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

• Defrost Mode: Directs all airflow through thedefrost outlets.

Bunk Override ButtonThe bunk override button, equipped on sleeper cabsonly, allows the driver to control the sleeper heat andA/C settings from the cab. See Fig. 8.4.

Press the bunk override button to turn the sleeperheat or A/C on. An amber indicator will illuminatewhen bunk override mode is activated.

Press the bunk override button again to turn bunkoverride mode off. Adjusting the sleeper climate con-trols at any time will also cause the bunk overridemode to cancel.

Sleeper Climate Control PanelThe standard sleeper climate control panel has a fanswitch and a temperature control switch with an A/Cbutton.

If the bunk override button has been activated, theoverride mode can be canceled by changing thesleeper fan speed or temperature setting. The cli-mate control system will then operate from thesleeper controls.

Fan SwitchThe fan switch activates the fan, which forces airthrough the air outlets. The fan switch has eight fanspeeds and an OFF position. See Fig. 8.5.

To operate the fan switch, turn the switch clockwiseto increase airflow; turn the fan switch counterclock-wise to decrease airflow. If the vehicle has Optimized

06/08/2007 f610947

1

1. Air Conditioning Button

Fig. 8.3, Temperature Control Switch

06/08/2007 f610948

1

2

3

45

6

7

8

9

10

1. Face Mode2. Selection Between Face Mode and Bi-Level Mode3. Bi-Level Mode4. Selection Between Bi-Level Mode and Floor Mode5. Floor Mode6. Selection Between Floor Mode and Defog Mode7. Defog Mode8. Selection Between Defog Mode and Defrost Mode9. Defrost Mode10. Bunk Override Button (on sleeper-cabs only)

Fig. 8.4, Mode Control Switch With Bunk OverrideButton

Climate Control

8.2

Idle, the fan will not operate with the key in acces-sory mode. Optimized Idle may also turn the fan offto reduce stress on the batteries. Refer to Chap-ter 11 for more information.

When the cab air conditioner (A/C) is on, the sleeperfan will operate at low speed even if the sleeper fanswitch is in the off position. This is necessary to pro-tect the evaporator in the sleeper heater and air con-ditioner system from freezing. At lower fan speed set-tings, a slight increase in airflow levels may appearat times, as the control acts to regulate the evapora-tor temperature.

When the park brake is set, any temperature orblower speed setting changes on the bunk HVACunit control panel will be mimicked by the front HVACunit. For example, if you set bunk blower speed to HIand the temperature to COLD, the front unit will alsooperate on HI/COLD.

When the park brake is not set, the front and rearHVAC settings function independently, unless thebunk override button is pressed, or "minimum ACsupport" is required.

Minimum AC support is when the front unit is off andthe bunk unit is set such that AC is requested (needsthe AC compressor to run). In this case, the front unitwill go into minimum AC support mode by operatingthe front blower at minimum speed to prevent thefront unit evaporator from freezing up. This is alsotrue, if the rear unit is off and the front unit is setsuch that AC is requested, in order to prevent thebunk evaporator from freezing up.

Temperature Control SwitchThe temperature control switch is used to select thedesired temperature in the sleeper. Turn the switchcounterclockwise for cool air, or clockwise for hot air.

Air Conditioning ButtonThe A/C cools and dehumidifies the air inside thesleeper. Press the air conditioning button, located inthe center of the temperature control switch, to turnthe A/C on and off.

Smartway Certified Parked HeaterOperationAll vehicles equipped with diesel operated coolantheaters are "Smartway Certified". The coolant heaterwill keep the engine coolant between approximately150 and 180°F (65 and 82°C). Heated coolant isrouted through the auxiliary HVAC heater core toallow heater-only function of the auxiliary HVAC sys-tem.

System Operation1. Turn the block heater on.

2. Set the temperature dial to the desired heat set-ting.

3. Turn the HVAC blower on.

ParkSmart™ HVAC SystemThere are two variations of the ParkSmart vehicleconfiguration. The standard configuration is the mostcommon, and includes all vehicles without DetroitDiesel Optimized Idle (O/I). The second variation in-cludes vehicles equipped with Detroit Diesel Opti-mized Idle (O/I). Both configurations are operated inthe same way, the differences are in how the batter-ies and charging system are configured. Refer to"Standard Vehicle Configuration" or "Vehicles withDetroit Diesel Optimized Idle" below for more infor-mation on your vehicle.

Standard Vehicle ConfigurationThe ParkSmart™ climate control panel replaces thestandard sleeper control panel in ParkSmart-equipped sleeper cabs. The ParkSmart HVAC sys-tem is designed to maintain a comfortable tempera-ture inside the sleeper, and can operate in

06/08/2007 f610949

1 2

3

1. Fan Switch2. Temperature Control Switch3. Air Conditioning Button

Fig. 8.5, Sleeper Climate Control Panel

Climate Control

8.3

combination with the cab climate control systemwhen the vehicle is running, or independently whenthe vehicle is parked. It uses a set of four dedicatedbatteries mounted aft of the starting batteries, eitherbetween the frame rails behind the cab or outsidethe frame rail.

The ParkSmart climate controls operate similarly tothe standard sleeper climate controls. The tempera-ture settings range from 60°F (15°C) to 85°F (29°C),with 74°F (23°C) at the very center of the range. Thefan switch activates the fan. The fan switch has eightfan speeds. Zero (0) is the OFF position. SeeFig. 8.6. To operate the fan switch, turn the switchclockwise to increase airflow; turn the fan switchcounterclockwise to decrease airflow.

The ParkSmart HVAC system operates both whenthe engine is running and when the engine is off.When the engine is running, the air conditioning(A/C) is powered by the vehicle electrical system,while the auxiliary heater core is supplied with enginecoolant. While the engine is running, the ParkSmartbatteries are also being recharged by the vehicleelectrical system.

When the engine is off with the key in the ACC orON positions, A/C mode is powered by theParkSmart batteries. The cab fan will also circulateair in the cab using power from the main vehicle bat-teries. The available power for other vehicle-suppliedaccessories (house loads) will be affected when run-ning in this mode. If there is no Low Voltage Discon-nect (LVD) control on the main electrical system, theability to start the vehicle could also be compromisedif this mode is activated for an extended time period.

When the engine is off with the ignition switch in theOFF position, the ParkSmart system runs thebattery-operated A/C or diesel-operated coolantheater, depending on the temperature requested,and power is drawn from the batteries. The main bat-teries and the ParkSmart batteries will both be useduntil the system voltage drops to 12.5 volts, then thesystem will switch to the ParkSmart batteries only.The ParkSmart system will run until the dedicatedbatteries reach 11.3 volts.

Before operating the ParkSmart system, bring thesleeper interior temperature to the desired tempera-ture with the engine running and the bunk curtainopen. The ParkSmart system is designed to maintainan established comfortable bunk temperature, inparked mode, for up to 12 hours with the bunk cur-tain closed. See Table 8.1 for recommended settingsfor comfort while the vehicle is parked. Table 8.2shows the temperature knob setting for desired tem-peratures.

To use the ParkSmart control panel, select a fanspeed (other than off) and push the PARK button.Adjust the temperature control knob to the desiredtemperature. Refer to Table 8.1 or Table 8.2, de-pending what mode is being used.

Start the fuel-operated heater once per month andallow it to run for 15 minutes. Periodically running theheater will keep fresh fuel in the lines and ensure theheater is ready to perform when needed.

IMPORTANT: Wait three minutes after shuttingdown the ParkSmart system before turning thecab load disconnect switch (CLDS) to OFF.

NOTE: The Espar Hydronic 5 water heater canuse biodiesel blends up to 10% (B-10). Consultthe engine manufacturer’s manual to confirm thelowest allowable blend (engine or heater) is notbeing exceeded.

IMPORTANT: The condition and charge of theauxiliary batteries will directly affect run time ofthe ParkSmart system. If the vehicle run-timebetween discharges is less than eight hours, orif additional loads are added to the auxiliary bat-teries, the ParkSmart run-time will be less thanexpected.

f610949c

1 2

305/24/2011

ECONOMY

1. Fan Switch2. Temperature Control

Switch

3. PARK Mode ControlButton

Fig. 8.6, ParkSmart Climate Control Panel

Climate Control

8.4

Parked HVAC Comfort Guide

Rest Hours Desired

Weather Setting GuideOutdoor TemperatureLess Than or Equal

to: °F (°C)

Sunshine Less Thanor Equal to:

Maximum BlowerSpeed

MinimumTemperature Knob

Setting4 105 (40) Light Sun 8 Full Cold

6

95 (35) Full Sun 8 Mid90 (32) Light Sun 8 Full Cold

100 (38) Night Time 8 Full Cold110 (43) Full Sun 6 3 O’clock

875 (24) Night Time 6-8 Full Cold95 (35) Light Sun 6 10 O’clock

10

85 (30) Light Sun 6 10 O’clock100 (38) Light Sun 6 Mid95 (35) Night Time 6 10 O’clock

105 (40) Night Time 6 Mid

1290 (32) Night Time 6 10 O’clock

100 (38) Night Time 6 Mid

Table 8.1, Parked HVAC Comfort Guide

Temperature Control Knob Position to RequestedOutput Temperature

Temperature ControlKnob Position (Clicks)

Requested SleeperTemperature: °F (°C)

1 60 (16)2 60 (16)3 62 (17)4 64 (18)5 66 (19)6 68 (20)7 70 (21)8 71 (22)9 72 (22)10 73 (23)11 74 (23)12 75 (24)13 76 (24)14 77 (25)15 78 (25)16 79 (26)17 80 (27)18 82 (38)19 84 (29)20 85 (29)

Temperature Control Knob Position to RequestedOutput Temperature

Temperature ControlKnob Position (Clicks)

Requested SleeperTemperature: °F (°C)

21 Full Hot

Table 8.2, Temperature Control Knob Position toRequested Output Temperature

Vehicles with Detroit Diesel OptimizedIdleIf a Cascadia vehicle is equipped with Detroit Dieseloptimized idle (O/I), it will affect the way theParkSmart operates. When the driver initiates theO/I, the ParkSmart will operate in O/I mode as fol-lows.

• The ParkSmart runs unless the ParkSmart fanspeed control knob is turned to the "OFF" posi-tion. See Fig. 8.6. The fan speed control knobmust be set at "1" or higher.

• The engine will periodically start and run for atleast two hours to maintain battery voltagethen shut off. The ParkSmart will continue tooperate during this time.

• If the O/I shuts down due to a fault in the O/Isystem, the ParkSmart will continue to operate

Climate Control

8.5

until it is shut off by the driver or one of theautomated failsafes.

• The ParkSmart ON/OFF button and LED indi-cator on the parked HVAC control module donot function when the vehicle is in O/I mode.When the vehicle is not in O/I mode, theParkSmart ON/OFF button and LED indicatoroperate normally.

All other functions are the same as the standard sys-tem.

Accessory HeatersOptional accessary heaters are available from thefactory in several configurations. Familiarize yourselfwith the equipment on your specific vehicle, and fol-low the manufacturer’s operating and maintenanceinstructions.

WARNINGDo not operate fuel-operated heaters in an areawhere flammable vapors, including gasoline ordiesel fumes, are present, such as at filling sta-tions and tank farms. Turn off a fuel-operatedheater and allow it shut down completely beforeentering an area where flammable gases or liq-uids are present. Heaters continue to operate forup to three minutes after being turned off.

Failure to observe these precautions could causean explosion or fire, resulting in serious propertydamage, and personal injury or death.

NOTICEAlways ensure that air inlet and outlet grilles arenot restricted. Restriction of any air inlet or outletports could result in damage to the auxiliaryheater.

IMPORTANT: To maintain reliable performance,run the accessory heater for at least 15 minutesevery month to prevent fuel from degrading.

Accessory heaters function when the ignition switchis in the off position and the cab load disconnectswitch is on, if equipped.

IMPORTANT: Wait three minutes after shuttingdown an accessory heater before turning thecab load disconnect switch (CLDS) to OFF.

NOTE: The low voltage disconnect (LVD) controlprevents a heater from draining the batteriesbelow starting voltage.

Espar HeaterRefer to the Espar website, www.espar.com, for ad-ditional information.

Espar Mini-ControllerTo turn the heat on, press the heat button. SeeFig. 8.7. The red indicator will illuminate when heatmode is activated. Adjust the desired temperaturewith the control knob; rotate the temperature controlknob clockwise for warmer air, or counterclockwisefor cooler air. To turn the heat off, press the off but-ton.

To turn the fan on, press the fan button. The blueindicator will illuminate when ventilation mode is acti-vated. To turn the fan off, press the off button.

Espar Digi-ControllerVehicles built after December 8, 2011 with the Digi-Controller and D2 air heaters are equipped with an

02/06/2012 f61116112

3

4

56

1. Temperature Control Knob2. Fan Button3. Fan Indicator (blue)4. Off Button5. Heat Indicator (red)6 Heat Button

Fig. 8.7, Espar Mini-Controller

Climate Control

8.6

http://www.espar.com

internal LVD in the Digi-Controller that prevents theheater from draining battery voltage below 12.0 volts.

To turn heat mode on, press the heat button and theheater will begin its start-up cycle. See Fig. 8.8. ONwill display briefly followed by the ambient tempera-ture, and the green indicator will illuminate. Ambientdisplay temperature range is 41°F to 90°F.

To adjust the desired temperature, press the up ordown arrow buttons. The desired temperature willdisplay briefly, followed by the ambient temperature.The desired temperature will remain in the modulatormemory when the heater is not in operation. Tem-perature adjustment range is from 41°F to 90°F.

To turn heat mode off, press the heat button again.The heater will initiate a 3-minute cooling cycle.

To turn the fan on, press and hold the fan button untilthe blue indicator illuminates and the display showsactive rotating digits. To turn the fan off, press thefan button again.

NOTE: The Digi-Controller also has a program-mable run timer that will automatically shut the

heater off after the set time limit. The defaulttime limit setting is 10 hours.

Webasto HeaterTo turn the heater on, rotate the heater control knobclockwise until the indicator light illuminates. SeeFig. 8.9. The Webasto heater requires one to twominutes to warm up before warm air is delivered.

To set the desired temperature, rotate the heatercontrol knob clockwise for warmer air, or counter-clockwise for cooler air.

To turn the heater off, rotate the heater control coun-terclockwise until it clicks and the indicator light isextinguished. The heater will initiate a two-minutecooling cycle.

Refer to the Webasto website, techwebasto.com,for additional information.

02/06/2012 f611160

Espar

81

2

3

4 5

6

7

1. Ambient Temperature Sensor2. Down Arrow Button3. Fan Button4. Fan Indicator (blue)5. Heat Indicator (green)6 Heat On/Off Button7. Up Arrow Button8. Ambient Temperature Display

Fig. 8.8, Espar Digi-Controller

10/24/2014 f611162

1

2

1. Off Position2. Heater On Indicator Light

Fig. 8.9, Webasto Heater Control Knob

Climate Control

8.7

http://techwebasto.com

9

Cab FeaturesWindows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

WindowsPower windows are standard on Cascadia™ vehicles.The driver’s door has two switches mounted in thetop of the door, that control the driver and passengerwindows separately. See Fig. 9.1. The passengerdoor has a switch mounted in the top of the door thatcontrols the passenger-side power window.

WARNINGThere is no anti-pinch protection when the win-dow is almost closed. Be sure to clear all objectsfrom the window before closing.

The window switches have three positions: lowerwindow, neutral, and raise window. Press forward onthe switch to lower the window. Hold the switch downin the forward position for approximately one secondto activate the express function; the window will con-tinue to roll down after the switch is released. Pressthe switch in the rearward position (bump) to raisethe window.

MirrorsThe standard outside mirrors are mounted on thedoor frame. The power mirrors are controlled with aleft-hand or right-hand mirror selector switch, and adirectional switch. Select the left (driver) mirror, orthe right (passenger) mirror using the selector switch.

The mirror can then be adjusted by pressing the di-rectional switch arrow for the direction the mirrorshould be adjusted.

The outside door mirrors can be heated to keepthem clear of fog, frost, and ice. To heat the mirrors,press the upper part of the mirror heat switch on thedash. See Fig. 9.2. When the mirror heat switch ison, an amber indicator light illuminates inside theswitch. If the vehicle has Optimized Idle, mirror heat-ing will not operate with the key in accessory mode,or if the Optimized Idle feature turns mirror heatingoff to reduce stress on the batteries. Refer to Chap-ter 11 for more information.

Cab AmenitiesCascadia vehicles are available with many optionalfeatures. The following are some of those options.

Cup HoldersTwo cup holders and a storage tray are molded intothe center dash. See Fig. 9.3.

LightingSee Chapter 5 for detailed information regardinglighting controls.

Power OutletsPower outlets that supply 12V power for accessoriesare located on either side of the cup holders. An op-tional ashtray/coin holder may be located in the cen-ter dash. See Fig. 9.3.

06/13/2007 f602318

1

23 4

1. Passenger-Side Window Switch2. Driver-Side Window Switch3. Mirror Directional Switch4. Left-Hand or Right-Hand Mirror Selector Switch

Fig. 9.1, Door Switches (driver-side shown)

MIRRHEAT

f61090402/26/2007

Fig. 9.2, Mirror Heat Switch

Cab Features

9.1

Radio and CBThe radio and CB are typically installed in the over-head console. An optional hot mount may be in-stalled on the dash for fleet CB radios.

StorageStorage compartments/grab handles are molded intothe lower portion of the driver and passenger doors.

The glove box is located in front of the passengerseat. To lock the latch, insert the key in the lock, andturn it 1/2-turn clockwise. Remove the key. To unlockthe latch, insert the key in the lock, and turn it 1/2-turn counterclockwise. The glove box door is hingedat the bottom. To open the unlocked door, push thebutton in with your thumb and pull gently on thetang-style latch. The door will swing downwards, thenstop in the open position. To close the door, swing itupwards, and put gentle pressure on the latch. Thedoor will be secured, but not locked.

Storage pockets are located in the overhead console,above the driver and passenger seats. A glove box islocated in the center of the overhead console. SeeFig. 9.4.

Sleeper AmenitiesCascadia sleepers are available with many optionalfeatures. The following are some of those options.

NOTE: See Chapter 8 for detailed informationregarding sleeper climate controls.

Baggage Compartment DoorsThe baggage compartment doors are intended as aconvenient means to stow or remove items under thebunk. The baggage compartment doors can beopened using the pull cable located near the aft edgeof the cab door opening on the sidewall behind theseat. Pull the cable handle labeled BAGGAGE for-ward to open the door.

IMPORTANT: The baggage compartment doorsare two-stage latching. When closing the doors,ensure that they are completely latched to pre-vent wind noise and water intrusion.

LightingSee Chapter 5 for detailed information regardinglighting controls.

Power OutletsPower outlets are located underneath the lowerbunk.

Sleeper Access DoorThe sleeper access door is not intended for entry orexit. The door is intended only as a convenientmeans to stow or remove personal belongings in thesleeper area. The sleeper access door can beopened using two different methods. The primarymethod is the pull cable located near the lower rearedge of the cab door opening on the sidewall behind

ENGSHDN ATC

ENGBRK

MIRRHEAT UTLY

LAMPDOME

HI

LO

0

2 4

8

6

POW

ER

OU

TLET

12V−10A

IS IN MOTION SUSPAIR

LOWERAUTO

POWEROUTLET12V−10A

TRLRAUX

OVRD TC

06/14/2007 f610950a2

1

1

1. Power Outlets2. Cup Holders and Storage Tray

Fig. 9.3, Center Dash

02/25/2014 f602319a

1 1

2

3 34

1. Cargo Storage with Netting2. Overhead Storage Compartment3. Storage Pocket4. Glove Box

Fig. 9.4, Overhead Storage

Cab Features

9.2

the seat. Pull the cable handle labeled ACCESS for-ward to open the sleeper door. The secondarymethod is the black knob located at the upper rearedge of the sleeper door opening. Pull the knobdown to open the sleeper door.

IMPORTANT: The sleeper access doors aretwo-stage latching. When closing the doors, en-sure that they are completely latched to preventwind noise and water intrusion.

Sliding Side WindowThe lower section of the sliding side window movesvertically and may be locked in multiple positions tosuit. Two spring-loaded tabs are located at the top ofthe sliding section. To adjust the window, pull bothtabs toward the center of the glass and move thesliding section to the desired height. Release thetabs to lock the sliding section.

Cab Features

9.3

10

Engine Starting, Operation,and Shutdown

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

Engine StartingThis engine chapter is to serve as a guide for bestpractices only. Each engine model may have operat-ing characteristics that are unique to that particularengine, and will be documented in the engine manu-facturer’s literature. Always refer to specific instruc-tions and recommendations from the engine manu-facturer.

NOTE: Before starting the engine, read Chap-ter 4, Instruments, and Chapter 5, DriverControls. Read the engine manufacturer’s oper-ating instructions before starting the engine.

WARNINGNever pour fuel or other flammable liquid into theair inlet opening in the air intake in an attempt tostart the vehicle. This could result in a flash firecausing serious personal injury or propertydamage.

IMPORTANT: Cascadia vehicles are equippedwith starter interlocks to enhance reliability andsafety. Anti-grinding, starter pinion, and thermalprotection logic limit the amount of time andconditions for starter engagement. Crankingmay be limited from 5 to 15 seconds, with a 30-second cool-down period, as determined by theprotection logic. If the engine is turning, thestarter will not engage. Depending on the trans-mission option, the starter will not engage if theclutch is not fully depressed, or if the transmis-sion is not in neutral.

IMPORTANT: The starter can not be used forpriming the fuel system. If the fuel/water separa-tor filter is replaced, and the fuel system needsto be primed, see the engine manufacturer’soperating instructions.

1. Before engine start-up, complete the pre- andpost-trip inspections and maintenance proce-dures in Chapter 21.

2. Set the parking brake.

3. Place the transmission in neutral. On vehicleswith manual transmissions, fully depress theclutch pedal.

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

4. Turn the ignition switch to the ON position andallow the gauge sweep to complete. SeeFig. 10.1. The audible alert will sound for ap-proximately four seconds.

During cold conditions, the WAIT TO STARTlamp may illuminate. Wait until the lamp goes outbefore turning the ignition key to START.

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

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

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

NOTICEDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the engine

07/19/2006 f610805

Fig. 10.1, Ignition Switch

Engine Starting, Operation, and Shutdown

10.1

if oil pressure does not build within approxi-mately ten seconds. Check to determine thecause of the problem. Operating the engine withno oil pressure will damage the engine.

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

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

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

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

Cold-Weather StartingSee the engine manufacturer’s operation manual forstarting aids that are approved for specific engines.

Starting After Extended ShutdownBefore engine start-up, complete the engine pretripinspections in Chapter 21.

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

An engine in storage for an extended period of time(over winter, for example) may accumulate water inthe oil pan through normal condensation of moistureon the internal surfaces of the engine. Oil diluted bywater cannot provide adequate bearing protection atstart-up. For this reason, change the engine oil andfilters after extended storage.

Engine OperationSafety and EnvironmentalConsiderations

WARNINGDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut off the engine when in an areawhere flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.

All engines on Freightliner vehicles comply with therequirements of the Federal (U.S.) Clean Air Act.Once an engine is placed in service, the responsibil-ity for meeting both state and local regulations is withthe owner/operator.

IMPORTANT: Depending upon local jurisdic-tional emissions guidelines, vehicles that aredomiciled outside of the U.S. and Canada maynot have engines and/or emissions aftertreat-ment systems that are compliant with EPA07,EPA10, or GHG14 regulations.

NOTICEIt is extremely important that the following guide-lines be followed for engines that comply withEPA07 or newer regulations, or damage mayoccur to the aftertreatment device, and the war-ranty may be compromised.

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

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

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

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

The driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop if


10.2

the engine malfunctions. If the driver doesn’t under-stand how the warning system works, an engineshutdown could occur, causing a safety hazard. SeeChapter 11 for more information.

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

Normal Operation

WARNINGDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut off the engine when in an areawhere flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.

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

Prolonged idling of engines is not recommended, andis illegal in some states. Idling produces sulfuric acidthat is absorbed by the lubricating oil, and eats intobearings, rings, valve stems, and engine surfaces. Ifyou must idle the engine for cab heating or cooling,use the high idle function of the cruise controlswitches. An idle speed of 900 rpm should beenough to provide cab heat in ambient temperaturesthat are above freezing.

If the engine is programmed with an idle shutdowntimer, 90 seconds before the preset shutdown time,the CHECK engine light will begin to flash at a rapidrate. If the position of the clutch pedal or servicebrake changes during this final 90 seconds the idleshutdown timer will be disabled until reset.

Cold-Weather OperationSatisfactory performance of a diesel engine operatingin low ambient temperatures requires modification ofthe engine, surrounding equipment, operating prac-tices, and maintenance procedures. The lower thetemperature, the greater the amount of modificationrequired. For service products approved for use incold weather for your engine, see the engine manu-facturer’s engine operation manual.

If satisfactory engine temperature is not maintained,maintenance costs will increase due to greater en-gine wear. If the engine coolant gets too cold, rawfuel will wash the lubricating oil off the cylinder wallsand dilute the crankcase oil, causing all moving partsof the engine to suffer from poor lubrication.

If the engine is in good mechanical condition and theprecautions necessary for cold-weather operation aretaken, ordinary cold weather will not cause difficultyin starting or loss of efficiency.

The following points are important to observe whenoperating in cold weather.

• Check for cracks in the battery cases, for cor-rosion of the terminals, and for tightness of thecable clamps at the terminals.

• Charge the batteries to full capacity. Replacedamaged batteries.

• If equipped, turn off the load disconnect switchafter the engine is shut down to prevent batterydischarge.

• Have the alternator output checked at an au-thorized Freightliner service provider.

• Check the condition and tension of the drivebelts.

• Refer to the engine manufacturer’s operationmanual for recommended heaters, low-viscosity lubricating oils, winter-grade fuels,and approved coolants.

• Periodically check the coolant mixing ratio(concentration of antifreeze in the coolant). Addmore if necessary.

• At outside temperatures below -4°F (-20°C), acoolant preheater is recommended.


10.3

NOTICEFor Detroit engines (EPA07 and newer), use of awinterfront is not recommended, as it can causefalse fault codes with the engine and aftertreat-ment system, and possible emission componentfailures.

If using a winterfront, leave at least 25% of the grilleopening exposed in sectioned stripes that run per-pendicular to the charge-air-cooler tube-flow direc-tion. This assures even cooling across each tube,and reduces header-to-tube stress, and possiblechance of component failure. For engine-specificguidelines, see below:

Cummins and Mercedes-Benz engines: A winterfrontmay be used to improve cab heating while idling, andonly when the ambient temperature remains below10°F (-12°C).

Detroit engines (EPA07 and newer): Use of a winter-front is not recommended. Using a winterfront cancause excessive fan run time, increased fuel con-sumption, and failure of the DEF system heaters tooperate correctly, resulting in fault codes, poor per-formance, and power reduction. A winterfront shouldonly be used temporarily in the following situations:

• To improve cab heating while idling in an ex-tremely cold ambient temperature;

• When the ambient temperature remains below-22°F (-30°C) and the engine is unable tomaintain a running coolant temperature of175°F (80°C) during normal over-the-roadoperation.

High-Altitude OperationEngines lose horsepower when operated at high alti-tude because the air is too thin to burn as much fuelas at sea level. This loss equals about three percentfor each 1000 ft (300 m) altitude above sea level fora naturally aspirated engine.

All engines used on Freightliner vehicles are altitude-compensated by the use of a turbocharger. This re-duces smoky exhaust at high altitudes, requires lessdownshifting, and allows the engine to make betteruse of its fuel. Nevertheless, shift gears as needed toavoid excessive exhaust smoke.

Engine Shutdown1. With the vehicle stopped, set the parking brake

and place the transmission in neutral.

NOTICEIdle the engine one to two minutes before shut-ting it down. After hard operation, shutting downthe engine without idling may cause damage tothe turbocharger.

2. Allow the engine to idle one to two minutes be-fore shutting it down. This allows the lubricatingoil and the coolant to carry heat away from thecombustion chambers, bearings, shafts, andseals.

NOTICEExcept in an emergency, do not shut down theengine when the coolant temperature is above194°F (90°C). To do so could damage the engine.

3. Turn off the ignition switch and shut down theengine.


10.4

11

Optional Engine SystemsEngine Protection—Warning and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2Optimized Idle® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

Engine Protection—Warningand ShutdownNOTE: The engine warning and shutdown sys-tem is present on EPA07-compliant and newervehicles.

The driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifnecessary. If the driver doesn’t understand how thewarning system works, the driver may not be able toutilize the advantage of the advance warning systemto pull over appropriately.

The engine will begin a warning and derate and/orshutdown process if the engine coolant temperature,coolant level, engine oil pressure, or exhaust after-treatment system (ATS) reach preset levels. Onsome engines, the warning process will begin whenthe engine oil temperature, engine coolant tempera-ture, or the intake air temperature reach preset lev-els. Detroit™ engines may also begin the warningand shutdown process if water is detected in the fuel.

See the engine manufacturer’s operation manual forspecific details for your vehicle. See Chapter 12 forthe warning and shutdown modes associated withthe ATS.

Electronic engine protection can be specified as ei-ther SHUTDOWN or WARNING and DERATE.

WARNINGWhen the STOP engine or CHECK engine lampilluminates, most engines are programmed toshut down automatically within 30 seconds. Thedriver must immediately move the vehicle to asafe location at the side of the road to preventcausing a hazardous situation that could causebodily injury, property damage, or severe damageto the engine.

In SHUTDOWN mode, the red STOP engine lampwill illuminate when the problem is serious enough toreduce power or speed. See Fig. 11.1. Engine powerwill ramp down, then the engine will shut down if theproblem continues while in derate mode. The driverhas 30 or 60 seconds (depending on the critical faulttype) after the STOP engine lamp illuminates tomove the vehicle safely off the road. If the vehiclecannot be moved to a safe location within that time,turn the ignition switch to OFF for at least five sec-

onds, then restart the engine. Repeat this action untilthe vehicle is safely off the road.

Do not operate the vehicle further until the problemcausing the shutdown has been corrected.

Some vehicles may have a shutdown overrideswitch, which can be used to momentarily overridethe shutdown sequence. This switch resets the shut-down timer, restoring power to the level before thederate. The switch must be pressed again after fiveseconds to obtain a subsequent override. SeeFig. 11.2.

NOTICEWhen the derate process begins, immediately getthe vehicle serviced in order to prevent severedamage to the engine.

Detroit engines may begin a warning and derate pro-cess if water is detected in the fuel, or for high en-gine coolant temperature. In WARNING and DER-ATE mode, the CHECK engine, STOP engine, or MIL

07/09/2009 f6110361 2 3

CHECK STOP

1. Malfunction Indicator Lamp (MIL)2. CHECK Engine Lamp3. STOP Engine Lamp

Fig. 11.1, Engine Warning Lamps

ENGSHDN

f61090002/26/2007

OVRD

Fig. 11.2, Shutdown Override Switch

Optional Engine Systems

11.1

lamp will illuminate to indicate an engine problemthat requires service and the engine controls willbegin a derate of engine output. Continuing to runthe engine while it is in derate mode could causesevere damage to the engine.

Engine Idle LimitingIdle Shutdown TimerThis feature is an optional 1- to 100-minute idle shut-down system. Its purpose is to conserve fuel byeliminating excessive idling, and allowing a turbo-charger cool-down period. Idle shutdown timing andparameters are programmable. See the enginemanufacturer’s operation manual for specific detailsfor your vehicle.

The idle shutdown system requires that the transmis-sion be in neutral with the parking brake set.

California Engine Idle LimitingIn order to meet the California Air Resources Board(CARB) engine idle limit, vehicles are equipped withan engine idle shutdown feature. The automatic shut-down feature is required on all California-certifiedengines (with the exception of engines used in spe-cific vehicle types that are exempt from the require-ment). Owners that wish to have the shutdown fea-ture disabled on vehicles operating in Californiashould consult with California authorities to determineif their vehicle qualifies for the exemption.

When the CARB engine idle limiting feature is en-abled, the engine will typically shut down after fiveminutes of continuous idling with the transmission inneutral or park, and the parking brake set. It will alsoshut down after 15 minutes with the transmission inneutral or park, and the parking brake off. See theengine manufacturer’s operation manual for specificdetails for your vehicle.

Changing the position of the brake pedal, clutchpedal, accelerator pedal, shutdown override switch,or parking brake during the final 30 seconds willcause the shutdown timer to reset. After an auto-matic shutdown, the engine may be restarted andoperated normally.

Power Takeoff (PTO) Governor

WARNINGTo avoid injury, do not install a PTO that is notDetroit Diesel approved onto a Detroit™ Trans-mission. Use of a non-Detroit Diesel approvedPTO with a Detroit Transmission could result inunintended operation which could lead to severepersonal injury.

Engine power takeoffs (PTO) tap into engine powerto run auxiliary devices, such as hydraulic pumpsthat power additional equipment. The following aregeneral guidelines for operating a PTO.

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

2. Press the dash PTO switch. Release the switchwhen the light begins to blink.

When the light illuminates steadily, the PTO isengaged and ready to operate. In stationarymode, the vehicle must remain in neutral with theparking brake set.

3. To activate mobile mode, shift from neutral toreverse, 1st, or 2nd gear. The clutch will openand the PTO will disengage for a moment.

4. Touch the accelerator pedal to close the clutchand engage the PTO in mobile mode. The PTOmay be operated with the transmission in neutralor reverse, and 1st and 2nd gears only.

NOTE: Do not attempt to change gears whilethe vehicle is moving. The transmission will ig-nore the request.

5. To deactivate mobile mode, bring the vehicle to astop. The clutch will open and shut down powerto the PTO.

6. To resume stationary mode, shift to neutral. ThePTO will engage.

7. To deactivate PTO, press the PTO switch again.When the light in the switch goes out, power tothe PTO is shut off.

Optimized Idle®Optimized Idle reduces engine idle time by runningthe engine only when required. Optimized Idle auto-matically shuts down and restarts the engine as


11.2

needed to ensure engine oil temperature remainswithin factory preset limits, the batteries staycharged, and cab/sleeper temperature remains at thethermostat setting. The benefits of the system in-clude reduced engine idle time, fuel savings, reduc-tion of exhaust emissions and noise, increasedstarter and engine life, and reduced chance of deadbatteries.

Vehicles equipped with Optimized Idle have a labelon the dash, and a telltale (OPT IDLE) in the ICU.See Fig. 11.3 for the dash label detail. If equipped, athermostat is located above the sleeper bunk. SeeFig. 11.4.

Optimized Idle operates in two modes:

• Engine mode: Keeps the battery charged andengine oil temperature between 60 and 104°F(16 to 40°C).

• Thermostat mode (activated when the optionalthermostat is turned on): Keeps the cab andsleeper at a constant preset temperature, inaddition to all functions available in enginemode.

Thermostat mode controls the set point, which is thedesired temperature of the cab and sleeper, and thecomfort zone, which is the allowed temperature de-viation from the set point before the engine starts.

The thermostat display defaults to show the tempera-ture of the sleeper, but changes accordingly as thebuttons are pressed.

The button functions are as follows:

• Up arrow: Increases the set point and comfortzone (allowed temperature variation).

• Down arrow: Decreases the set point and com-fort zone.

• Cool/Heat: Sets either cooling or heating op-eration.

• MODE: Scrolls through the various functions. Itcan also be used to set desired temperaturevalues.

If a vehicle has Optimized Idle, the following func-tions will not operate with the key in accessorymode. Optimized Idle may also turn these functionsoff to reduce stress on the batteries.

• Cab climate control fan

• Sleeper climate control fan

• Mirror heat

• Fuel/water separator heat

• Seat heat

• Advertising light

• Auxiliary circulation fan (windshield)

• Air dryer

1. To activate Optimized Idle (engine mode):

1.1 Set the parking brake.

1.2 If it is open, close and secure the hood.

11/13/96 f080062

TO AVOIDUNINTENTIONAL

VEHICLE MOVEMENT,DO NOT MOVE SHIFT

LEVER OR RANGESELECTOR WHEN

OPTIMIZED IDLE IS ON

OPTIMIZED IDLETM

TO USE:− IDLE ENGINE− CLOSE HOOD− ENGAGE PARKING BRAKES− PUT TRANSMISSION IN

NEUTRAL ANDHI RANGE (IF EQUIPPED)

− THEN, MOVE CRUISE SWITCHFROM OFF TO ON

− IF DESIRED, TURN CABTHERMOSTAT ON (IF EQUIPPED)

Fig. 11.3, Optimized Idle Dash Label

MODE

°F

°C

11/08/96

1

2

3 4 5

6

7

8

910 f601250

1. Down Arrow Button2. Up Arrow Button3. Upper/Lower

Temperature Icon4. Temperature Display5. Degrees Fahrenheit

Indicator

6. MODE Button7. Cooling Icon8. Cool/Heat Selection

Button9. Heating Icon10. Degrees Celsius

Indicator

Fig. 11.4, Optimized Idle Thermostat


11.3

1.3 Start the engine and let it idle.

1.4 Put the transmission in neutral.

1.5 Turn on the cruise control.

The OPT IDLE lamp will blink, indicatingthat Optimized Idle is active. The systemis now in engine mode and after an initialphase, in which the idle speeds up to1000 rpm, the engine will stop and startautomatically to keep the battery chargedand the engine oil warm.

IMPORTANT: The cruise control must beturned on once the engine is idling. If it waspreviously turned on, turn the cruise controloff, then turn it on again.

2. Activate thermostat mode, if equipped.

NOTE: When the system is in thermostatmode, it is also in engine mode. It will con-tinue to operate in engine mode even if ther-mostat mode is turned off.

2.1 With the system in engine mode, set thecab and sleeper heater or air conditionercontrols to the highest setting.

2.2 Turn on the thermostat by touching any ofthe four buttons. See Fig. 11.4.

The display will flash the current sleepertemperature and the previous mode (cool-ing or heating) selected. If the cab needsto be cooled or heated, the cool/heat iconwill flash.

2.3 Choose either cool or heat by pressing theCool/Heat button. Make sure the selectionmatches that of the cab controls.

IMPORTANT: If the heat or cool selection ofthe thermostat does not match that of thecab controls, the system will idle and cycleexcessively.

2.4 Select Fahrenheit or Celsius by pressingand holding the MODE button until eitherthe "F" or "C" is displayed.

2.5 Select the temperature set point by press-ing the up or down arrows, as applicable.Holding the button will cause the display

to scroll up or down rapidly. When the de-sired set point is displayed, release thebutton. The set point is stored in memory.

2.6 Select the temperature comfort zone bypressing the MODE button until the upperand lower temperature limit icon is dis-played. Then use the up or down arrow toselect one of the three comfort zones: 4°F(2°C), 7°F (4°C), or 10°F (6°C).

3. To deactivate thermostat mode and return to justengine mode, press and hold the MODE buttonfor three seconds.

4. To shut down Optimized Idle completely, eitherturn off the ignition or use the drive away feature.

The drive away feature allows the use of all theengine features. Use the drive away feature asfollows:

4.1 If the engine is running: Release the park-ing brakes or put the transmission in gear.

If the engine is not running: Start the en-gine. Release the parking brakes or putthe transmission into gear.

4.2 Let the engine return to base idle. Theactive light will turn off. Optimized Idle isnow disabled.


11.4

12

Emissions and Fuel EfficientComponents

Greenhouse Gas Emissions and Fuel Consumption Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1EPA-Regulated Emissions Aftertreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3

Greenhouse Gas Emissionsand Fuel ConsumptionStandardsVehicles and/or engines manufactured after Decem-ber 31, 2006 and domiciled in the U.S. or Canadaare required to meet all EPA and NHTSA regulationseffective as of the vehicle build date. Engines manu-factured between January 1, 2007 and December 31,2009 meet EPA07 requirements. Engines manufac-tured between January 1, 2010 and December 31,2012 meet EPA10 requirements. Engines manufac-tured from January 1, 2013 meet NHTSA and EPA2014 fuel efficiency and greenhouse gas emissionstandards (GHG14) requirements.

Model year 2013 and later vehicles meet additionalrequirements as specified by GHG14 requirements.These vehicles are equipped with components thatincrease fuel efficiency and reduce GHG emissions.Components may include, but are not limited to, low-rolling resistance tires; aerodynamic devices such ashood, cab/sleeper extenders, and fuel tank fairings;vehicle speed limiter; and idle shutdown timer. If re-placement of any drag-reducing component is re-quired, the replacement component must meet orexceed the drag reduction performance of the origi-nally installed component in order to maintain compli-ance with GHG14 requirements.

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

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

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

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

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

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

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

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

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

EPA10 and Newer EnginesThe EPA mandates that all engines built after De-cember 31, 2009 must reduce the level of emissionsexhausted by the engine to the following levels:

• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

• Particulate Matter (PM) – .01 g/bhp-hr

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

Emissions and Fuel Efficient Components

12.1

RegenerationThe harder an engine works, the better it disposes ofsoot. If the exhaust temperature is high enough, aprocess called passive regeneration (regen) occursas the vehicle is driven normally. However, if the en-gine isn’t running hot enough, the electronic controlsmay initiate an active regen, whereby extra fuel isinjected into the exhaust stream to superheat andreduce the soot trapped in the DPF to ash. Activeregen happens only when the vehicle is movingabove a certain speed, determined by the enginemanufacturer. See your engine operation manual forcomplete details. Both active and passive regen hap-pen automatically, without driver input.

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

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

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

Regen SwitchesThe regen request switch, located on the dash, isused to initiate a parked regen. See Fig. 12.1. Toaccess the regen request switch, lift the guard andpress the yellow button.

Some vehicles may be equipped with a regen inhibitswitch. See Fig. 12.1. To stop a regen in progress orprevent the start of a regen, press the lower half of

the switch. Regen is then delayed until the switch isno longer active.

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

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

Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-als, and anything else that may be damaged orinjured by prolonged exposure to high heat.

To initiate a parked regen, perform the followingsteps.

1. Park the vehicle away from all flammable materi-als, put the transmission in neutral, and set theparking brake.

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

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

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

f61115702/08/2012

NORGEN

12

1. Regen RequestSwitch

2. Regen Inhibit Switch

Fig. 12.1, Regen Request and Inhibit Switches


12.2

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

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

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

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

• shut down the engine.

ATS Warning LampsThere are three warning lamps that alert the driver ofhigh exhaust temperature, the need to perform aparked regen or service the DPF, or of an enginefault that affects emissions. A decal attached to thedriver’s sun visor explains the ATS warning lamps.Fig. 12.2.

See Fig. 12.3 for an explanation of the ATS warn-ings, and actions required to avoid engine protectionsequences.

Malfunction Indicator Lamp (MIL)A steadily illuminated yellow malfunction indicatorlamp (MIL) indicates an engine fault that affectsemissions. See Fig. 12.4.

DPF Status LampWhen soot accumulates in the DPF and the DPF sta-tus lamp illuminates, see Fig. 12.5, perform a parkedregen or bring the vehicle up to highway speed toincrease the load (thus starting an active regen).

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

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

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

Steady illumination of the HEST lamp alerts thedriver of high exhaust temperature during the regenprocess if the vehicle speed is below 5 mph (8 km/h), or during a parked regen. See Fig. 12.6.

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

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

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

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

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

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


12.3

Pre-2013 DEF supply lines are electrically-heatedand are purged when the engine is shut down; com-plete purging of the DEF lines requires approximatelyfive minutes after the engine is shut down.

DEF supply lines with engine model year 2013 andnewer are designed to survive freezing conditionswhile containing DEF, so purging is not required.

DEF TankEngines that are compliant with EPA10 and newerregulations are equipped with a DEF tank located onthe driver’s side of the vehicle behind the battery boxor forward of the fuel tank. See Fig. 12.7 andFig. 12.8. The DEF tank has a 19 mm filler neck inletthat prevents the hose from a diesel outlet frombeing inserted, and has a blue cap for easyidentification.

Fuel/DEF GaugeThe diesel fuel and DEF levels are measured in adual-purpose gauge. See Fig. 12.9.

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

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

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

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

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

DPF Regen Needed

Hot Exhaust

DEF Refill Needed

Diesel Particulate Filter (DPF)regeneration is needed.

If flashing, regenerate as soon aspossible. Engine derate possible.

Hot exhaust can cause fire.

Keep flammables and people awayfrom exhaust.

Diesel Exhaust Fluid (DEF) level islow. Engine derate likely.

Refill tank with certified DEF.

See operator’s manual for complete instructions.24−01656−000

IMPORTANT

DEF

11/30/2010 f080161

1

2

3

Fig. 12.2, Warning Lamp Decal, Sun Visor


12.4

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

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

• One bar flashing red—DEF empty, refill DEF

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

DEF Level Low—Initial WarningWhen the DEF level is low, the following lamps notifythe driver. See Fig. 12.10. Refill the DEF tank inorder to cancel the warning sequence.

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

• The DEF warning lamp illuminates solid amber.

f080147


Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended

Filter is reaching


Filter RegenerationNecessary


To avoid enginederate bring vehicle



Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service


CHECK CHECK

(Flashing)

INDICATORLAMP(S)



Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

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

Regeneration mustbe performed −engine will beginderate.

Regeneration must be performed.Check engine operator’s manualfor details −engine will shut down.


06/29/2009

24−01583−000B

WARNING


Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.


Flashing

Solid

Fig. 12.3, ATS Warning Lamps

09/25/2006 f610814a

Fig. 12.4, Malfunction Indicator Lamp (MIL)

09/25/2006 f610815a

Fig. 12.5, DPF Status Lamp


12.5

DEF EmptyWhen the DEF level reads empty, the followinglamps notify the driver. See Fig. 12.11.

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

• The DEF warning lamp flashes amber.

• The MIL lamp illuminates.

Pre-2013 Detroit engines: Power is limited, with a 55mph (90 km/h) speed limit.

Cummins and 2013 Detroit engines: Power is limitedwith progressively harsher engine power limitsapplied.

DEF Tank Empty and IgnoredIf the empty warning is ignored and the DEF tank isnot refilled, the red STOP engine lamp illuminates inaddition to the MIL lamp and CHECK engine lamp(on vehicles with a Cummins ISB or ISC/L engine.)See Fig. 12.12.

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

DEF Contamination or SCR Tampering

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

If contaminated DEF or tampering with the ATS isdetected, the DEF warning light flashes and the MILlamp illuminates to warn the driver. The CHECK en-gine lamp also illuminates on vehicles with a Cum-mins ISB or ISC/L engine. See Fig. 12.12.

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

09/25/2006 f610816a

Fig. 12.6, HEST Lamp

07/24/2009 f470542

1

2

1. Batteries 2. DEF Tank

Fig. 12.7, DEF Tank Located Behind the Battery Box

07/24/2009 f470541

12

1. DEF Tank 2. Fuel Tank

Fig. 12.8, DEF Tank Located Forward of the Fuel Tank


12.6

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

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

11/08/2010 f611037

B


E F

DEF

FE


E F

DEF

FE


E F

DEF

FE

A C

1 2

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

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

1. Low Fuel Warning Lamp 2. DEF Warning Lamp

Fig. 12.9, Fuel/DEF Gauge

A

B

07/09/2009 f470537

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

Fig. 12.10, DEF Level Low Initial Warning

A

B

11/08/2010 f470539a

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

Fig. 12.11, DEF Empty Warning


12.7

A

B

11/08/2010 f470540a

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

Fig. 12.12, DEF Empty and Ignored Warning


12.8

13

Brake SystemsAir Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Meritor WABCO® Antilock Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5

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

WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol, resulting in property damage or personalinjury.

Brake System ComponentsThe warning light and buzzer come on if air pressuredrops below approximately 70 psi (483 kPa) in eithersystem. If this happens, check the air pressuregauges to determine which system has low air pres-sure. Although the vehicle’s speed can be reducedusing the foot brake control pedal, either the front orrear service brakes will not be operating at full ca-pacity, causing a longer stopping distance. Bring thevehicle to a safe stop and have the air system re-paired before continuing.

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

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

WARNINGDo not release the spring parking brakes andthen drive the vehicle. There would be no meansof stopping the vehicle, which could result in se-rious personal injury or vehicle damage. Before

releasing the spring parking brakes, make theconnection to a towing vehicle or chock the tires.

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

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

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

Brake System OperationBefore driving your vehicle, allow time for the aircompressor to build up a minimum of 100 psi (689kPa) pressure in both the primary and secondarysystems. Monitor the air pressure system by observ-ing the air pressure gauges and the low-air-pressurewarning light and buzzer. The warning light andbuzzer shut off when air pressure in both systemsreaches approximately 70 psi (483 kPa).

IMPORTANT: Before driving the vehicle, secure allloose items in the cab so that they will not fly forwardduring a full brake application. Make sure all passen-gers are wearing seat belts.

During normal brake stops, depress the foot brakecontrol pedal until braking action slows down the ve-hicle. Increase or decrease the pressure on thepedal so that the vehicle comes to a smooth, safestop. Apply the spring parking brakes if the vehicle isto be parked.

IMPORTANT: An air brake proportioning systemmay be used in tractor air brake systems whenthe vehicle is not equipped with antilock brakingsystem (ABS). When operating in bobtail mode,the rear brake chambers (on which the axleload has been greatly reduced) receive reduced(proportional) air pressure, while the front axlebrake chambers receive full (normal) air pres-sure. This results in a different brake pedal"feel," as the pedal seems to require more travel

Brake Systems

13.1

and/or effort to slow or stop the vehicle. How-ever, the air brake proportioning system actuallyimproves vehicle control when the tractor is inbobtail mode. When the tractor is towing atrailer, the rear brake chambers will receive full(normal) application air pressure.

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

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

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

Brake ControlsThe trailer brake lever (hand control valve) is usedfor applying the trailer brakes without applying thetruck or tractor service brakes. It is usually mountedon the right-hand control panel. See Fig. 13.1. Thevalve can be partially or fully applied, but in any par-tially on position it will be overridden by a full applica-tion of the service brake pedal. Moving the leverdown applies the trailer brakes, while moving it upreleases the trailer brakes. The lever will automati-cally return to the up position when it is released.

WARNINGDo not use the trailer service brakes for parking;they are not designed for this purpose. If airbleeds out of the trailer air tank during parking,the vehicle could roll, causing serious personalinjury or property damage.

The red octagonal-shaped knob in the control panelactuates the trailer air supply valve. See Fig. 13.2.After the vehicle’s air hoses are connected to atrailer and the pressure in both air systems is at least65 psi (448 kPa), the trailer air supply valve must bepushed in. It should stay in to charge the trailer airsupply system and to release the trailer spring park-ing brakes.

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

The yellow diamond-shaped knob in the controlpanel actuates the parking brake valve. SeeFig. 13.2. Pulling out the parking brake valve appliesboth the tractor and trailer spring parking brakes and

10/17/2001 f610591

Fig. 13.1, Trailer Brake Lever

f610291

1 2

03/10/99

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

Fig. 13.2, Brake Valve Knobs

Brake Systems

13.2

automatically causes the trailer air supply valve topop out.

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

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

If the trailer is not equipped with spring parkingbrakes, pulling out the parking brake valve appliesthe tractor spring parking brakes and the trailer ser-vice brakes. When the tractor and trailer parkingbrakes (or trailer service brakes) are both applied,the trailer brakes are released by pushing in thetrailer air supply valve, leaving the tractor parkingbrakes applied. Air pressure in the primary or sec-ondary reservoir must be at least 65 psi (447 kPa)before the tractor spring parking brakes, or the trailerservice or spring parking brakes, can be released.

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

When the brake pushrod stroke exceeds the legalbrake adjustment limit on a vehicle, there is likely amechanical problem with the foundation brake com-ponents or the adjuster is improperly installed.

Visit a repair facility as soon as possible whenbrakes equipped with automatic slack adjusters aredetermined to be out of adjustment.

WARNINGManually adjusting an automatic slack adjuster tobring the pushrod stroke within legal limits islikely masking a mechanical problem. Adjustmentis not a repair. Before adjusting an automaticslack adjuster, troubleshoot the foundation brakesystem and inspect it for worn or damaged com-

ponents. Improperly maintaining the vehicle brak-ing system may lead to brake failure, resulting inproperty damage, personal injury, or death.

Meritor WABCO® AntilockBraking SystemThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel speed monitoring and controlsystem that works with the standard air brake sys-tem. ABS passively monitors vehicle wheel speed atall times, and controls wheel speed during emer-gency stops.

IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit. Installing different-sized tires could result in a reduced brakingforce, leading to longer stopping distances.

ABS includes signal-generating tone wheels and sen-sors located in the wheel hubs of each sensedwheel. The sensors transmit vehicle wheel speedinformation to an electronic control unit (located be-hind the center dash). The control unit’s main circuitinterprets the speed sensor signals and calculateswheel speed, wheel retardation, and a vehicle refer-ence speed. If the calculations indicate wheel lockup,the main circuit signals the appropriate modulatorvalve to reduce braking pressure. During emergencybraking, the modulator valve alternately reduces, in-creases, or maintains air pressure supply in thebrake chamber to prevent front and rear wheellockup.

The electronic control unit (ECU) also has a safetycircuit that constantly monitors the wheel sensors,traction control valve (if equipped), modulator valves,and the electrical circuitry.

The Meritor WABCO ABS combines one front-axlecontrol channel with one rear-axle control channel toform one control circuit. For example, the sensor andmodulator valve on the left-front axle form a controlcircuit with the sensor and modulator valve on theright-rear axle. If, during vehicle operation, the safetycircuit senses a failure in any part of the ABS, thetractor warning lamp (TRACTOR ABS) illuminatesand the control circuit where the failure occurred isswitched to normal braking action. The remainingcontrol circuit will retain the ABS effect. Even if theABS is completely inoperative, normal braking ability

Brake Systems

13.3

is maintained. An exception would be if a modulatorvalve (or combination modulator valve) is damagedand inoperative. As these components are an integralpart of the air brake system, normal braking may beimpaired or inoperative.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS will control allwheels to provide steering control and a reducedbraking distance.

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

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

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

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

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

• If the lamp illuminates and stays on during ve-hicle operation, there is a fault with the trailerABS. Repair the trailer ABS system immedi-ately to ensure full antilock braking capability.

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

Automatic Traction ControlVehicles with electronic engines and ABS may haveAutomatic Traction Control (ATC). On these vehicles,the ATC system automatically limits wheel spin dur-

ing reduced-traction situations. In normal braking ap-plications, the standard air brake system is in effect.

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

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

ATC includes a deep snow and mud option to in-crease available traction on extra soft surfaces likesnow, mud, or gravel. A rocker switch labeled ATCwill be located on the dash. Pressing the switch willtemporarily allow more drive wheel spin. The activa-tion of the deep snow and mud option is indicated bya flashing WHEEL SPIN lamp. Pressing the switchagain will cycle the system back to normal operation.

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

After the ignition switch is turned on, the TRACTORABS lamp and the WHEEL SPIN indicator lampcome on for about three seconds. After three sec-onds, the warning lights go out if all of the tractor’sABS components are working.

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

ECAS Automatic Load Transfer(ECAS only)On vehicles equipped with Electronically ControlledAir Suspension (ECAS), ECAS works in conjunctionwith ABS. When wheel slippage is detected by theABS, the ECAS system transfers weight from the tagaxle to the drive axle by changing air pressures inthe suspension air bellows, increasing drive wheeltraction.

Brake Systems

13.4

The ECAS Load Transfer feature is optimized toapply the maximum available vehicle load on thedrive axle, up to the maximum allowable limit, deter-mined by the gross axle weight rating (GAWR). Inbobtail or with a loaded trailer less than the GAWR,the tag axle supports a negligible load while the driveaxle supports nearly the full weight. Above theGAWR, the drive axle is loaded with approximatelythe maximum allowable load and the tag supportsthe remainder.

On vehicles equipped with the ICU4Me, when LoadTransfer mode is active, "Load Transfer" will displayin the message field of the driver message center.See Figure 13.3.

Load transfer mode will automatically deactivatewhen the vehicle reaches 45 mph (72 kmh).

Engine BrakeEach engine manufacturer uses a specific enginebrake for their engine. Regardless of the manufac-turer, the engine brake is operated with the principlesoutlined in here. Refer to the engine manufacturer’soperation manual for details of their particular enginebrake product.

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

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

• when driving without a trailer or pulling anempty trailer;

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

NOTE: When the engine brake is enabled, theengine brake lamp illuminates in the ICU. SeeFig. 13.4, Item 1.

Whenever vehicle braking is required on good roadconditions, the engine brake may be used in con-junction with the service brakes. There is no timelimit for operation of the engine brake. However, anengine brake does not provide the precise control of,and is not a substitute for, service brakes.

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

Since the engine brake is most effective at rated en-gine speed, gear selection is very important. Gearingdown the vehicle within the limits of the rated enginespeed makes the engine brake more effective. Rec-ommended engine braking speed is above 1800 rpmand below the rated speed.

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

"Control speed" is the speed at which the enginebrake performs 100 percent of the required downhillbraking, resulting in a constant speed of descent.The control speed varies, depending on vehicleweight and the downhill grade.

For faster descent, select a higher gear than thatused for control speed. Service brakes must then beused intermittently to prevent engine overspeed andto maintain desired vehicle speed.

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

02/04/2015 f611291

Fig. 13.3, Load Transfer Notification, ICU4Me Only

Brake Systems

13.5

If the engine is equipped with both cruise control andan engine brake, the engine brake can operate auto-matically while cruise control is activated. The maxi-mum amount of braking is selected with the enginebrake control. When the vehicle returns to the setcruise speed, the engine brake will turn off.

The engine brake will only operate when the accel-erator and clutch pedals are fully released.

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

Engine Brake Operation

NOTICEDo not allow the engine to exceed its governedspeed, or serious engine damage could result.

NOTE: Depending on the brake type, the enginebrake may be disabled when engine tempera-ture falls below a set level.

The engine brake control depends on vehicle con-figuration. On some vehicles, there is an enginebrake (ENG BRK) switch located in the right-handpod on the steering wheel that is used to turn theengine brake on and off, and an engine brake levelswitch on the dash used to set the intensity—high,medium, or low. See Fig. 13.5 and Fig. 13.6.

ABS ABSCHECK STOP

OPT 2 OPT 4 OPT 5 OPT 6 OPT 9

05/07/2012 f611094

1

6 7 8 9 10 11

12 13 14 15 16 17

18 19 21 22 24 2520 23

2 3 4 5

IDLE

MGMT

BRAKE

1. Engine Brake2. Optional3. Wait To Start4. Check Transmission5. Optimized Idle6. CHECK Engine7. STOP Engine8. Malfunction Indicator Lamp (MIL)9. Vehicle ABS10. Transmission Overheat

11. Trailer ABS12. Low Engine Oil Pressure13. High Coolant Temperature14. Unfastened Seat Belt15. Park Brake On16. Diesel Particulate Filter (DPF)

Status17. High Exhaust Temperature

(HEST)

18. Left-Turn Signal19. Low Battery Voltage20. Water In Fuel21. Driver Message Center22. High Beams On23. Brake Air24. Cruise Control On25. Right-Turn Signal

Fig. 13.4, ICU3 Message Center (typical)

Brake Systems

13.6

On vehicles equipped with a column-mounted Detroitmultifunction control, the engine brake is controlledby the lever position, as shown in Fig. 13.7. At thetop position, the engine brake is off, and at the threelower positions, the engine brake is on and the inten-sity (low, medium, high) increases with each stepdown.

NOTE: On vehicles equipped with a Detroit mul-tifunction control, setting the engine brake withthe cruise control set activates DecelerationMode. Setting the cruise control while the en-gine brake is on activates Descent ControlMode. For information on these modes, see"Cruise Control" in Chapter 5.

On vehicles equipped with an engine brake switch inthe right-hand pod on the steering wheel, operate theengine brake after the engine is warmed up and thevehicle is in motion, as follows:

1. Remove feet from both the clutch and accelera-tor pedals.

2. Press the upper half of the on/off switch (seeFig. 13.5) to turn the engine brake on. The en-gine brake will engage at the rate last set on theengine brake intensity switch and the enginebrake lamp will illuminate.

3. Press the upper or lower half of the intensityswitch (see Fig. 13.6) to select the desired brak-ing intensity.

Use the intensity switch set at the LOW positionwhen driving on flat, open stretches of road. Ifthe service brakes are still required to slow downon a grade, switch to a higher setting on thedash switch to maintain constant speed of de-scent. Grade descent speed should be such thatthe service brakes are used infrequently and re-main cool, thus retaining their effectiveness.

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

5. To cancel the engine brake application, press thelower half of the on/off switch.

06/15/2007

ON/OFF

ACC/RES

CNCL

DEC/SET

MRKRINT

ENGBRK

−

+

f462049a

Fig. 13.5, Steering Wheel Switches

ENGBRK

f61090505/02/2007

HI

LO

Fig. 13.6, Engine Brake Level Switch

Brake Systems

13.7

0

1

2

3

02/19/2013 f270164a

0. Off1. Low

2. Medium3. High

Fig. 13.7, Engine Brake Positions, Detroit MultifunctionControl

Brake Systems

13.8

14

Manual Transmissions andHydraulic Clutch

Eaton Fuller 13-Speed and 18-Speed Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . 14.1Eaton Fuller 10-Speed Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5

Eaton Fuller 13-Speed and 18-Speed Splitter and Range-ShiftTransmissionsRefer to the Eaton website for additional information,www.roadranger.com.

General Information, Eaton FullerSplitter and Range-ShiftCombination splitter and range-shift transmissionsallow the choice of two splitter ratios in each leverposition as well as the additional ratio provided ineach lever position after shifting to the other range.

IMPORTANT: Not all lever positions are used ineach range and the shift patterns vary betweentransmissions. Be sure to read the shift patterndecal on the dash for the operating instructionsfor the specific transmission installed in your ve-hicle.

13-Speed RTLO ModelsEaton Fuller 13-speed transmissions have thirteenforward speeds and two reverse speeds. Each trans-mission consists of a 5-speed front section, and a3-speed auxiliary section. The auxiliary section con-tains low- and high-range ratios, plus an overdrivesplitter gear. See Fig. 14.1 for the shift pattern.

All of the 13 speeds are controlled with one shiftlever. A range preselection lever and a splitter controlbutton are built into the shift knob. The range prese-

lection lever controls range selection and the splittercontrol button (located on the side of the shift knob)controls gear splits.

Low gear in the front section is used only as a start-ing ratio. The remaining four forward positions areused once in the low range and once in the highrange. However, each of the four high range gearpositions can be split with the underdrive ratio (RTmodels), or overdrive ratio (RTO models) of the split-ter gear. Ratios cannot be split while the transmis-sion is in low range.

18-Speed RTLO Splitter and Range-ShiftModelsEaton Fuller 18-speed transmissions have 18 forwardspeeds and four reverse speeds. These transmis-sions consisting of a 5-speed front section and a3-speed auxiliary section. The auxiliary section con-tains low and high range ratios, plus an overdrivesplitter gear.

One ratio in the front section (low) is used as a start-ing ratio; it is never used when the transmission is inhigh range. Low gear can be split to provide both adirect and an overdrive ratio.

The other four ratios in the front section are usedonce in low range and once again in high range;however, each of the five ratios (low–1–2–3–4) in lowrange and each of the four ratios (5–6–7–8) in highrange can be split with the overdrive splitter gear.

All of the 18 speeds are controlled with one shiftlever. A range preselection lever and a splitter controlbutton are built into the shift knob. The range prese-lection lever controls range selection and the splittercontrol button (located on the side of the shift knob)controls gear splits.

Operation, Eaton Fuller Splitter andRange-ShiftIMPORTANT: The shifter knob has an interlockfeature that prevents the splitter control buttonfrom being moved forward when the range pre-selection lever is down (in low range); when inhigh range and the splitter control button is inthe forward position, the range preselectionlever cannot be moved down.

R1 3

2 4LOW

Dir OD5 5

Dir OD

Dir OD Dir OD

7 7

6 6 8 8

Hi

Lo

A

B

C D

1

03/13/96 f260044a

N

A. High RangeB. Low Range

C. Overdrive (forward)D. Direct Drive (rearward)

1. Splitter Control Button

Fig. 14.1, Eaton Fuller 13-Speed Transmission ShiftPattern

Manual Transmissions and Hydraulic Clutch

14.1

www.roadranger.com

1. When operating off-road, or under adverse condi-tions, always use low gear when starting to movethe vehicle forward.

When operating on-highway, with no load, orunder ideal conditions, use 1st gear when start-ing to move the vehicle forward.

For all conditions, use the highest gear that isstill low enough to start the vehicle moving withthe engine at or near idle speed, and withoutslipping the clutch excessively.

2. Use the clutch brake to stop gear rotation whenshifting into low (or 1st) or reverse when the ve-hicle is stationary. The clutch brake is actuatedby depressing the clutch pedal all the way to thefloor.

For normal upshifts and downshifts, only a partialdisengagement of the clutch is necessary tobreak engine torque.

3. Use double-clutching between all upshifts anddownshifts that require movement of the shiftlever. Splitting of the high range gears does notrequire movement of the shift lever.

4. Never move the shift lever into low gear while inhigh range.

5. Never move the splitter control button while inneutral.

6. Do not preselect with the splitter control button;after moving the control button, complete theshift immediately.

7. Except when downshifting from 5th direct to 4thgear, never push the range preselection leverdown into low range while operating in highrange—the splitter will become inoperative.

8. Do not shift from high range to low range at highvehicle speeds.

9. Do not make range shifts with the vehicle movingin reverse gear.

10. Never attempt to move the range preselectionlever with the gear shift lever in neutral while thevehicle is moving. Preselection with the rangepreselection lever must be made prior to movingthe shift lever out of gear into neutral.

11. After your shifting ability improves, you may wantto skip some of the ratios. This may be done

only when operating conditions permit, depend-ing on the load, grade, and road speed.

Upshifting1. Position the gear shift lever in neutral. Start the

engine, and bring the air system pressure up to100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down, intolow range. See Fig. 14.2.

3. Make sure the splitter control button is in the di-rect (rearward) position. See Fig. 14.2.

4. For 13-speed transmissions:

Press the clutch to the floor, shift into low or 1stgear; then engage the clutch, with the engine ator near idle speed, to start the vehicle moving.Accelerate to 80 percent of engine governedspeed.

For 18-speed transmissions:

Press the clutch to the floor, shift into low; thenengage the clutch, with the engine at or near idlespeed, to start the vehicle moving.

To shift from low direct to low overdrive, movethe splitter control button into the overdrive (for-ward) position, then immediately release the ac-celerator. Press and release the clutch pedal.After releasing the clutch, accelerate again.

5. For 13-speed transmissions:

Shift upward from low to 1st gear, 2nd, etc. until4th gear, double-clutching between shifts, and

N

R 1Dir

5Dir

5OD1

OD3

Dir

7Dir

7OD3

OD

2Dir

6Dir

6OD2

OD4

Dir

8Dir

8OD4

ODLOWDir

LOWOD

A

B

C D

1

03/13/96 f260157a

A. High RangeB. Low Range

C. Overdrive (forward)D. Direct Drive (rearward)

1. Splitter Control Button

Fig. 14.2, Eaton Fuller 18-Speed Transmission ShiftPattern


14.2

accelerating to 80 percent of engine governedspeed. See Fig. 14.1.


Shift upward from low overdrive to 1st direct byfirst moving the splitter control button into thedirect (rearward) position (Fig. 14.2). Move theshift lever, double-clutching, to the 1st gear posi-tion.

Continue upshifting through the shift pattern.Double-clutch during lever shifts (1st to 2nd to3rd to 4th); single-clutch during split shifts (1stdirect to 1st overdrive, etc.).

6. When in 4th gear (13-speed transmissions) or4th overdrive (18-speed transmissions) andready to shift up to 5th gear, use the range shiftlever as follows:


While in 4th gear, pull the range shift preselec-tion lever up, into high range. The transmissionwill automatically shift from low to high range asthe shift lever passes through neutral. Then, dis-engage the clutch; double-clutch through neutral;move the shift lever to 5th gear; engage theclutch, and accelerate the engine.


While in 4th overdrive, pull the range shift prese-lection lever up, into high range. The transmis-sion will automatically shift from low to highrange as the shift lever passes through neutral.

Move the shift lever, double-clutching, to the 5thgear position. Just before making final clutch en-gagement, move the splitter control button to thedirect (rearward) position; then engage the clutchand accelerate. Do not move the control buttonwhile the shift lever is in neutral.

7. Shift up through the high range gears as follows:


To shift from 5th direct to 5th overdrive, move thesplitter control button (Fig. 14.1) into the over-drive (forward) position, then immediately releasethe accelerator. Press and release the clutchpedal. After releasing the clutch, accelerateagain.

Continue upshifting through the shift pattern.Double-clutch during lever shifts (6th to 7th to

8th); single-clutch during split shifts (6th direct to6th overdrive, etc.).


To shift from 5th direct to 5th overdrive, move thesplitter control button (Fig. 14.2) into the over-drive (forward) position, then immediately releasethe accelerator. Press and release the clutchpedal. After releasing the clutch, accelerateagain.

Continue upshifting through the shift pattern.Double-clutch during lever shifts (6th to 7th to8th); single-clutch during split shifts (6th direct to6th overdrive, etc.).

Downshifting1. Downshift from 8th overdrive to 8th direct without

moving the shift lever. Flip the splitter control but-ton to the direct (rearward) position, then imme-diately release the accelerator, and disengagethe clutch. Engage the clutch, and accelerate theengine only after the transmission has shifted.

2. Start the downshift from 8th direct to 7th over-drive by flipping the splitter control button to theoverdrive (forward) position; then, immediatelydouble-clutch through neutral, moving the shiftlever from 8th to 7th gear.

3. Shift downward through each of the high rangegears, alternating the procedures in steps 1 and2, above, until reaching 5th direct.

4. While in 5th direct and ready for the downshift to4th (13-speed transmissions) or 4th overdrive(18-speed transmissions), push the range prese-lection lever down. Then, double-clutch throughneutral and move the shift lever to the 4th gearposition. On 18-speed transmissions, move thesplitter control button to the overdrive (forward)position beforeengaging the clutch. Do not movethe control button while the shift lever is in neu-tral.

5. Continue downshifting from 4th to 1st as follows:


Downshift through the low range gears as condi-tions require.



14.3

Continue downshifting from 4th overdrive to 4thdirect, then 4th direct to 3rd overdrive, 3rd over-drive to 3rd direct, etc. Single-clutch when splitshifting (direct to overdrive, overdrive to direct).Double-clutch when making lever shifts (4th to3rd, 3rd to 2nd, etc.).

IMPORTANT: Never use the clutch brake whendownshifting, or as a brake to slow the vehicle.

Eaton Fuller 10-Speed Range-Shift TransmissionsRefer to the Eaton website for additional information,www.roadranger.com.

General Information, Eaton FullerRange-ShiftTo operate a range-shift transmission, move the shiftlever through all the low gear positions and then acti-vate a range switch to provide an additional set ofratios in the high range. Using the same shift leverpositions as in low range, move the shift leverthrough each position as before. On some models,the initial low gear is often used only in low range.

IMPORTANT: Not all lever positions are used in eachrange and the shift patterns vary between transmis-sions. Be sure to read the shift pattern decal on thedash for the operating instructions for the specifictransmission installed in your vehicle.

10-Speed FR/FRO and RT/RTO/RTXModelsEaton Fuller 10-speed transmissions have 10 selec-tive, evenly spaced forward ratios. Each transmissionhas a 5-speed front section and a 2-speed rearrange section. The 10 forward speeds are obtainedby twice using a 5-speed shift pattern: the first timein low range, the second time in high range. SeeFig. 14.3 for the shift patterns.

NOTE: The 4th/9th and the 5th/10th shift posi-tions in the RT (direct ratio) and RTX (overdriveratio) transmissions are directly opposite in theRTO (overdrive ratio) transmissions

Operation, Eaton Fuller Range-Shift1. When operating off-highway, or under adverse

conditions, always use low gear (if so equipped)when starting to move the vehicle.

When operating on-highway, with no load, orunder ideal conditions, use 1st gear when start-ing to move the vehicle (except when equippedwith a 9-speed RTO transmission, then alwaysstart in low gear).

For all conditions, use the highest gear that isstill low enough to start the vehicle moving withengine idling, and without slipping the clutch ex-cessively.

2. Use the clutch brake to stop gear rotation whenshifting into low (or 1st) or reverse when the ve-hicle is stationary. The clutch brake is actuatedby depressing the clutch pedal all the way to thefloor.

For normal upshifts and downshifts, only a partialdisengagement of the clutch is necessary tobreak engine torque.

3. Do not make range shifts with the vehicle movingin reverse gear.

4. Never attempt to move the range preselectionlever with the gear shift lever in neutral while thevehicle is moving. Preselection with the rangepreselection lever must be made prior to movingthe shift lever out of gear into neutral.

5. Do not shift from high range to low range at highvehicle speeds.

4

N

7 2

9

6 1

8 3

10 5

R HI

LO

f261053

A

B

12/15/1999

A. High Range B. Low Range

Fig. 14.3, Eaton Fuller 10-Speed Transmission ShiftPatterns


14.4

www.roadranger.com

6. Double-clutch between all upshifts and down-shifts.

7. After your shifting ability improves, you may wantto skip some of the ratios. This may be doneonly when operating conditions permit, depend-ing on the load, grade, and road speed.

Upshifting1. Position the gear shift lever in neutral. Start the

engine, and bring the air system pressure up to100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down, intolow range.

3. Press the clutch pedal to the floor; shift into lowor 1st gear (Table 14.1), then engage the clutch,with the engine at or near idle speed, to start thevehicle moving. Accelerate to 80 percent of en-gine governed speed.

Eaton Fuller Shift Progressions

TRANS.MODEL

LOW RANGE HIGHRANGEOff-Highway On-Highway

10-SpeedDirect orOverdrive

(RT orRTX)

2

3

4

1

f260329

R

5

2

3

4

1

f260329

R

5

9

8 10

7

f260330

R

6

Table 14.1, Eaton Fuller Range-Shift ShiftProgressions

4. Shift progressively upward from low or 1st gear,to the top gear in low range (Table 14.1),double-clutching between shifts, and acceleratingto 80 percent of engine governed speed.

5. While in the top gear of the low range shift pat-tern, and ready for the next upshift, flip the rangepreselection lever up into high range. Double-clutch through neutral, and shift into the bottomgear in high range (Table 14.1). As the shift leverpasses through neutral, the transmission will au-tomatically shift from low range to high range.

6. With the transmission in high range, shift pro-gressively upward through each of the highrange gears (Table 14.1), double-clutching be-tween shifts.

Downshifting1. With the transmission in high range, shift pro-

gressively downward to the bottom gear in highrange, double-clutching between shifts.

2. When in the bottom gear of the high range shiftpattern, and ready for the next downshift, pushthe range preselection lever down into low range.Double-clutch through neutral, and shift into thetop gear of the low range shift pattern. As theshift lever passes through neutral, the transmis-sion will automatically shift from high range tolow range.

3. With the transmission in low range, downshiftthrough the low range gears as conditions re-quire.

IMPORTANT: Never use the clutch brake whendownshifting, or as a brake to slow the vehicle.

ClutchGeneral InformationThe hydraulic clutch control system consists of apedal unit and a slave cylinder, connected by a hy-draulic hose and fastened with quick-disconnectclamps. The components of the system have beenspecially designed to use DOT 4 brake fluid. Thepedal unit includes a hydraulic subassembly, com-posed of the master cylinder and reservoir, whichcan be removed from the pedal unit for service pur-poses. When the clutch pedal is depressed, the fluidin the master cylinder is forced through a hydraulicline to the slave cylinder. The fluid pressure movesthe slave cylinder piston, pushing the plunger rodand clutch release lever, which disengages theclutch. The hydraulic system is self-adjusting.

Clutches are designed to absorb and dissipate moreheat than encountered in typical operation. The tem-peratures developed in typical operation will notbreak down the clutch friction surfaces. However, if aclutch is slipped excessively, or asked to do the jobof a fluid coupling, high temperatures develop quicklyand destroy the clutch. Temperatures generated be-tween the flywheel, driven discs, and pressure platescan be high enough to cause the metal to flow andthe friction facing material to char and burn.

Heat and wear are practically nonexistent when aclutch is fully engaged. But during the moment ofengagement, when the clutch is picking up the load,


14.5

it generates considerable heat. An improperly ad-justed or slipping clutch will rapidly generate suffi-cient heat to destroy itself.

To ensure long service life of the clutch; start in theright gear, be alert to clutch malfunctions, and knowwhen to adjust the clutch.

Clutch OperationClutch Break-InWith a new or newly installed clutch, the clutch mayslip for a short time while the friction surfaces break-in. However, allowing the clutch to slip for more thantwo seconds can severely damage the clutch disc,pressure plate, and the flywheel.

During initial operation of a new vehicle or a vehiclewith a new clutch, check for clutch slippage duringacceleration. If the clutch slips, decelerate until theclutch does not slip. Allow the clutch to cool 15 to 30seconds, and then gradually accelerate again. If theclutch continues to slip, repeat the procedure. If nec-essary, repeat the procedure up to five times. If theclutch slips after five attempts, stop the vehicle. Allowthe clutch to cool for at least one hour. Notify yourFreightliner dealer of the problem.

CAUTIONDo not allow sustained slippage of the clutch;this could severely damage the clutch disc, pres-sure plate, or flywheel. Damage caused by clutchslippage due to improper break-in is not warrant-able.

Moving the Vehicle in the Proper GearAn empty truck can be started in a higher transmis-sion gear than can a partially or fully loaded truck. Agood rule of thumb for the driver to follow is to selectthe gear combination that allows the vehicle to startmoving with an idling engine, or, if necessary, justenough throttle to prevent stalling the engine. Afterthe clutch is fully engaged, the engine can be accel-erated to the correct rpm for the upshift into the nexthigher gear.

Gear Shifting TechniquesShift into the next higher gear when the vehiclespeed allows the transmission input shaft speed tomatch the flywheel speed when engaging the clutch.This technique results in the smallest speed differ-

ence between the clutch disc and the flywheel andcauses the least heat and wear on the clutch assem-bly. When downshifting, the input shaft speed mustbe increased by slightly revving the engine to matchthe flywheel speed for smooth clutch engagement.For transmission operating instructions, refer to thetransmission headings in this manual.

Vehicle LoadingClutches are designed for specific vehicle applica-tions and loads. These weight limitations should notbe exceeded.

CAUTIONExceeding vehicle load limits can not only resultin damage to the clutch, but can also damage theentire powertrain.

Using the ClutchThe clutch pedal must be used only to start the ve-hicle moving or while shifting. To start the vehiclemoving, depress the clutch pedal all the way to thefloor plate (see "Using the Clutch Brake") and shiftfrom neutral to a low gear. Slowly raise your foot untilthe clutch starts to engage. In this position the clutchis starting to connect the transmission input shaft tothe flywheel and is causing the most heat and wear.Slightly increase the engine speed and smoothlyallow the clutch pedal to return to its at rest position.Do not allow the clutch to remain in the partially en-gaged position any longer than necessary to obtain asmooth start.

To shift gears while the vehicle is moving, push theclutch pedal most of the way (but not all of the way)to the floor plate. Shift the transmission into neutraland fully release the clutch pedal. If upshifting, waitlong enough for the engine speed to decrease to theroad speed. If downshifting, increase the enginespeed to match the road speed. Again, push downthe clutch pedal part way and then move the shiftlever to the next gear position. Fully release theclutch pedal after completing the shift.

Slightly depressing the clutch pedal while driving isdamaging to the clutch, because partial clutch en-gagement causes slippage and heat. Resting yourfoot on the clutch pedal will also put a constant thrustload on the release bearing, thinning the bearing lu-bricant and increasing the wear on the bearing.


14.6

Using the Clutch BrakeThe clutch brake is applied by depressing the clutchpedal past the fully released clutch position, almostto the floor plate. The last part of the clutch pedaltravel will compress the clutch brake plates together,stopping the transmission input shaft. The purpose ofthe clutch brake is to stop the transmission gearsfrom rotating in order to quickly engage a transmis-sion gear after idling in neutral.

CAUTIONNever apply the clutch brake when the vehicle ismoving. If the clutch brake is applied when thevehicle is moving, the clutch brake will try tostop or decelerate the vehicle, causing rapidwear of the clutch brake friction discs. Consider-able heat will be generated, causing damage tothe release bearings and the transmission frontbearings.

Holding the Vehicle on an InclineAlways use the vehicle service brakes to prevent thevehicle from rolling backwards while stopped on ahill. Slipping the clutch on a hill to maintain the ve-hicle position will quickly damage the clutch assem-bly.

CoastingCoasting with the clutch pedal depressed and thetransmission in a low gear can cause high drivendisc speed. The clutch speed can be much higherunder these conditions than when the engine is driv-ing the clutch. This condition creates a hazardoussituation due to the lack of vehicle control and due tothe high clutch disc speed. Engaging the clutchunder these conditions can cause component dam-age because of the shock loads to the clutch anddrivetrain.

WARNINGAlways shift into the gear that is correct for thetraveling speed of the vehicle and engage theclutch. Coasting with the clutch disengaged canprevent engagement of the correct transmissiongear which can cause loss of vehicle control,possibly resulting in personal injury or propertydamage.

High clutch disc speeds while coasting can alsocause the clutch facing to be thrown off the disc.Flying debris from the clutch can cause injury topersons in the cab.

Clutch MaintenanceClutch AdjustmentEaton Fuller Solo clutches are adjustment-free. Asthe clutch wears, its wear-adjusting technology moni-tors clutch components and makes any necessaryadjustments. The wear adjusting technology comesfrom two sliding cams, which rotate to maintain theproper adjustment. Atop the upper cam, a wear indi-cating tab mirrors the cam’s movement, letting youknow when it’s time to replace the clutch.

CAUTIONOperating the vehicle with incorrect free pedalcould result in clutch damage.

Hydraulic Clutch Fluid ReservoirCheckingMake sure that the clutch fluid reservoir is full. SeeFig. 14.4. The reservoir is full when the fluid level isup to the "max" mark. The fluid level must always beabove the "min" mark. Use only heavy-duty brakefluid, DOT 4, in the clutch hydraulic system.

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Fig. 14.4, Clutch Fluid Reservoir


14.7

15

Automated TransmissionsDetroit™ Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Freightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6Eaton Fuller AutoShift Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11Eaton Fuller UltraShift PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14

Detroit™ AutomatedTransmissionsDetroit transmissions have twelve forward gears andup to four reverse gears that can be shifted automati-cally or manually. Shifting and clutch actuation arecomputer controlled, and there is no clutch pedalneeded to operate the vehicle. Automatic shifts areselected for fuel economy or engine power. Manualshifts can be requested with the shift control and thetransmission ECU grants them when conditions per-mit. In all cases, shifts depend on the following fac-tors: engine speed, accelerator pedal position, ser-vice brake usage, engine brake operation, vehicleload status, and road conditions.

NOTE: To avoid potential engine stall risk or un-expected shifting, use the interaxle differentiallock when the vehicle is operated in slipperyconditions. See Chapter 16 for informationabout the interaxle differential lock.

Detroit™ Multifunction ControlVehicles with Detroit transmissions use the controlshown in Fig. 15.1. This control can be used to re-quest manual shifts, change driving mode, and setengine brake levels. See Table 15.1 for an overviewof control functionality.

D/N/R SwitchUse the "D/N/R Switch" to request drive (D), neutral(N), or reverse (R).

Mode SwitchThe driving mode can be changed using the Modeswitch on the shift control (see Fig. 15.1). To activatethe manual drive mode, press and hold the switchbriefly. Press the switch quickly to activate the auto-matic drive mode or change between AutomaticEconomy and Automatic Performance modes.

Upshifting and DownshiftingGear shifts can be requested manually; push thelever away to request a downshift, or pull the levertoward you to request an upshift. See Table 15.1 formore information about upshift and downshiftrequests.

B

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1

( + )

( − )

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C

See Table 15.1 for a description of control functionality.A. Front ViewB. Shift RequestsC. Four positions for engine brake settings1. Engine Brake Symbol2. D/N/R Switch3. Mode Switch4. Gear Shift Symbol

Fig. 15.1, Detroit Multifunction Control

Automated Transmissions

15.1

Functionality, Detroit Multifunction ControlFunction/Switch Action/Position Request

D/N/RD Forward gearsN NeutralR Reverse gears

ModeDepress switch and release it quickly Activate the automatic drive mode, or switch between

Automatic Economy and Automatic Performance.Depress switch and hold it briefly Activate the manual drive mode.

Upshifting andDownshifting

Pull the lever toward you momentarily Upshift, single gearPull the lever toward you in quick repetitions Upshift, multiple gearsPush the lever away momentarily Downshift, single gearPush the lever away in quick repetitions Downshift, multiple gears

Engine Brake*

Lever at position 0 (top) Engine brake offLever at position 1 Low intensityLever at position 2 Medium intensityLever at position 3 (bottom) High intensity

* For functions with cruise control active, see Chapter 5.

Table 15.1, Functionality, Detroit Multifunction Control

Engine BrakeThe engine brake is controlled by the lever position(as shown in Fig. 15.1, Ref. C). At the top position,the engine brake is off, and at the three lower posi-tions, the engine brake is on and the intensity (low,medium, high) increases with each step down. Formore information about using the engine brake, seeChapter 13.

NOTE: Using the engine brake with cruise con-trol can be used to activate Descent ControlMode or Deceleration Mode. For more informa-tion, see "Cruise Control" in Chapter 5.

Power Up and Shift into Gear1. With the parking brake set and Neutral (N) se-

lected on the shift control, turn the ignition switchto the ON position.

2. Start the engine.

3. Apply the service brake.

4. Select the desired starting gear.

5. Release the parking brake.

6. Release the service brake and apply the accel-erator.

Gear Display WindowThe gear display window shows the current transmis-sion gear and driving mode. See Fig. 15.2.

Driving ModesThere are three driving modes: Manual, AutomaticEconomy, and Automatic Performance.

In Automatic Economy mode, gear shifts are de-signed for saving fuel. In Automatic Performancemode, gear shifts are designed for higher perfor-mance and are made at higher engine speeds. Inmanual mode, gear shifts are requested manually.See Chapter 5 for more information about upshiftingand downshifting using the control.

5A econ

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1. Driving Mode2. Current Gear

Fig. 15.2, Gear Display Window


15.2

NOTE: In Automatic Performance mode, thetransmission will automatically change to Auto-matic Economy mode if it hasn’t received a re-quest for more power in several minutes, unlesscurrent road conditions require higher engineperformance.

Selected GearIf the selected gear is different than the current gearfor longer than a half second, the current gear dis-play will flash and the selected gear value will beshown. Once the current gear and selected gearmatch, the selected gear display disappears and thecurrent gear display stops flashing. See Fig. 15.3.

Suggested ShiftIn Manual mode only, a suggested shift is displayedto indicate the most economical gear available. Thesuggested shift is the number of up or down arrowsfrom the current gear with a maximum of three up ordown arrows. See Fig. 15.4.

eCoastThe eCoast feature can improve driving economy.When conditions permit, the transmission control au-tomatically shifts the transmission to neutral to coastat speeds of approximately 22 mph (35 km/h) andabove. An "E" shows in the gear display windowwhen eCoast is in effect. See Fig. 15.5.

The eCoast function is not active when any of thefollowing occur:

• the accelerator pedal is pressed.

• vehicle acceleration rate is exceeded.

• the service brake pedal is pressed.

• the engine brake is in use.

• cruise control brakes or accelerates.

• vehicle speed exceeds the cruise control setspeed by more than approximately 4 mph (6km/h).

• the speed limiter is active and the maximumspeed set is exceeded.

• diesel particulate filter (DPF) regeneration oc-curs.

The eCoast function cannot be deactivated when theAutomatic Economy mode is active.

NOTE: To disable eCoast, see an authorizedFreightliner service facility.

Creep ModeCreep mode allows the vehicle to be maneuvered atvery slow speeds. To activate Creep mode for thefirst time within the current driving cycle, press theaccelerator pedal to launch the vehicle, thereby fully

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1. Selected Gear2. Current Gear

Fig. 15.3, Selected Gear Display

Manual

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1. Suggested Shift Arrows2. Current Gear

Fig. 15.4, Suggested Shift

E

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N70 °F

NOTE: Upshift and downshift arrows are not shownwhen "E" is shown in the gear display window.

Fig. 15.5, eCoast Display


15.3

engaging the clutch. Following this and for the dura-tion of the current driving cycle, Creep mode is ac-tive.

Once the vehicle is stopped via the service brakes,the vehicle will begin to creep again, without the ac-celerator pedal actuation, as soon as the servicebrakes are released.

To begin using Creep mode (once active) from aparked position, shift from neutral to either drive orreverse, release the service brakes, and briefly de-press the accelerator pedal. The vehicle’s urge tomove can then be felt.

If creep is active and no acceleration is achievedwithin five seconds, then Creep mode will abort. Adisplay message notifies the operator when Creepmode is about to be aborted.

IMPORTANT: When slowing down from higherspeeds in drive or reverse, remember thatCreep mode will be in effect at lower speeds.Use the service brakes to stop the vehicle.

Clutch Abuse ProtectionA vehicle equipped with a Detroit transmission doesnot have a clutch pedal, but still has a clutch that isoperated automatically and can be damaged by abu-sive driver actions. To protect the clutch, the vehiclehas a clutch abuse protection system that alerts thedriver and restricts functionality when needed. Ex-tended periods in Creep Mode, slipping the clutch(using the accelerator pedal to hold the vehicle on ahill, for example), and high clutch temperatures canactivate the clutch abuse protection system. A displaymessage notifies the operator when the protectionsare needed.

NOTICETo hold the vehicle stationary on an uphill slope,use the service brakes, not the accelerator pedal.Using the accelerator pedal can overheat anddamage the clutch. To start moving, use the ac-celerator pedal and release the brakes as the ve-hicle begins to move.

There are three clutch abuse protection levels. Ateach, the driver is alerted and functionality is modi-fied; see Table 15.2.

To avoid clutch overheating, follow these tips:

• To hold the vehicle stationary on an uphillslope, use the service brakes, not the accel-erator pedal.

• To start moving on an uphill slope, use the ac-celerator pedal and release the brakes as thevehicle begins to move.

• When hooking up to a trailer, ensure the traileris high enough to back under, and use firstgear reverse.

• Avoid starting in higher gears, and start in firstgear when a trailer is attached.

• Ensure trailer brakes have had time to com-pletely release prior to starting.

• Do not use Creep mode for an extended pe-riod. Stop or adjust the vehicle speed whenwarned to deactivate Creep mode.

Engine Overspeed AlertsTo help protect the engine, the system has displaymessages to notify the operator when the engine hasexceeded certain thresholds and needs to be sloweddown before significant engine damage occurs.There are two warnings, one at about 2400 rpm andanother at 2500 rpm, indicated with messages and afault code.

Low Transmission Air WarningPneumatic controls are used to shift the transmis-sion. If there is inadequate air pressure, a warning isdisplayed and the quality of gear shifts may be de-graded. Wait for air pressure to build before operat-ing the vehicle.

IMPORTANT: If the low transmission air warningindicator appears while the vehicle is in opera-tion, safely pull the vehicle off the road, and cor-rect the problem.

Clutch Abuse Alerts and Protections

Alert Level AlertProtections

Highest Start Gear Creep Mode Clutch Function1 Heavy clutch load message 1 No restriction Normal function


15.4

Clutch Abuse Alerts and Protections

Alert Level AlertProtections

Highest Start Gear Creep Mode Clutch Function2 Heavy clutch load message 1 Disabled Normal function

3 Clutch overload message andbuzzer 1 Disabled

If the accelerator pedal isdepressed, the clutch closesat fixed rate.

If the accelerator pedal isreleased, the clutch opens atfixed rate.

Table 15.2, Clutch Abuse Alerts and Protections

Freightliner SmartShift ShiftControlGeneral Information, SmartShiftThe SmartShift transmission control is an electronictransmission control device. It is installed with thefollowing transmissions:

• Eaton Fuller UltraShift™

• Eaton Fuller UltraShift™ PLUS

• Eaton Fuller AutoShift™

It replaces the typical floor-mounted shift lever ordash-mounted push button control.

SmartShift accepts driver requests for transmissionfunctions and transmits them through hard wiring tothe transmission control unit (TCU). SmartShift is atrue shift-by-wire system.

SmartShift offers two main advantages over conven-tional transmission control devices. Without a floor-mounted shift control, usable cab space is increased.The SmartShift control mounts to the right-hand sideof the steering column and is operated by the fingersof the driver’s right hand, allowing both hands to re-main on the steering wheel.

A two-position slide switch (Fig. 15.6) is mounted onthe body of the control lever just before the paddlewidens out. The slide switch allows the driver tochoose automatic (AUTO) or manual (MAN) mode.

In AUTO mode, gears shift automatically, withoutdriver interaction. Manual gearshifts are accom-plished by a momentary pull or push on the control inthe plane perpendicular to the steering wheel. Pullupward (toward you) on the control to upshift andpush downward (away from you) to downshift. The

control is spring-loaded and returns to mid-positionwhen released after an upshift or downshift.

For Eaton Fuller UltraShift, UltraShift PLUS, and Au-toShift transmissions (Fig. 15.6), a four-position (R,N, D, L) selector switch is located at the end of thelever.

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To upshift manually, pull the lever up (towards you). Todownshift manually, push the lever down (away fromyou).1. SmartShift Control Lever2. Slide Switch (forward driving mode switch)3. MAN Mode (of slide switch)4. AUTO Mode (of slide switch)5. Upshift Direction6. Reverse Position (of selector switch)7. Selector Switch8. Neutral Lock Button9. Neutral Position (of selector switch)10. Drive Position (of selector switch)11. Low Position (of selector switch)12. Downshift Direction

Fig. 15.6, SmartShift Control (Eaton Fuller UltraShift,UltraShift PLUS, and AutoShift Transmissions)


15.5

Embedded in the selector switch is a small neutrallock button to prevent accidental shifts into gear fromneutral. Any time you shift through N, press down onthe neutral lock button to move the switch from neu-tral (N) to another gear, such as drive (D), low (L), orreverse (R). When shifting to N, it is not necessary topress the neutral lock button.

Eaton Fuller UltraShiftGeneral Information, UltraShift DMEaton® Fuller® UltraShift™ DM is a ten-speed heavy-duty fully automated transmission. No clutch pedal isrequired to operate the vehicle.

UltraShift DM uses a dry clutch system which is of-fered only on this automated transmission system.

The UltraShift transmission uses the four-positionSmartShift lever on the steering column to selectgears. To know what gear the transmission is in, lookat the round current gear indicator on the right-handcontrol panel as shown in Fig. 15.7. All forward shiftscan be made either manually or automatically, at thedriver’s choice.

Operation, UltraShift DMPower Up1. With the parking brake set, select neutral (N) by

moving the selector switch to the N position.

2. With the transmission in neutral, turn on the igni-tion switch. The CHECK TRANS and TRANSTEMP telltale lights come on and go out again(bulb check).

3. After the ignition is turned on, the current gearindicator shows the dot display, arranged in asquare pattern. All dots in the pattern should lightup, without gaps or spaces. See Fig. 15.8.

4. Wait for the current gear indicator to show a solidN. When the N is solid, rather than flashing, theUltraShift DM TCU is powered up. Apply the ser-vice brake and start the engine.

5. Select drive (D) by pressing in the neutral lockbutton and moving the selector switch downwardto the position below neutral. Release the park-ing brake. The gear is displayed on the currentgear indicator.

NOTE: When D is selected, the transmissioncontroller starts up in second gear. If desired,the driver can select to start up in first. No otherstart gear is available.

6. On a level grade, release the service brake andpress down on the throttle pedal to allow the ve-hicle to move forward. The vehicle will not moveuntil the pedal is depressed.

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To know what gear the transmission is in, look at thecurrent gear indicator.1. Current Gear Indicator2. SmartShift Control

Fig. 15.7, Shift Controls and Indicators, UltraShiftTransmissions

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Fig. 15.8, Power-Up Dot Display


15.6

WARNINGWhen starting or stopping on hills and grades,use extra care to prevent the vehicle from rollingback. A rollback accident could cause death, seri-ous personal injury, or property damage.

7. Prevent the vehicle from rolling backwards whenstopped on a hill or grade, or when the vehicle isstarting from a stop on a hill or grade.

7.1 To start from a full stop on a hill or grade,quickly move your foot from the brakepedal and press firmly on the throttlepedal.

On steep hills, set the parking brake, andrelease it only when there is enough en-gine power to prevent rollback.

7.2 To stop on a hill or grade, press and holdthe brake pedal to keep the vehicle frommoving.

On steep hills, set the parking brake.When parking, chock the tires, front and/orrear. Never hold a hill with the throttlepedal. This will cause the clutch to over-heat.

Power Down1. Apply the service brakes.

2. Select neutral (N) by pressing in the neutral lockbutton and moving the selector switch to N.When the N on the current gear indicator is solid,rather than flashing, the UltraShift DM TCU isready to power down.

3. With the transmission in neutral, set the parkingbrake.

4. Turn off the ignition key and shut down the en-gine.

Automatic and Manual ModesThe SmartShift control has a slide switch located onthe body of the control lever just before the paddlewidens out. See Fig. 15.9. The slide switch controlsthe forward driving mode, automatic or manual.

To change mode at any time, move the slide switchin the desired direction. This allows the driver to re-spond to a wide range of driving conditions, such asblind corners, tight curves, and steep hills.

IMPORTANT: Whatever the mode, it is alwayspossible to shift manually by moving the leverup or down as needed. When the engine speedis within 75 revolutions per minute (rpm) of theload-based shift point for an automatic shift, theUltraShift DM TCU will advance the shift.

In either mode, the gear indicator displays the cur-rent gear. See Fig. 15.10.

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3

1. Slide Switch (controls forward driving mode)2. Selector Switch (controls gear selection)3. Neutral Lock Button (prevents accidental shift into

gear)

Fig. 15.9, Switches, UltraShift Transmissions

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

Fig. 15.10, Current Gear Display


15.7

At the start of a shift, the current gear continues todisplay until the transmission has been pulled intoneutral. At this point, as the transmission is synchro-nizing for the new (target) gear, the gear indicatorflashes the number of the new gear.

When the shift is complete, the new gear displayssolid, without flashing.

Automatic Mode (AUTO)In automatic drive mode (AUTO), upshifts and down-shifts are made by the transmission without driverintervention. Press in the neutral lock button, movethe selector switch to drive (D), and press down onthe throttle pedal. The transmission will shift auto-matically.

If driving conditions require, it is still possible to re-quest a manual shift. The transmission will make theshift if the engine speed is within 75 rpm of the load-based shift point for that gear.

If the driver presses down on the throttle pedal aftera manual downshift in automatic mode, the transmis-sion will upshift again if the UltraShift DM TCU re-quires it.

Manual Mode (MAN)In manual drive mode (MAN), upshifts and down-shifts are made by the driver:

• To shift up, pull the lever up (towards you).

• To shift down, push the lever down (away fromyou).

The system will hold the current gear until the driverrequests a shift. In downhill situations in particular,the driver must be alert to vehicle speed by down-shifting and/or using the service brakes as needed.

A shift request will still be refused if the selected gearwould cause engine overspeed or excessive lugging.

Selecting GearsReverseReverse (R) is at the upper end of the four-positionselector switch located at the end of the SmartShiftcontrol lever. To select R, press in the neutral lockbutton and move the selector switch upward to theposition above neutral.

UltraShift DM has two reverse gears, reverse lowand reverse high. To shift manually between them,

use the shift lever as described for MAN mode.There is no AUTO mode for reverse.

When reverse low is selected, the letter R displayson the current gear indicator. When reverse high isselected, the letter H displays on the current gearindicator. See Fig. 15.11.

IMPORTANT: Under normal conditions, do notselect reverse with the vehicle moving forward.

The vehicle must be moving at less than two milesper hour (3 km/h) before selecting reverse. If reverseis selected when the vehicle is moving faster, an au-dible alert will sound and continue sounding at three-second intervals until the control lever is returned tothe D position or the vehicle slows to the properspeed.

If necessary to rock the vehicle, use the selectorswitch to shift back and forth at low speed betweenreverse and drive.

Neutral

IMPORTANT: Always start the engine with thetransmission in neutral, the parking brake set,and the service brakes applied.

Neutral (N) is directly below R on the four-positionselector switch located at the end of the SmartShiftcontrol lever. To select N, press in the neutral lockbutton and move the selector switch to the positionbelow R. When neutral is selected, the letter N dis-plays on the current gear indicator. See Fig. 15.12.

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Fig. 15.11, Reverse Gear Display


15.8

WARNINGDo not coast in neutral. Coasting in neutral cancause an accident, possibly resulting in severepersonal injury or death.

Neutral is always available during operation, what-ever the vehicle speed. When in neutral, requests toupshift or downshift are ignored. If the selector switchis moved from neutral to drive while the vehicle ismoving, the transmission will shift into a gear withinthe engine’s operating speed range.

When shifting from neutral, always press on thebrake pedal. If the brake pedal is not pressed, thetransmission will not shift, the current gear displaywill flash N, and an audible alert will sound.

NOTE: To reset the transmission, return the se-lector switch on the SmartShift lever to N andattempt the shift again, this time with the brakepedal pressed.

Before shutting down the engine, return the selectorswitch to N. When the ignition is turned off, the trans-mission will reset to neutral in a few minutes regard-less of the position of the shift lever.

DriveDrive (D) is directly below N on the four-position se-lector switch located at the end of the SmartShiftcontrol lever. To select D, press in the neutral lockbutton and move the selector switch to the positionbelow N. When drive is selected, the number of the

currently selected forward gear (1 through 10) dis-plays on the gear indicator. See Fig. 15.10.

When in drive, requests to upshift or downshift areenabled. Either manual or automatic mode can beselected on the slide switch.

Two starting gears are available, first and second.The default starting gear is second, but first can beselected by the driver, if desired. To change the start-ing gear, press the brake pedal and select D with thevehicle stopped. The current gear indicator will dis-play the starting gear. Move the shift lever up ordown until the desired starting gear is displayed.

The UltraShift DM TCU adapts to the working condi-tions of each vehicle and its driver. After power up ora load change, it needs to learn the new conditions.While learning, it may hold a gear too long beforeupshifting. Start the upshift manually. It may takethree or four shifts before UltraShift succeeds inlearning the new load-based shift points, but afterthat it will handle the shifting automatically.

LowLow (L) is at the lower end of the four-position selec-tor switch located at the end of the SmartShift controllever. To select L, press in the neutral lock buttonand move the selector switch to the position belowD.

When in low, the current gear is maintained. Re-quests to upshift are not enabled.

IMPORTANT: If the engine is approaching over-speed, the UltraShift DM TCU will override thecurrent gear setting and upshift to prevent en-gine damage.

To enhance engine braking, downshifts are per-formed at higher rpm than normal.

If L is selected from neutral while stopped, the ve-hicle starts up in first gear and stays there until theengine approaches overspeed.

UpshiftingTo request an upshift with the transmission in drive,pull the control lever up (towards you). If the gear isavailable, the transmission upshifts and the new geardisplays on the gear indicator. No skip shifts areavailable while upshifting.

No upshifts are available in low, except to preventengine overspeed.

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Fig. 15.12, Neutral Display


15.9

If the transmission does not upshift quickly enoughafter power-up or a load change, begin the shiftmanually. The UltraShift DM TCU will learn the newload-based shift conditions after three or four shifts.

If the gear requested is unavailable, a tone willsound. An unavailable request to upshift is not storedin memory. The upshift must be requested again.

Downshifting

NOTE: The driver can manually downshift atany time, even when the slide switch is set toAUTO mode.

To request a downshift with the transmission in driveor low, push the control lever down (away from you).If the gear is available, the transmission downshiftsand the new gear displays on the gear indicator. Skipshifts are available while downshifting.

For best engine braking, select low while moving. Inlow, downshifts are performed at higher rpm than indrive.

IMPORTANT: If the engine is approaching over-speed, the UltraShift DM TCU will override thecurrent gear setting and upshift to prevent en-gine damage.

If the gear requested is unavailable, a tone willsound. An unavailable request to downshift is notstored in memory. The downshift must be requestedagain.

When coasting to a stop, the UltraShift DM TCU maynot finish the downshift until the driver presses downon the throttle pedal again.

IMPORTANT: A downshift request can neverresult in a shift into neutral, even if the vehicle isin the drive position in the lowest possible gear.

Before starting down a hill, slow down. Downshift toa speed that you can control without hard pressureon the service brakes.

Before entering a curve, slow down to a safe speed.Downshift if necessary. This lets you use somepower through the curve to help the vehicle be morestable on the turn. It also allows you to regain speedfaster as you come out of the curve.

Ultrashift DiagnosticsClutch Protection FaultExcessive clutch slippage creates heat and reducesthe life of the clutch. These are some conditionswhich lead to clutch abuse:

• Using the throttle to hold the vehicle on agrade

• Starting the vehicle in too high a gear

• Overloading the vehicle

• Using high idle with the vehicle in gear

The UltraShift DM TCU is programmed to preventclutch abuse. When the clutch overheats, the follow-ing alerts take place:

• The TRANS TEMP light comes on

• The current gear indicator displays CA

• A warning tone sounds at one-second intervals

The alerts continue until the clutch cools, the throttleis released, or the clutch is fully engaged.

System ProblemIn the event of a problem, do the following steps.

1. Note the driving conditions at the time the prob-lem occurred.

2. Record the status of the transmission at the timeof the problem (AUTO or MAN mode, gear set-ting R, N, D, or L, current gear, engine speed,etc.)

3. Reset the system, using the procedure below.

Reset ProcedureTransmission operation can sometimes be restoredby doing the following reset procedure:

1. Stop the vehicle when it is safe to do so. Set theparking brake.

2. Place the selector switch in neutral and turn offthe ignition.

3. Check all harness connectors as described inChapter 21.

4. Wait at least two minutes with the engine shutdown.

5. Restart the engine.


15.10

If the problem continues, contact an authorizedFreightliner or Eaton service facility.

Locked In GearIf the transmission becomes locked in gear, a dash(–) will appear on the current gear indicator when thevehicle is restarted during the reset procedure.

NOTE: If the transmission becomes locked ingear while the vehicle is moving, increasedbraking effort may be required to stop the ve-hicle.

If the current gear indicator displays a dash duringpower-up with the selector switch in neutral, do thefollowing steps.

1. Make sure the parking brake is set.

2. Turn off the ignition and wait at least two min-utes.

3. Apply the service brakes.

4. With the service brakes applied, release theparking brake.

5. Make sure the selector switch is in neutral andturn on the ignition key. Do not attempt to startthe engine at this time.

6. If necessary to get the transmission to shift intoneutral, release the pressure on the brake pedalslightly.

7. Once the UltraShift DM TCU reaches neutral, asolid N will appear on the current gear indicatorand the vehicle will start. Make sure the servicebrakes are applied and the parking brake is set.

If the current gear indicator continues to display adash, contact an authorized Freightliner or Eaton ser-vice facility.

Eaton Fuller AutoShiftAutomated TransmissionsRefer to the Eaton website for additional information,www.roadranger.com.

General Information, AutoShift10-Speed RT/RTO ModelsEaton Fuller 10-speed AutoShift transmissions have10 forward speeds and two reverse speeds. The

transmission consists of a 5-speed front section anda 2-speed rear section. The driver must use theclutch to start and stop the vehicle.

The driver does not need to break torque or increaseor decrease engine speed to synchronize the shift.The transmission signals the engine controller whento break torque and the engine controller automati-cally increases or decreases engine speed. Whenengine speed is correct, the transmission engagesthe next gear and signals the engine controller toresume operation.

WARNINGWhen starting or stopping on hills and grades,use extra care to prevent the vehicle from rollingback. A rollback accident could cause death, seri-ous personal injury, or property damage.

The AutoShift system consists of the following com-ponents:

• The SmartShift control paddle on the steeringcolumn. See Fig. 15.6.

• The gear display module (Fig. 15.13) mountedon the dashboard indicates the current gearposition or transmission status. The displayalso flashes the next gear to be engaged whilethe transmission is in neutral during a gearchange.

• The shifter mechanism performs shifts at thefront portion of the transmission. It preselectsthe shift to neutral and completes the gearchange after driver input.

• The Electronic Control Unit (ECU) includes twocontrollers: a transmission ECU and a systemECU. The transmission ECU controls all trans-mission shift functions and the system ECUmanages all vehicle interfaces for transmissionshift functions.

• An electronic range valve, controlled by thetransmission ECU, is used to perform rangeshifts.

Operation, AutoShift with SmartShiftAutomatic and Manual ModesA two-position slide switch (forward driving modeswitch) is located near the end of the control(Fig. 15.6). The switch positions are labelled MAN


15.11

www.roadranger.com

(manual shift mode) and AUTO (automatic drivemode).

NOTE: In automatic drive mode, upshifts anddownshifts require no driver interaction. Movethe selector switch to the drive (D) position, dis-engage the clutch to engage the gear selected,engage the clutch and drive the vehicle. Inmanual shift mode, upshifts and downshifts re-quire either a pull upward or push downward onthe control.

Driver Message CenterGear information is presented to the driver on thedash display. In automatic drive mode, the number ofthe forward gear currently engaged appears continu-ally on the message display screen when in drive(D). In manual shift mode, the current gear is dis-played until a new gear is requested. When neutral(N) is engaged, "N" will appear on the message dis-play screen. When reverse (R) is engaged, either"RL" or "RH" will appear on the message displayscreen.

IMPORTANT: The information shown on themessage display screen indicates the state ofthe transmission only, not the state of theSmartShift control.

Neutral PositionSelect neutral by sliding the selector switch to the"N" position.

NOTE: Neutral is always available during opera-tion. When in neutral, upshift and downshift re-quests are ignored. If the mode selector switchis moved from neutral (N) to drive (D) while thevehicle is moving, the transmission will shift intoa gear causing the engine to go to a high torquelevel, under the engine’s rated torque.

WARNINGDo not coast in neutral. Coasting in neutral cancause an accident, possibly resulting in severepersonal injury or death.

Selecting a Starting Gear1. In automatic mode, select drive (D) by sliding the

selector switch downward to the next positionbelow the neutral position.

2. Disengage the clutch to engage the gear se-lected. Engage the clutch and drive the vehicle.

Changing the Default Starting GearTo select a starting gear other than the default start-ing gear, follow the instructions below.

1. Make sure the vehicle is stopped and in drive.

2. In either automatic or manual mode, pull upwardon the control (to increase), or push downward(to decrease). Each pull upward on the controlincreases the starting gear by one gear, but nohigher than fourth gear.

3. The number of the gear selected will flash on themessage display screen until the driver engagesthe clutch. This gear will be stored in memory asthe default starting gear until either a differentstarting gear is selected by the driver or the en-gine is shut down.

NOTE: The transmission may also be pro-grammed so that it is not possible to select astarting gear other than the preprogrammed de-fault starting gear.

Upshifting

NOTE: With the transmission in drive (D) in theautomatic mode, upshifts require no driver inter-action.

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

Fig. 15.13, Gear Display Module


15.12

1. With the transmission in drive in the manualmode, request an upshift by pulling upward onthe control. If the requested gear is available, thetransmission will upshift.

NOTE: A single, momentary pull upward on thecontrol selects the next higher gear when it isavailable. Two consecutive, momentary upwardpulls will cause a skip shift when the next twohigher gears are available and conditions areright.

2. To skip shift, move the control two times in lessthan 1/2 second. The number of the gear en-gaged will appear on the message displayscreen.

NOTE: The Eaton Fuller AutoShift 18-speedtransmission is able to perform triple upshiftswhen the next three higher gears are availableand conditions are right. To triple-shift this trans-mission, move the control three times in lessthan 1/2 second.

If a requested gear is not available, an audiblewarning will sound and the gear display modulewill indicate that the gear is not available. Anunavailable requested upshift is not stored inmemory. The upshift must be requested again.

Downshifting

NOTE: With the transmission in drive (D) in theautomatic mode, downshifts require no driverinteraction.

1. With the transmission in drive in the manualmode, request a downshift by pushing downwardon the control. If the requested gear is available,the transmission will downshift.

NOTE: A single, momentary push downward onthe control selects the next lower gear when it isavailable. Two consecutive, momentary down-ward pushes will cause a skip shift, when thenext two lower gears are available and condi-tions are right.

2. To skip shift, move the control two times in lessthan 1/2 second. The number of the gear en-gaged will appear on the message displayscreen.

NOTE: The Eaton Fuller AutoShift 18-speedtransmission is able to perform triple downshiftswhen the next three lower gears are availableand conditions are right. To triple shift this trans-mission, move the control three times in lessthan 1/2 second.

If a requested gear is not available, an audiblewarning will sound and the gear display modulewill indicate that the requested gear is not avail-able. Unlike upshifting, an unavailable requesteddownshift is stored in memory and the shift willbe made when the gear is available. The timelimit for this memory is a programmable param-eter.

Start-Up1. With the parking brake applied, press the clutch

all the way down to the floor.


3. Check to make sure the transmission is in neu-tral.

4. With the transmission in neutral, release theclutch.

NOTE: This allows the speed sensor on theinput shaft to get a reading.

5. Press down on the clutch again and release theparking brake.

6. Select the desired starting gear.

7. Release the clutch.

Reverse1. To engage reverse (R), slide the selector switch

upward to the next position above the neutralposition and disengage the clutch.

NOTE: AutoShift 10- and 18-speed transmis-sions have a dual-range reverse. Reverse low(RL) is the default reverse gear.

2. Select reverse high (RH) by pulling upward onthe control.

NOTE: Reverse may be engaged below a pro-grammable forward speed in order to rock thevehicle. If reverse is selected above the pro-grammed forward speed, an audible warning will


15.13

sound and a message indicating that the gear isnot available will appear on the message dis-play screen.

Low Gear OperationUse low (L) when descending steep hills and usingcompression braking. Engine speed will be increasedby 200 rpm and shift points will be offset by 200 rpm.The efficiency of the exhaust brake will be maxi-mized.

Using the ClutchUse the clutch to start and stop the vehicle.

Eaton Fuller UltraShift PLUSEaton Fuller UltraShift PLUS automated transmis-sions use shift selection software and electric clutchactuation; a clutch pedal is not needed to operate thevehicle. These transmissions use the four-positionSmartShift control (see Fig. 15.6) on the steeringcolumn to select mode, direction, neutral, low, and tomake manual shifts. To know what gear the transmis-sion is in, see the current gear indicator on the dash.Forward shifts can be made either manually orautomatically.

Power UpNOTE: Engine cranking is delayed until thetransmission power-up is complete and the geardisplay shows a solid "N".

1. With the parking brake set, turn the ignitionswitch to the ON position.


3. Apply the service brake.

NOTE: If the service brake is not applied whileselecting a starting gear, the initial start gear willnot be found and the driver will need to selectNeutral and press the service brake while se-lecting the desired mode.

4. Select the desired mode and starting gear. (Inap-propriate start gear selections are ignored toavoid damaging the transmission.)

5. Release the parking brake.

6. Release the service brake and apply the accel-erator.

Power Down1. Select Neutral on the shift control.

NOTE: If the gear display does not show a solid"N", neutral has not yet been obtained. Neutralshould always be reached before poweringdown an UltraShift PLUS, except in cases ofemergency.


3. Turn off the ignition, and shut down the engine.

Reverse (R)NOTE: If attempting to select a non-Neutralmode without applying the service brakes, thetransmission will not shift into gear. To shift intogear, select Neutral, apply the service brakes,and select the desired mode again. Also, thevehicle will not engage reverse above 2 mph (3km/h).

Reverse (R) is at the upper end of the four-positionselector switch located at the end of the SmartShiftcontrol. To select R, press in the neutral lock buttonand move the selector switch to the position aboveneutral. The default Reverse gear is engaged.

NOTICEAvoid launching the vehicle in high range.Launching the vehicle in high range increasesthe likelihood of clutch abuse and could be detri-mental to clutch life.

Automatic Mode (AUTO)In automatic drive mode (AUTO), upshifts and down-shifts are made by the UltraShift PLUS without driverintervention. Press in the neutral lock button, movethe selector switch to Drive (D), and press down onthe throttle pedal. The transmission will shift auto-matically.

NOTE: If attempting to select a non-Neutralmode without applying the service brakes, thetransmission will not shift into gear. To shift intogear, select Neutral, apply the service brakes,and select the desired mode again.

In Drive, the start gear is automatically selected. Theselected start gear can vary depending on several


15.14

vehicle inputs such as load, grade, and axle/transmission ratio. The start gear can be changedusing the SmartShift control, provided the selectedgear would allow the vehicle to launch without dam-aging the transmission. If the start gear is changedusing the SmartShift control, it will be the default untilthe vehicle is powered down or the selection ischanged again manually.

IMPORTANT: Prior to ascending a steep grade,either reduce the default start gear by one(using the SmartShift control) or apply fullthrottle for the duration of the grade so the ve-hicle maintains the proper engine and vehiclespeed during the entire grade.

In Drive, the transmission automatically performs up-shifts and downshifts. However, when the transmis-sion is near the shift point, the shift can be forcedusing the upshift or downshift function of the Smart-Shift control.

NOTE: The transmission may deny a shift whileascending or descending a grade if the load ofthe vehicle and grade of the terrain in combina-tion with the drivetrain ratio and engine torquefall outside of the acceptable range to perform ashift. If the shift is denied, a tone will sound.

Manual Mode (MAN)In manual mode (MAN), the driver selects upshiftsand downshifts instead of letting the UltraShift PLUSselect them automatically. Manual shifting may behelpful when traversing a work site, railroad tracks,or steep grades, for example. To drive forward, pressin the neutral lock button, move the selector switch toDrive (D), and press down on the throttle pedal. Toshift up, pull the lever up (towards you); to shiftdown, push the lever down (away from you). Thesystem holds the current gear unless a shift is re-quested or if the system initiates a manual modeoverride.

NOTE: The transmission may deny a shift whileascending or descending a grade if the load ofthe vehicle and grade of the terrain in combina-tion with the drivetrain ratio and engine torquefall outside of the acceptable range to perform ashift. If the shift is denied, a tone will sound.

NOTE: If attempting to select a non-Neutralmode without applying the service brakes, the

transmission will not shift into gear. To shift intogear, select Neutral, apply the service brakes,and select the desired mode again.

Manual Mode OverrideThe system is equipped with a manual mode over-ride function. If the vehicle is being "back driven" (forexample, descending a grade and vehicle speed ex-ceeds engine speed) and the engine speed is exces-sively high, the system will upshift automatically.Also, if the start gear is changed and it causes theengine to lug at takeoff, the system will override thecurrent position and select the best available gear.

Low (L)Low (L) is at the lower end of the four-position selec-tor switch located at the end of the SmartShift con-trol. Use Low when wanting to maximize enginebraking and minimize the use of the brake pedal—forexample, when driving down long grades or whencoming to a stop. To select Low, press in the neutrallock button and move the selector switch to the Lposition. The lowest available start gear will be se-lected (the starting gear cannot be changed in Low).

If Low is selected while moving, the transmission willnot upshift (unless the system initiates a Low over-ride). The system will downshift at the earliest oppor-tunity to provide maximum engine braking.

NOTE: If attempting to select a non-Neutralmode without applying the service brakes, thetransmission will not shift into gear. To shift intogear, select Neutral, apply the service brakes,and select the desired mode again.

Low OverrideThe system is equipped with a Low override function.If the vehicle is being "back driven" (for example, de-scending a grade and vehicle speed exceeds enginespeed) and the engine speed is excessively high, thesystem will upshift automatically. Also, if the startgear is changed and it causes the engine to lug attakeoff, the system will override the current positionand upshift.

Clutch Abuse ProtectionAlthough a vehicle equipped with an UltraShift PLUSuses an automated clutch, the clutch can still over-heat and slip with improper use. The clutch abuse


15.15

protection feature helps protect the clutch if the auto-mated clutch starts to overheat. When the clutchabuse protection feature initiates and sounds a warn-ing tone, full clutch actuation must be completedquickly. If it is not completed quickly enough, the sys-tem will either open the clutch (if the throttle pedal isnot being pressed) or close the clutch (if the throttlepedal is being pressed). If the abuse continues, thesystem will open the clutch and take away throttlecontrol briefly to allow the clutch to cool down.

To protect the clutch:

• Select the lowest possible start gear for theapplication.

• Use Creep Mode when appropriate.

• Use the service brakes and the Hill Start Aidwhen launching on a grade.

• Minimize the time it takes to engage the clutchfrom rest.

• Do not use the throttle to hold the vehicle on agrade; use the service brakes.

• Do not use the throttle to stop roll back on anincline after Hill Start Aid disengages; use theservice brakes, and then relaunch.

• Do not continually start and stop, especiallywhen loaded; use a lower gear or Creep Mode.

Creep ModeThe Creep Mode function allows the vehicle to main-tain a constant speed at engine idle without thedriver holding the throttle pedal position. This modeis useful for very low-speed maneuvering and appli-cations where steady vehicle speed is required. Thevehicle speed is determined by the selected gearratio operating at governed low engine idle speed.Any available gear may be selected, though thetransmission will downshift or exit Creep Mode toprevent stalling if the engine lugs due to load condi-tions.

By default, Creep Mode can be activated while inManual Mode or Low. Eaton’s ServiceRanger diag-nostic software can be used to enable Creep Modein Automatic Mode and/or Reverse.

Engaging Creep ModeTo engage Creep Mode:

1. Select Low or Manual Mode and the desiredgear (while stopped or moving).

2. Apply the throttle pedal to accelerate the vehicleuntil the clutch is closed (engaged).

3. Release the throttle pedal. The vehicle will con-tinue moving at governed low engine idle speed.

Exiting Creep ModeTo exit Creep Mode, apply the throttle pedal to accel-erate temporarily, or select a higher gear in ManualMode. (Creep Mode can be resumed in the selectedgear by releasing the throttle pedal.)

NOTE: The transmission will exit Creep Mode ifthe engine lugs 150 rpm below the governedlow engine idle speed. In this case, a lower gearshould be selected if available.

Hill Start AidUltraShift PLUS transmissions are equipped with aHill Start Aid (HSA) feature to prevent the vehiclefrom rolling while on grades steeper than 3% andallow for a controlled launch. A grade sensor is usedto determine when to engage the feature.

HSA is "on" by default. It can be turned off by press-ing and releasing the override switch on the dash(see Chapter 5). HSA will turn back on after the firstsuccessful launch.

When the vehicle is stopped on a grade greater than3% and in a forward mode or reverse, depress theservice brakes then release them. The vehicle willbegin to move after 3 seconds, and the clutch willperform partial engagements to slow the vehicle mo-tion. Either step on the brake or apply the throttle tocontinue negotiating the grade.

Engine Overspeed ProtectionThe system will upshift if necessary to prevent en-gine overspeed in Drive, Manual, and Low.

Shuttle ShiftingShuttle shifting from reverse to any forward mode isonly allowed if the vehicle speed is approximatelyzero.


15.16

Auto Start Gear Selection andOverrideThe UltraShift PLUS system uses various inputs toautomatically select the best start gear in Drive andManual. This selection can be changed using theSmartShift control; however, if the selection re-quested could cause damage or engine lugging, therequest will be denied and a tone will sound.

Skip ShiftingWhen appropriate, the UltraShift PLUS system mayskip shift in Drive. When prevailing conditions likeload and grade allow, skip shifts can be performed inManual mode using the SmartShift control.

Auto NeutralThe UltraShift PLUS system will automatically shift toneutral if the vehicle is left in Drive and the parkingbrake is set. "AN" will show on the gear display. Tore-engage the transmission, select Neutral and theneither Drive or Reverse on the shift control (it will re-engage regardless of whether the parking brake isreleased).

Automatic Traction ControlThe UltraShift PLUS system requires the AutomaticTraction Control (ATC) option to be enabled whendriving in soft soil/sand to prevent wheel slippageand shifting issues. The ATC system has two modes:"normal" (for sand and loose road surface) and amud/snow setting.

ATC Normal ModeIn normal mode, the system will engage the brakeson the wheel or side that the wheel slip is occurringto help the vehicle gain traction. The point at whichthe traction control will actuate the braking systemincreases with throttle: low throttle allows the systemto brake the wheels earlier; heavy/full throttle raisesthe point of the acceptable wheel slip.

Adhere to the following points when driving in ATCnormal mode:

• If using Automatic mode in soft soil and/orsand, maintain the engine speed between1000 and 1300 rpm to prevent unnecessaryupshifting.

• If using Manual mode in soft soil and/or sand,do not attempt an upshift and try to maintainthe current gear.

• If the vehicle comes to a stop in the sand itmay be necessary to back up prior to attempt-ing forward movement.

ATC Mud/Snow ModeTo select the mud/snow mode, depress the ATCswitch (see Chapter 5). This mode raises the wheelslip speed that is allowed before the traction controlactivates. The point at which the traction control willactuate the braking system increases with throttle:low throttle allows the system to brake the wheelsearlier; heavy/full throttle raises the point of the ac-ceptable wheel slip.

Load-Based ShiftingThe UltraShift PLUS system is adaptive and willchange the shift points based on grade, engine RPM,throttle position, and vehicle load. After changingloads or powering up, the system needs to relearnthese inputs for the first few shifts to make theproper adjustments.

CoastingWhen coasting to a stop on level terrain, the Ultra-Shift PLUS system may not downshift into the lowergears. It will select a gear after the throttle is applied.


15.17

16

Drive AxlesDifferential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Two-Speed Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2

Differential LocksTandem Drive Axles with InteraxleDifferential LockAn interaxle differential lock is standard on vehiclesequipped with tandem drive axles. It is driver-actuated by means of a LOCK/UNLOCK controlvalve switch located on the dash in the cab (seeChapter 5 for more information about the switch).Engagement can be at any speed, provided thewheels are not slipping or spinning. A red indicatorilluminates when the interaxle differential lock is en-gaged.

In the UNLOCK position, there is differential actionbetween the two axles. The differential compensatesfor different wheel speeds and variations in tire size.Keep the interaxle differential unlocked for normaldriving on roads where traction is good.

In the LOCK position, the interaxle differential islocked out and the driveshaft becomes a solid con-nection between the two axles. Power entering theforward axle is also transmitted straight through tothe rear axle, so both axles turn together at the samespeed. The LOCK position should be used when thevehicle encounters poor traction conditions; however,it also increases drivetrain and tire wear and shouldbe used only when improved traction is required.

Interaxle Differential Lockout Operation

NOTICEDo not actuate the interaxle differential controlvalve while the tires are slipping. Do not operatethe vehicle continuously with the interaxle differ-ential locked during extended good road condi-tions. Using the IAD lock when wheels have goodtraction can harm the axle, wear the tires exces-sively, and increases fuel consumption. Releasethe IAD lock as soon as road conditions permit it.

To lock the interaxle differential and achieve maxi-mum pulling power when approaching slippery orpoor road conditions, move the lockout control valveto LOCK while maintaining vehicle speed, before en-countering the poor road conditions. Let up momen-tarily on the accelerator to engage the differentiallock. Proceed over poor road conditions with caution.Do not wait until traction is lost and the tires arespinning before locking the interaxle differential.

To unlock the interaxle differential, move the lockoutcontrol valve to UNLOCK while maintaining vehiclespeed, after leaving the poor road conditions. Let upmomentarily on the accelerator to allow the shift,then resume driving at normal speed.

Driver-Controlled Differential Lock(DCDL)Some vehicles are equipped with a driver-controlleddifferential lock (DCDL) that is operated by a dashswitch in the cab (see Chapter 5 for more informa-tion about the switch). The differential lock providesmaximum traction for slippery conditions by forcingthe wheels on a drive axle to rotate together. Thedifferential lock should be engaged when the vehicleis stopped or moving at a low, constant speed andthe wheels are not spinning, slipping, or losing trac-tion. Do not exceed 25 mph (40 km/h) when the dif-ferential lock is engaged.

On tandem axles there are three possible DCDL op-tions:

• Forward-rear carrier only

• Rear-rear carrier only

• Both rear carriers.

An indicator light comes on when the DCDL is en-gaged. An optional buzzer can also be used to indi-cate DCDL engagement.

The DCDL provides maximum traction under slipperyconditions. When the DCDL is engaged, the clutchcollar completely locks the differential case, gearing,and axle shafts together, maximizing traction of bothwheels and protecting against spinout. Under normaltraction conditions, do not engage the DCDL; operatethe axle with differential action between both wheels.

WARNINGBe especially careful when driving under slipperyconditions with the differential locked. Thoughforward traction is improved, the vehicle can stillslip sideways, causing possible loss of vehiclecontrol, personal injury, and property damage.

Drive Axles

16.1

Main Differential Lock Operation

NOTICEThe differential lock should be engaged when thevehicle is stopped or moving at a low, constantspeed and the wheels are not spinning, slipping,or losing traction. Engagement at high speed orpower can damage the axle(s).

Do not permit rear wheels to spin freely for morethan ten seconds when traction is lost. Shift intoLOCK to prevent damage to interaxle and maindifferentials.

To lock the main differential and obtain maximumtraction under slippery conditions, move the controlswitch to the lock position.

NOTE: On some vehicles, the differential locksystem is connected through the low speedrange of the transmission. If this system is used,the transmission must be in the low speedrange for the differential to fully lock.

If the vehicle is moving, maintain a constant vehiclespeed while engaging the differential lock. Briefly letup on the accelerator to relieve torque on the gear-ing, allowing the differential to fully lock. The indica-tor light should come on and the buzzer shouldsound on vehicles so equipped. When the differentialis fully locked, the turning radius will increase be-cause the vehicle understeers. See Fig. 16.1. Drivecautiously and do not exceed 25 mph (40 km/h).

To unlock the main differential, move the controlswitch to the unlock position. Briefly let up on theaccelerator to relieve torque on the gearing, allowingthe differential to fully unlock.

NOTE: If the differential lock system is con-nected through the low speed range of thetransmission, shifting out of low speed range willalso unlock the differential.

When the differential lock disengages, the indicatorlight will go off and the buzzer will stop.

Single Drive Axles with TractionEqualizerSome single drive axles are equipped with a tractionequalizer that is a load-sensing, self-actuating fea-ture. A traction equalizer provides normal differentialaction where traction is good. When one wheel be-gins to spin faster than the other, clutch plates in thedifferential housing automatically engage, deliveringpower to both wheels. There is no operator controlwith this feature.

A traction equalizer occasionally tends to slip in ajerking motion, producing irregular intervals of sharpnoises. This generally occurs when the vehicle is op-erating at low speeds on fairly sharp turns. This con-dition is corrected by adding a friction modifier to theaxle lubricant. This additive tends to reduce the staticcoefficient of friction to a value equal to, or lowerthan, the sliding coefficient.

See Group 35 of the Cascadia™ MaintenanceManual for additional information on friction modifiersand when to add them to axle lubricants.

CAUTIONTire sizes on both rear wheels should be thesame on axles equipped with a traction equalizer.If not, excessive wear may occur in the tractionequalizer.

Two-Speed Drive AxlesAxle Shift

CAUTIONTo prevent transmission and axle damage, makesure the automatic transmission is in high range

02/09/96 f350079a

A

B

A. Turning Radius When Differential is Locked(engaged)—Understeer Condition

B. Turning Radius When Differential is Unlocked(disengaged)

Fig. 16.1, Turning Radius

Drive Axles

16.2

when performing an axle shift with the vehiclemoving.

Axle shift is a function installed on vehicles with two-speed axles to allow the use of the low speed rangewhen greater traction and maximum pulling power isneeded at low engine speed (rpm).

Under normal operating conditions, the vehicle is op-erated using the high-speed gear ratios of the axle.Under extreme weather or off-road conditions, at lowspeed and rpm and/or to pull heavy loads, the ve-hicle must be operated using the low-speed, or re-duction, gear ratios of the axle.

Axle Shift SwitchThe axle shift switch is a two-position rocker switch(Fig. 16.2) installed on vehicles with two-speedaxles.

To shift the axle from low speed to high speed, pressthe top of the switch. To turn the axle shift off (switchfrom high speed back to low speed), press the bot-tom of the switch. When the axle has shifted speed,the LED turns off.

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

IMPORTANT: If the LED in the switch begins toblink during normal operation, when the switchhas not been activated, this indicates an errorcondition. Bring the vehicle to an authorizedFreightliner service facility as soon as possible.

When the axle shift switch is pressed, three re-sponses are possible: a normal response, a slow re-sponse, and an abnormal response.

Normal Response: The LED in the switch blinks untilthe axle shifts speed. At this point, the LED comeson steady and stays illuminated. In normal operation,the axle may shift so quickly that the blinking of theswitch is barely noticeable.

If operation of the switch is not possible for any rea-son (interaxle lock is on, ignition is turned off, etc.),the LED will stop blinking and turn off.

Slow Response: If operation of the switch is slowedfor any reason (by cold weather, low air pressure,etc.), the switch will continue to blink until the axleshifts. As in the normal response, the LED comes onsteady and stays illuminated.

Abnormal Response: If the LED blinks for more than30 seconds, the axle shift function/mechanism maynot be operating correctly. Bring the vehicle to anauthorized Freightliner service facility for testing.

Axle Switch Interlock

NOTE: On vehicles with tandem drive axles,there is an interlock that prevents an axle fromshifting speed whenever the interaxle lock is on.

If the axle shift switch is pressed when the interaxlelock is on, the axle shift will not be completed. TheLED does the following:

• If the LED is off, the LED comes on briefly andturns off again.

• If the LED is on, it stays on.

To complete the axle shift, turn off the interaxle lockand press the axle shift switch again. If still needed,the interaxle lock can then be reactivated.

AXLESHIFT

f61095106/12/2007

Fig. 16.2, Axle Shift Switch

Drive Axles

16.3

17

Steering SystemPower Steering System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1Power Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1

Power Steering SystemGeneral InformationWhen there is no load on the vehicle, and the fronttires are pointed straight ahead, the steering wheelspokes should be centered, ±10 degrees, as shownin Fig. 17.1. See Group 46 of the Cascadia™ Work-shop Manual for steering adjustment procedures.

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

WARNINGDriving the vehicle without the power-assist fea-ture of the steering system requires much greatereffort, especially in sharp turns or at low speeds,which could result in an accident and possibleinjury.

Drivers should carefully use the power available witha power steering system. If the front tires becomelodged in a deep chuckhole or rut, drive the vehicleout, instead of using the steering system to lift thetires from the hole. Also, avoid turning the tires whenthey are against a curb, as this places a heavy loadon steering components and could damage them.

Power Steering SystemsSteering Gear SystemThe steering gear system includes the power steer-ing gear, hydraulic hoses, power steering pump, res-ervoir, and other components. Some models are alsoequipped with a separate hydraulic power cylinder onthe right side of the front axle, or a right-hand slavegear (such as the TRW RCH-45). The power steeringpump, driven by the engine, provides the power as-sist for the steering system. If the engine is not run-ning, there is no power assist. If the power-assistfeature does not work due to hydraulic fluid loss,steering pump damage, or some other cause, bringthe vehicle to a safe stop. Do not drive the vehicleuntil the cause of the problem has been corrected.

Rack and Pinion Steering SystemThe rack and pinion steering gear is mounted to thefront axle with two brackets, and connected by tie-rod ends to the axle steering arms. When the steer-ing wheel is turned, the intermediate steering shaftturns the input shaft, rotating the torsion bar and thevalve. When the valve turns, power steering fluid isredirected and provides power assist to turn the pin-ion gear meshed with the rack teeth, moving the rackleft or right. The rack, with a tie-rod at each end,then moves the steering arms on the axle, and pivotsthe wheels.

This design provides drivers with more responsivesteering, with increased performance and “road feel.”It virtually eliminates steering issues when the driverhits a bump (bumpsteer), and significantly reducesroll steer when a vehicle goes into a curve. Wander-ing is significantly reduced as well, so the vehicletends to drive straight on the highway. It has a lowersteering ratio, which means drivers don’t have to turnthe steering wheel as much to get the wheels to turna given distance. Overall, rack and pinion steeringgreatly improves steering response, and reducesdriver effort and fatigue.

06/13/2007 f462080

10°

10°

1 2

10°

10°

1. 9 o’Clock 2. 3 o’Clock

Fig. 17.1, Proper Steering Wheel Position (with tirespointed straight ahead)

Steering System

17.1

18

Fifth WheelsFifth Wheels, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7

Fifth Wheels, GeneralInformation

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

Air-Suspension Dump ValveThe air-suspension dump valve may be used to ad-just the tractor height to aid with coupling to or un-coupling from a trailer. See Fig. 18.1. When theswitch is set to LOWER, the air-suspension dumpvalve deflates the air springs to lower the rear of thevehicle. In the AUTO position, the automatic ride-control valves operate for normal driving.

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

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

Fifth Wheel Lubrication

WARNINGKeep the fifth wheel plate lubricated to preventbinding between the tractor and trailer. A bindingfifth wheel could cause erratic steering and lossof vehicle control, possibly resulting in personalinjury or death.

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

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

For lubrication instructions, see Group 31 of theCascadia® Maintenance Manual.

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

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

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

prevent the trailer from moving.

2. Ensure the fifth wheel jaw is fully open and theoperating rod is in the unlocked position. SeeFig. 18.2 or Fig. 18.3.

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

10/25/2010 f611101

DO NOT LOWERWHEN VEHICLEIS IN MOTION

LOWER AUTO

SUSPAIR

Fig. 18.1, Air-Suspension Dump Valve

Fifth Wheels

18.1

4. Position the tractor so that the center of the fifthwheel is in line with the trailer kingpin. The king-pin should be in a position to enter the throat ofthe locking mechanism.

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

5. Adjust the trailer height if required.

For a standard fifth wheel plate, the trailershould contact the fifth wheel approximately 4 to8 inches (10 to 20 cm) behind the fifth wheelpivot. See Fig. 18.4.

For a low-lube fifth wheel plate, the fifth wheelmust slide freely under the trailer, and the trailershould contact the fifth wheel at the pivot. SeeFig. 18.5.

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

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

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

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

1

1

2

2 10/26/2010 f310110a

A

B

NOTE: Make sure the safety latch is down when thecontrol handle is locked.

A. Unlocked B. Locked1. Safety Latch 2. Lock Control Handle

Fig. 18.2, Fontaine Locking Mechanism

1

1

2

3

11/02/2010 f310447

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

Fig. 18.3, Holland Simplex SE Locking Mechanism

10/28/2010 f311124

A

B

C

D

A. Fifth wheel must lifttrailer

B. Adjust trailer height

C. Ramps tilted downD. 4 to 8 inches

Fig. 18.4, Trailer Connection Point, Standard FifthWheel

Fifth Wheels

18.2

7. Apply the tractor parking brakes.

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

8. Perform a coupling inspection, checking thatthere is no gap between the bottom of the trailerand the fifth wheel, and that the kingpin is se-curely locked. See Fig. 18.6

When lockup has occurred, the fifth wheel con-trol handle moves to the locked position. Makesure that the safety latch is down over the lockcontrol handle to hold the control handle in thelocked position. (The safety latch will only rotatedown if the operating rod is fully retracted in thelocked position.) See Fig. 18.2 for Fontaine fifthwheels. See Fig. 18.3 for Holland fifth wheels.

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

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

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

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

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

12. With the trailer wheels chocked and the brakesset, check for clearance between the kingpin andthe fifth wheel jaws by moving the tractor forwardand backward against the locked kingpin. If slackis present, uncouple the trailer and have the fifthwheel inspected and adjusted by a certifiedtechnician.

Jost Fifth Wheel Coupling1. Tilt the ramp down.

2. Open the kingpin locks. See Fig. 18.7.

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

4. Chock the trailer wheels.

5. Connect the air lines and electrical cable.

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

09/10/2010 f311125

A

B

A. Adjust trailer height B. Ramps tilted down

Fig. 18.5, Trailer Connection Point, Low-Lube FifthWheel

09/10/2010 f311126

A B

A. No gap between trailerand fifth wheel

B. Kingpin inside lock

Fig. 18.6, Coupling Inspection

Fifth Wheels

18.3

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

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

7. Adjust the trailer height (if required).

For a standard fifth wheel plate, the trailershould contact the fifth wheel approximately 4 to8 inches (10 to 20 cm) behind the pivot. SeeFig. 18.4.

For a low-lube fifth wheel plate, the fifth wheelmust slide freely under the trailer, and the trailershould contact the fifth wheel at the pivot. SeeFig. 18.5.

8. Back the tractor under the trailer.

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

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

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

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

nect, possibly resulting in serious personal injuryor death.

10. Apply the tractor parking brake, then perform aphysical check for positive kingpin lockup, andthat there is no gap between the trailer and thefifth wheel. See Fig. 18.6.

11. Ensure that the release handle is in the lockedposition adjacent to the casting. See Fig. 18.8.

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

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

2. Chock the trailer rear wheels.

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

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

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

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

6.1 Fontaine: Lift the safety latch and pull thelock control handle to the unlocked posi-tion. See Fig. 18.2.

6.2 Holland: In the locked position the safetyindicator swings freely over the operatingrod. See Fig. 18.9, View A.

To unlock the mechanism, manually rotatethe safety indicator toward the rear of thefifth wheel. See Fig. 18.9, View B.

Pull the operating rod out. When theupper operating rod shoulder is outsidethe slot, raise the handle and place theshoulder of the upper rod against the platecasting, above the slot. See Fig. 18.9,View C.

09/10/2010 f311128

A

A. Lock held open by catch mechanism

Fig. 18.7, Jost Release Handle Unlocked

Fifth Wheels

18.4

The fifth wheel is now in the lockset posi-tion and is ready for uncoupling. As thetractor pulls away from the trailer the king-pin forces the jaw to rotate, contacting thelock. Continued rotation of the jaw forcesthe lock to move outward, and drops theupper rod back into the slot. See Fig. 18.9View D. The wheel is now ready forcoupling.

6.3 Jost: Pull the retractable handle out, thensecure it in the open position with thecatch. See Fig. 18.7.

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

Air-Actuated UncouplingAn air-actuated kingpin release valve is optional withall fifth wheels. See Fig. 18.10.

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

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

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

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

1. Apply the tractor and trailer parking brakes.

2. Chock the trailer rear wheels.

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

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

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

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

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

09/10/2010 f311127

OK OK

Fig. 18.8, Jost Release Handle Locked

Fifth Wheels

18.5

2. Pull and hold the kingpin release valve(Fig. 18.10) until the kingpin lock mechanismopens and locks in place.

3. Release the pull valve.

4. Release the tractor parking brake.

5. Drive out from under the trailer.

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

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

11/02/2010 f311133

A

B

C

D

1

2

3

4

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

rear of the fifth wheel)

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

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

3. Upper Rod4. Plate Casting

Fig. 18.9, Holland Kingpin Locking Mechanism

Fifth Wheels

18.6

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

2. Release the tractor parking brake.

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

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

Fifth Wheel Slide

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

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

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

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

Manual Slide OperationThe manual slide feature is operated from the fifthwheel plate with a manual release handle using thefollowing procedure. See Fig. 18.11.

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

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

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

10/26/2010 f611102

Fig. 18.10, Air-Actuated Kingpin Release Valve

07/25/95 f310190

1

2

1. Locking Wedge2. Slide Release Pull Handle

Fig. 18.11, Manual Release Sliding Fifth Wheel(Fontaine shown)

Fifth Wheels

18.7

handle will stay in the unlocked positionuntil it is manually disengaged from theguide plate. See Fig. 18.12.

2.2 Holland: Pull the operating rod out. Makesure both side plungers have released.See Fig. 18.13.

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

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

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

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

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

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

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

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

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

10/26/2010 f310050

Fig. 18.12, Releasing the Sliding Fifth Wheel, (Fontaine)

1

2

3

45

6

3

10/26/2010 f310445

7

8

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

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

Fig. 18.13, Sliding Fifth Wheel Manual Release,(Holland Simplex)

Fifth Wheels

18.8

Air Slide OperationThe slide feature may be operated with an air switchmounted in the dash, that operates an air cylinderthat locks and unlocks the slide. See Fig. 18.14.

1. Set the air-slide switch (Fig. 18.14) to UNLOCK.

Ensure the locking plungers have released. SeeFig. 18.15.

For Jost fifth wheels, the mechanism activates asshown in Fig. 18.16.

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

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

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

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

5. Apply the tractor parking brakes.

WARNINGCheck that the locking wedges have seated in theslots. Failure to achieve complete lockup may

LOCKUNLOCK

FIFTHWHL

SLIDE

MUST BELOCKED WHENVEHICLE IS INMOTION

10/22/2009 f611074

1

1. Fifth Wheel Air-Slide Switch

Fig. 18.14, Air-Slide Switch

07/25/95 f310189

1

2

1. Locking Wedge 2. Air Cylinder

Fig. 18.15, Air-Operated Sliding Fifth Wheel (Fontaineshown)

09/10/2010 f311131

A

B

A. Unlocked B. Locked

Fig. 18.16, Jost Sliding Fifth Wheel

Fifth Wheels

18.9

allow disengagement of the tractor from thetrailer, possibly resulting in serious personal in-jury or death.

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

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

Fifth Wheels

18.10

19

Trailer CouplingsAir-Suspension Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

Air-Suspension Dump ValveThe air-suspension height switch may be used to aidin connecting or disconnecting from a trailer. Whenthe switch is set to LOWER, the air-suspensiondump valve deflates the air springs to lower the rearof the vehicle. In the AUTO position, the automaticride-control valves operate for normal driving.

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

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

Holland Trailer CouplingGeneral InformationThe Holland PH-T-60-AL trailer coupling is designedfor use with trailers having a maximum gross weightof 10,000 lb. See Fig. 19.1. It is a rigid-type pintlehook, used only on tractor applications, and is fas-tened to the rear closing crossmember of the vehicle.It is a non-air-adjusted coupling.

OperationTrailer Hookup1. Chock the front and rear tires of the trailer.

2. Remove the cotter pin, then lift the lock and raisethe latch.

3. Back up the vehicle, until the drawbar eye isover the pintle hook.

4. Lower the trailer, until the drawbar eye rests onthe pintle hook.

5. Close the latch, then insert the cotter pin.

6. Hook up the trailer electrical and air lines.

7. Remove the chocks from the trailer’s tires.

Trailer Release1. Apply the tractor and trailer parking brakes.

WARNINGDo not use the trailer air supply for parking trail-ers not equipped with spring parking brakes.This applies the trailer service brakes only. As airbleeds from the trailer brake system, brake appli-cation is lost. This could allow the unattendedvehicle to roll away, possibly resulting in seriouspersonal 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 out dirt.

4. Take the weight of the trailer drawbar off thepintle hook.

5. Open the latch, by first removing the cotter pin,then lift up the lock and raise the latch.

6. Slowly drive the vehicle away from the trailer.

1 2

3

4

01/20/95 f310314a

1. Lock2. Cotter Pin

3. Latch4. Pintle Hook

Fig. 19.1, Holland PH-T-60-AL Trailer Coupling

Trailer Couplings

19.1

20

Pre- and Post-TripChecklists

Periodic Inspections and Maintenance, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2

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

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

The checklists in this chapter can be copied and keptas a record that the procedures have been com-pleted. For details on how to inspect each item onthe checklists, see the corresponding procedure(step number) in Chapter 21.

ChecklistsNOTE: Checklists in this chapter correspondwith the procedures and steps in Chapter 21,Pre- and Post-Trip Inspections and Mainte-nance. Your vehicle may not be equipped withall components listed below.

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

Inspector Date

Suspension and Slack Adjusters Comp.1 Suspension components2 Slack adjusters

Wheels and Tires Comp.1 Wheel covers2 Tire condition3 Tire inflation4 Rims and wheel components

Wheels and Tires Comp.5 Wheel bearing oil seals and lubrication levels6 Mud Flaps

Saddle Tank Areas Comp.

1 Drain air reservoirs (without automatic drainvalves)

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

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

Cab Comp.

1 Reset dash-mounted air intake restrictionindicator

2 Air-pressure warning systems3 Air governor cut-in and cut-out pressures4 Air pressure build-up time5 Air system leakage6 Air pressure reserve7 Mirrors, windows, windshield8 Horn, windshield wipers, windshield washers9 Heater and defroster10 Interior lights11 Exterior lights12 Seat belts and tether belts13 Fuel level14 Mirror adjustment15 Service brakes16 Backup alarm

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

4 Plumbing components, fuel fill fitting, fuellines

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

6 Coolant hoses7 LNG fuel tank pressure

Pre- and Post-Trip Checklists

20.1

Natural Gas Fuel System Comp.8 LNG vaporizer9 Low pressure filter drain

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

Inspector Date

Engine Compartment Comp.1 Windshield washer reservoir level2 Air intake restriction indicator3 Water evacuation components4 Automatic transmission fluid level5 Water in fuel/water separator6 Steering components7 Serpentine drive belts

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

Inspector Date

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

Saddle Tank Areas Comp.

1 Drain air reservoirs (with automatic drainvalves)

2 Batteries (location may vary)3 Aerodynamic components

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

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

Fluids Added During InspectionFluid Amount Added

Wheel Bearing LubricantEngine OilPower Steering FluidEngine CoolantWindshield Washer FluidAutomatic TransmissionFluidHydraulic Clutch Fluid (DOT4 brake fluid)

Pre- and Post-Trip Checklists

20.2

21

Pre- and Post-TripInspections and

MaintenanceSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1Daily Pretrip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1Weekly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10Monthly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.13

Safety Precautions

DANGERWhen working on the vehicle, shut down the en-gine, set the parking brake, and chock the tires.Before working under the vehicle, always placejack stands under the frame rails to ensure thevehicle can not drop. Failure to follow thesesteps could result in serious personal injury ordeath.

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

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

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

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

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

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

• springs

• spring hangers

• shocks

• suspension arms

• suspension brackets

• axle seats

• bushings

2. Inspect slack adjusters for signs of damage. SeeFig. 21.1, Fig. 21.2, or Fig. 21.3.

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

• Inspect anchor straps, if equipped, fordamage.

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

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

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

f42139806/17/2003

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10

9

1. 7/16-inch AdjustingNut

2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston

Rod

6. Clevis7. ½-inch Clevis Pin8. 1/4-inch Clevis Pin9. Grease Relief

Opening10. Slack Adjuster Spline

Fig. 21.1, Gunite Automatic Slack Adjuster

Pre- and Post-Trip Inspections and Maintenance

21.1

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

IMPORTANT: Wheel covers decrease drag forceas a vehicle moves, thereby improving fuel effi-ciency. If replacement of a wheel cover is nec-essary, the replacement cover must meet or ex-ceed the drag reduction performance of theoriginally installed cover in order to maintaincompliance with greenhouse gas and full effi-ciency regulations (GHG14).

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

NOTE: During wheel cover installation, ensurethe V-notch in the liner inner retaining ring iscentered on the valve stem. The inner and outerretaining rings should be uniformly aligned toeach other and to the wheel rim. The outer re-

taining ring of the liner is equipped with twocanvas flaps. When installing the face cover,make sure the cover retaining ring is insertedbetween the two canvas flaps on the liner outerretaining ring so that the Velcro strips line upbetween the face cover and the liner. Make cer-tain the detachable view cover is centered onthe face cover, and the Velcro strips arepressed firmly in place.

2. Inspect each tire for the following:

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

• bulges, cracks, cuts, and penetrations

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1. Clevis2. Slack Adjuster3. Clevis Pin4. Manual Adjusting Nut5. Control Arm

6. Control-Arm Washersand Nut

7. Anchor Strap Slot8. Anchor Strap9. Brake Chamber

Fig. 21.2, Haldex Automatic Slack Adjuster

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910

1. Grease Fitting (ifequipped)

2. Slack AdjusterHousing

3. Brake ChamberPushrod

4. Clevis

5. Clevis Pin (large)6. Clevis Pin (small)7. Actuator Rod8. Boot9. Manual Adjusting Nut10. Camshaft Splines

Fig. 21.3, Meritor Automatic Slack Adjuster


21.2

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

• tread depth—if tread is less than 4/32 inch(3 mm) on any front tire, or less than 2/32inch (1.5 mm) on any rear tire, replace thetire

• debris lodged between duel tire sets

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

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

3. Check tire inflation.

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

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

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

WARNINGDo not operate the vehicle with underinflated oroverinflated tires. Incorrect inflation can stressthe tires and make the tires and rims more sus-ceptible to damage, possibly leading to rim ortire failure and loss of vehicle control, resultingin serious personal injury or death.

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

IMPORTANT: The load and cold inflation pres-sure must not exceed the rim or wheel manu-

facturer’s recommendations, even though thetire may be approved for a higher load inflation.Consult the rim or wheel manufacturer for thecorrect tire inflation pressure for the vehicleload.

4. Examine each rim and wheel component.

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

WARNINGHave any worn or damaged wheel componentsreplaced by a qualified person using the wheelmanufacturer’s instructions and the wheel indus-try’s standard safety precautions and equipment.Otherwise a vehicle or workshop accident couldoccur, possibly resulting in serious personal in-jury or death.

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

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

4.3 Make sure all wheel nuts are tightened. Iftightening is necessary, use the tighteningpattern in Fig. 21.4 to initially tighten theflange nuts to 50 to 100 lbf·ft (68 to 136N·m). Then tighten the flange nuts to 450to 500 lbf·ft (610 to 678 N·m).

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

If needed, fill the hubs to the level indicated onthe hub cap. See Group 35 of the Cascadia


21.3

www.epa.gov/smartway

Maintenance Manual for recommended lubri-cants.

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

Saddle Tank Areas Inspection

WARNINGWhen draining the air reservoir, do not look intothe air jets or direct them toward anyone. Dirt orsludge particles may be in the airstream andcould cause injury.

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

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

WARNINGNever operate the engine with the fuel tank shut-off valves partially closed. This could damage thefuel pump, causing sudden loss of engine power,

possibly resulting in serious personal injury dueto reduced vehicle control.

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

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

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

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

Inspect upstream of the aftertreatment device(ATD), if equipped, for cracking or signs of leaks,such as soot trails. Inspect downstream of theATD for signs of exhaust leaks, such as blister-ing or warping of nearby components.

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

oil, or coolant leaks.

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

NOTICEFailure to maintain a sealed air intake systemcould allow the entry of dirt and contaminantsinto the engine. This could adversely affect en-gine performance and result in engine damage.

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

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

3. Check the engine oil level.

NOTICEOperating the engine with the oil level below theminimum fill (or "add") mark or above the maxi-mum fill (or "full") mark could result in enginedamage.

f400268

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Fig. 21.4, Tightening Pattern, 10-Hole Wheels


21.4

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

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

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

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

4. Check the power steering reservoir fluid level.

The power steering fluid level should be betweenthe MIN COLD mark and the middle mark justabove it. See Fig. 21.5. If needed, fill the reser-voir with automatic transmission fluid that meetsDexron III or TES-389 specifications.

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

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

5. Check the engine coolant level in the radiatorsurge tank. See Fig. 21.6.

NOTICECoolant must be filled to the COLD MAX line ofthe surge tank. Low coolant could result in en-gine overheating, which could cause engine dam-age.

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

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

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

6. Inspect visible engine wiring for damage orlooseness. Check for loose wiring, chafed insula-tion, and damaged or loose hold-down clamps.

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

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f462079

NOTE: Typical reservoir shown; configurations mayvary.1. Filler Cap

Fig. 21.5, Power Steering Fluid Reservoir

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2

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1. Pressure Relief Cap2. Filler Cap3. COLD MAX Fill Line

4. COLD MIN Fill Line5. Coolant Level Sensor

Fig. 21.6, Coolant Surge Tank


21.5

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

intake restriction indicator, if equipped.

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

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

2.2 Turn the ignition to the ON position. TheICU will complete a full gauge sweep andbulb check, and an audible warning willsound. Ensure the low air pressure lamp(BRAKE AIR) remains illuminated and anaudible warning continues to sound afterthe gauge sweep is complete.

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

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

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

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

4. Check air pressure build-up time.

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

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

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

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

5. Check air leakage in the system.

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

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

If the pressure drop exceeds the limitsshown in Table 21.1, eliminate any leaksbefore operating the vehicle.

6. Check the air pressure reserve.

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

Maximum Allowable Air Leakage

DescriptionPressure Drop:

psi (kPa) Per MinuteReleased Applied

Truck or Tractor Only 2 (14) 3 (21)Truck or Tractor w/Single Trailer 3 (21) 4 (28)Truck or Tractor w/Two Trailers 5 (35) 6 (42)

Table 21.1, Maximum Allowable Air Leakage

WARNINGWhen cleaning windshields and windows, alwaysstand on the ground or on a secure ladder orplatform. Use a long-handled window cleaner. Donot use the cab steps, tires, fenders, fuel tanks,engine, or under-hood components to access thewindshield or windows. Doing so could cause afall and result in an injury.

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

8. Ensure that the horn, windshield wipers, andwindshield washers are operating properly.


21.6

These devices must be in good working order forsafe vehicle operation.

9. Ensure the heater and defroster are operatingproperly.

10. Check the operation of all interior lights.

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

10.2 Ensure all equipped driver controlswitches illuminate.

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

11. Check the operation of all exterior lights. SeeFig. 21.7.

11.1 Activate the high-beam headlights andhazard warning lights.

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

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

12. Inspect the seat belts and tether belts.

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

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

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

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

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

Do not mix gasoline or alcohol with diesel fuel.This mixture could cause an explosion, possiblyresulting in serious personal injury or death. Donot fill the fuel tanks in the presence of sparks,open flames, or intense heat. These could ignitethe fuel, possibly causing severe burns.

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

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

14. Adjust the rearview and down view mirrors asnecessary.

15. Test the service brakes.

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

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

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

16. Test the backup alarm.

16.1 Release the parking brake and put thetransmission in reverse.


21.7

16.2 Move the vehicle slightly backward to en-sure that the backup alarm is operatingcorrectly.

Natural Gas Fuel System Inspection

WARNINGAs with all pressure vessels, CNG/LNG storageand fuel delivery systems are inherently danger-

ous and should be treated as such. Beyond thevisual inspections listed below, all maintenanceand repairs to compressed natural gas (CNG) orliquified natural gas (LNG) systems should beperformed by trained personnel. Individuals whoare not trained in all aspects concerning CNG/LNG fuel delivery systems are not permitted toservice, maintain, test, or inspect a system in anyway. Failure to comply with safety regulationsmay lead to fire or explosion, resulting in prop-erty damage, personal injury, or death.

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1. High-Beam Headlight2. Fog Light, or Auxiliary High-Beam Light3. Low-Beam Headlight4. Marker Light5. Turn Signal

6. Side Turn Signal and Marker Light7. Clearance Light8. Stop Light, Taillight, and Turn Signal9. Back-Up Light10. Identification Light

Fig. 21.7, Exterior Lights


21.8

1. Inspect fuel tanks for dents, scratches, gouges,or other signs of damage. Inspect the fuel linesand connections for leaks.

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

CNG Fuel System: Ensure that the CNG fuel cyl-inder storage box is secured to the frame. In-spect for signs of looseness.

(LNG Fuel System: Ensure that the LNG fueltank is secured to the mounting brackets andthat the mounting brackets are secured to theframe. Ensure all rubber isolator straps are se-cure around the LNG fuel tank.

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

• Gas detection system overhead console;

• Above the door handle on both doors;

• Left front bumper;

• End-of-frame crossmember;

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

3. Check for the presence of vent caps on pressurerelief valves and devices. See Fig. 21.8. If anycaps are missing, have the fuel system inspectedby a qualified technician.

CNG Fuel System: Each fuel cylinder shouldhave two caps (one on each end), which are vis-ible on the back of the CNG fuel cylinder storagebox. One additional cap is located on the pres-sure relief valve on the inboard side of the CNGfuel box, next to the fuel outlet line. If equippedwith saddle tanks, there are also two vent tubeswith caps between the back of the cab and theback-of-cab fuel tanks.

LNG Fuel System: A red cap should be presenton the secondary relief valve. See Fig. 21.9.

4. Inspect all plumbing components, including thefuel shutoff valve(s), primary and secondary reliefvalves, and the LNG vapor shutoff and excessflow valves, if equipped, for signs of damage orleaks. See Fig. 21.9 or Fig. 21.10.

Inspect the fuel fill fitting for signs of damage orleaks.

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

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

6. Inspect all coolant hoses for signs of chafing,kinks, or leaks. The CNG fuel system utilizescoolant hoses between the engine and the pres-sure regulator inside the fuel panel. The LNGfuel system utilizes coolant hoses between theengine and the vaporizer.

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

8. Inspect the LNG vaporizer for signs of damageor leaks. See Fig. 21.9. Inspect the vaporizermounting brackets for signs of looseness.

9. On CNG systems, check the low pressure fuelfilter(s) at the engine for contamination.

9.1 Turn the engine off and remove the keyform the ignition.

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Fig. 21.8, CNG Vent Line Caps


21.9

9.2 Slowly open the drain petcock and drainany fluid into an appropriate container.

10. When fluid stops, close the drain petcock.

11. Examine the fluid.

If more than approximately one ounce of oil orother contaminants is found, have the systemchecked at a qualified service center.

Weekly Post-Trip Inspectionsand MaintenanceEngine Compartment Inspection

WARNINGWasher fluids may be flammable and poisonous.Do not expose washer fluid to an open flame orany burning material, such as a cigarette. Alwayscomply with the washer fluid manufacturer’s rec-ommended safety precautions.

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1. Pressure Control Regulator2. Coalescing Filter3. Fuel Fill Fitting4. Vapor Shutoff Valve5. Secondary Relief Valve (red cap)6. Fill Vent Fitting

7. Primary Relief Valve8. Tank Pressure Gauge9. Fuel Shutoff Valve (liquid)10. Fuel Level Sender Box11. Cover12. Fill Check Valve

Fig. 21.9, LNG Tank Plumbing Components

HIGH PRESSURE PRESSURELOW

CYLINDERSINSPECT CYLINDERS

EVERY 36 MONTHSOR 36000 MILES

WHICHEVER OCCURS FIRST

NATURALGAS

VEHICLE110 PSIG

ON

MANUAL

SHUT O

FFVALV

E

OPEN VALVESLOWLY

3600 PSIG MAX.SERVICE PRESSURE

REGULATOR

FILTER

INSPECT PRESSURERELIEF DEVICE

EVERY 2000 MILES

DRAIN HOUSINGEVERY 1500 MILESREPLACE ELEMENTEVERY 3000 MILES

1 2

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1. High Pressure Gauge2. Low Pressure Gauge3. Manual Fuel Shutoff Valve4. Fuel Fill Port

Fig. 21.10, CNG Fuel Panel


21.10

1. Check the windshield washer reservoir fluid level.The reservoir is usually located near the right-hand frame rail. See Fig. 21.11.

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

2.1 Check an indicator with graduations to seeif air restriction exceeds the value shownin Table 21.2.

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

Air Intake Maximum Restriction Values (inH2O)

Engine Make Pre-EPA07Engines

EPA07 andEPA10

Engines

GHG14Engines

Cummins 25 25 25Detroit 20 22 18Mercedes-Benz 22 22 –

Table 21.2, Air Intake Maximum Restriction Values

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

2.3 If air restriction exceeds the maximumvalue again, replace the air cleaner. Forinstructions, refer to Group 09 of the Cas-cadia Workshop Manual.

3. Inspect water evacuation components.

3.1 Inspect the vacuator valve(s) installed onthe hood interior and air cleaner. Makesure the lips of each valve are undam-aged and pliable, free of debris, and re-main closed during inspection. SeeFig. 21.12 and Fig. 21.13.

3.2 Inspect the rain tray installed at the baseof the windshield. Ensure that the seal onthe forward edge of the rain tray is ingood condition.

3.3 Inspect the drain hoses installed on therain tray. Both hoses should be securelyattached to the rain tray and direct waterdown the aft side of the front fenders. SeeFig. 21.14.

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

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

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

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

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

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

5.3 Alliance/Racor Models: Turn the drain plugcounterclockwise to open it. SeeFig. 21.15.

05/21/2007 f820442

1

1. Washer Fluid Filler Cap

Fig. 21.11, Windshield Washer Reservoir


21.11

DAVCO Models: Remove the vent capand open the drain. See Fig. 21.16.

5.4 Stop draining fluid when fuel begins todrain out.

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

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

6. Inspect the steering components.

6.1 Inspect tie rods, steering arms, and thedrag link for signs of looseness (i.e., shinyspots or rust tracks). See Fig. 21.17 for arack and pinion steering gear; seeFig. 21.18 for an integral steering gear.

6.2 Check the steering gear mounting boltsand pitman arm nut, if equipped, for signsof looseness.

6.3 Check the drag link nuts for missing cotterpins.

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

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

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

1

2

3 4 502/17/2012 f090497

1. Air Cleaner2. Vacuator Valve

3. Rain Tray Seal4. Rain Tray

5. Drain Hose

Fig. 21.12, Rain Tray Assembly

03/08/2012 f090498

1 1

1. Vacuator Valves

Fig. 21.13, Hood Interior


21.12

Monthly Post-Trip Inspectionsand MaintenanceBrake Component InspectionWalk around the vehicle and inspect brake systemcomponents for visible damage.

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

NOTICEIf the external breather tube or breather cap ismissing or incorrectly installed, road dirt and de-bris can adversely affect the operation of thebrake chamber. Once inside of the chamber, dirtand debris can cause the internal parts of thechamber to deteriorate faster.

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

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

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

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

02/17/2012 f820466

Ensure drain hoses are securely attached to the rain trayand drain down the aft side of the front fenders.

Fig. 21.14, Drain Hose

02/03/2010 f470552

1

2

34

56

7

8

9

10

11

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

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

Fig. 21.15, Alliance Fuel/Water Separator Assembly andInstallation


21.13

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

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

Saddle Tank Areas Inspection

WARNINGWhen draining the air reservoir, do not look intothe air jets or direct them toward anyone. Dirt orsludge particles may be in the airstream andcould cause injury.

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

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

NOTE: Battery locations vary between vehicles.

2. Inspect the batteries.

WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.

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

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

IMPORTANT: Aerodynamic components de-crease drag force as a vehicle moves, therebyimproving fuel efficiency. If replacement of an

05/05/2009 f470530

1

2

3

4

5

6

7

8

9

10

11

12

13

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

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

Fig. 21.16, DAVCO Fuel/Water Separator (Fuel Pro 482shown)


21.14

aerodynamic component is necessary, replace-ment components must meet or exceed thedrag reduction performance of the originally in-stalled component in order to maintain compli-ance with greenhouse gas and full efficiencyregulations (GHG14).

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

• Chassis fairings

• Roof fairing/deflector

• Side skirts

• Cab/sleeper extenders

• Battery access cover

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

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

f46216707/27/2009

1

1

1

1

2

2

3

3

45

6

6

7

7

1. Steering Tie Rod Arm2. Castellated Nut3. Outer Tie Rod

4. Power Steering Fluid Lines5. Power Steering Fluid Line Fittings

6. Steering Gear Mounting Bolts7. Steering Gear Mounting Nuts

Fig. 21.17, Rack and Pinion Steering Gear Assembly


21.15

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

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

3.1 Inspect the radiator and charge air coolerfor damage and accumulated debris.Straighten bent or damaged fins to permitairflow across all areas of the cores.

NOTE: When traveling through areas of highinsect concentration, it may be necessary toclean the exterior of the radiator or thecharge air cooler core as often as every 200miles (320 km).

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

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

3.4 Tighten hose clamps as necessary.

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

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

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

4. Check the steering wheel for excessive play.

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

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

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

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

10/11/2001 f461916

1

1

1

2

3

3

1. Steering Gear Mounting Bolts2. Pitman Arm Pinch Bolt Nut3. Drag Link Nut

Fig. 21.18, Integral Steering Gear Fasteners


21.16

www.alliancebrandparts.com

22

Cab AppearanceCab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3

Cab Washing and PolishingIMPORTANT: Carefully read all instructions be-fore using or applying any cleaner or product onthe vehicle or components. Failure to followmanufacturers’ recommendations can result indamage to the finish.

WARNINGDo not power wash or steam clean the enginebay in the area of vehicle electrical components,unless specified by vehicle manuals or serviceliterature. Power washing and steam cleaning cancause corrosion, permanently damaging thesecomponents, which could result in fire, personalinjury, or property damage.

To protect the finish of your new vehicle, follow theseguidelines carefully.

• During the first 30 days, rinse your vehicle fre-quently with water. If the vehicle is dirty, use amild liquid soap. Do not use detergent.

• During the first 30 days, do not use anythingabrasive on your vehicle. Brushes, chemicals,and cleaners may scratch the finish.

• During the first 120 days, do not wax yourvehicle.

To extend the life of your vehicle’s finish, follow theseguidelines.

• Avoid washing your vehicle in the hot sun.

• Always use water. After the cab is completelywashed, dry it with a towel or chamois.

• Do not dust painted surfaces with a dry cloth,as this will scratch the paint.

• Do not remove ice or snow from a painted sur-face with a scraper of any sort.

• To prevent damage to the finish, wax it regu-larly. Before waxing, if the finish has becomedull, remove oxidized paint using a cleanerspecifically designed for this purpose. Removeall road tar and tree sap before waxing.Freightliner recommends that a quality brand ofcleaner or cleaner-polish and polishing wax beused.

• Do not let diesel fuel or antifreeze stand on apainted surface. If either should occur, rinsethe surface off with water.

• To prevent rust, have any nicks or other dam-age on the finish touched up as soon as pos-sible.

• Park your vehicle in a sheltered area wheneverpossible.

To prevent delamination and deterioration of labelsand stickers on the cab, follow these guidlines care-fully:

• Do not pressure wash the label or sticker orsurfaces near it.

• Do not use strong alkaline soaps on or nearthe label or sticker.

Care of Fiberglass PartsWash unpainted fiberglass air fairings and shieldsmonthly with a mild detergent, such as dishwashingliquid. Avoid strong alkaline cleansers.

Apply a wax specifically designed for fiberglass.

Care of Chrome PartsTo prevent rust, keep chrome parts clean and pro-tected at all times. This is especially important duringwinter driving and in coastal areas where there isexposure to salt air.

When cleaning chrome parts, use clean water and asoft cloth or sponge. A mild detergent may also beused.

Sponge gently, then rinse. If necessary, use a non-abrasive chrome cleaner to remove stubborn rust orother material. Do not use steel wool.

To help protect the chrome after cleaning, apply acoat of polishing wax to the surface. Never use waxon parts that are exposed to high heat, such as ex-haust pipes.

Care of Exterior LightsClean the headlight lenses by hand only, using aflannel cloth with mild, non-caustic soap or detergent,and water.

Cab Appearance

22.1

CAUTIONDo not use a power buffer, paper towels, chemi-cal solvents, or abrasive cleaners on the head-light lens, all of which can remove the UV coatingfrom the surface, and result in yellowing of thelens.

Dashboard Care

NOTICEWhen cleaning the dashboard, instrument panel,or gauge lens covers, do not use Armor-All Pro-tectant®, STP Son-of-a-Gun®, window cleaner, orother equivalent treatments. These cleaners con-tain vinyl plasticizers which can cause stresscrazing in the interior plastic panels and can re-sult in cracking of the panels. Some cleaners canalso have an adverse effect on the clear plasticof instrument panels and gauge lens covers, re-sulting in a foggy or cloudy appearance. Thistype of damage is not covered by vehicle war-ranty.

To clean the dashboard, instrument panel, and gaugelens covers, use a cloth dampened with warm soapywater. Make certain to wring the cloth out well beforecleaning, as excess water will damage the electricalcomponents.

Vinyl Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Harshcleaning agents can cause permanent damage tovinyl upholstery. To preserve the upholstery and pre-vent damage, carefully review the following sectionsfor recommended cleaning procedures. Waxing orrefinishing improves soil resistance and cleanabilityfor all vinyls. Any hard wax, such as that used onautomobiles, may be used.

Ordinary DirtWash the upholstery with warm water and mild soap,such as saddle or oil soap. Apply soapy water to alarge area and allow to soak for a few minutes, thenrub briskly with a cloth to remove the dirt. This canbe repeated several times, as necessary.

If dirt is deeply imbedded, use a soft bristle brushafter applying the soap.

If dirt is extremely difficult to remove, wall-washingpreparations normally found around the home can beused. Powdered cleaners, such as those used forsinks and tiles, are abrasive and must be used withcaution as they can scratch the vinyl or give it a per-manent dull appearance.

Chewing GumHarden the gum with an ice cube wrapped in a plas-tic bag, then scrape it off with a dull knife. Any re-maining traces of gum can be removed with an all-purpose light oil (peanut butter will also work) andwiped off.

Tars, Asphalts, and CreosoteEach of these items stains vinyl after prolonged con-tact. They should be wiped off immediately and thearea carefully cleaned, using a cloth dampened withnaphtha.

Paint, Shoe Heel MarksPaint should be removed immediately. Do not usepaint remover or liquid-type brush cleaner on vinyl.An unprinted cloth, dampened with naphtha or tur-pentine may be used. Use care to prevent contactwith parts of the upholstery that are not vinyl.

Sulfide StainsSulfide compounds, such as those found in eggs andsome canned goods, can stain after prolonged con-tact with vinyl. These stains can be removed by plac-ing a clean, unprinted piece of cloth over the spottedarea and pouring a liberal amount of 6 percent hy-drogen peroxide onto the cloth. Allow the saturatedcloth to remain on the spot for 30 to 60 minutes. Forstubborn spots, allow the hydrogen-peroxide satu-rated cloth to remain on the area overnight. Use cau-tion to prevent the solution from seeping into theseams, or it will weaken the cotton thread.

Nail Polish and Nail Polish RemoverProlonged contact with these substances causes per-manent damage to vinyl. Careful blotting immediatelyafter contact minimizes damage. Do not spread theliquid during removal.

Cab Appearance

22.2

Shoe PolishMost shoe polishes contain dyes which penetratevinyl and stain it permanently. Shoe polish should bewiped off as quickly as possible using naphtha orlighter fluid. If staining occurs, try the procedure usedfor sulfide stains.

Ball Point InkBall point ink can sometimes be removed if rubbedimmediately with a damp cloth, using water or rub-bing alcohol. If this does not work, try the procedureused for sulfide stains.

MiscellaneousIf stains do not respond to any of the treatments de-scribed above, it is sometimes helpful to expose thevinyl to direct sunlight for up to 30 hours. Mustard,ball point ink, certain shoe polishes, and dyes oftenbleach out in direct sunlight, leaving the vinyl undam-aged.

Velour Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Spotclean with a mild solvent or an upholstery shampoo,or the foam from a mild detergent. When using a sol-vent or a dry-cleaning product, follow the instructionscarefully, and clean only in a well-ventilated area.Avoid any product that contains carbon tetrachlorideor other toxic materials. With either method, pretest asmall area before proceeding. Use a professionalupholstery cleaning service when extensive cleaningis needed.

Grease and Oil-Based StainsDampen a small absorbent cloth with dry-cleaningsolvent or spot remover. Apply the cloth carefully tothe spot from the outer edge to the center. Pat andblot the spot with a clean, dry cloth. Repeat severaltimes, as necessary, turning the cloths so that thestain does not redeposit on the fabric.

Sugar and Water-Based StainsApply water-based detergent or cleaner, working incircular motions. Pat and blot as dry as possible. Re-peat, if necessary, before drying thoroughly.

Chewing Gum or WaxHarden the gum or wax with an ice cube wrapped ina plastic bag, then scrape it off with a dull knife. Ex-cess wax can be absorbed by placing a thick whiteblotter over the wax and heating with a warm (nothot) iron. Remove the remainder by using the proce-dure for grease and oil-based stains.

MildewBrush the dry fabric with a soft brush. Sponge withdetergent, and blot. If the fabric is colorfast, dilute ateaspoon of bleach in one quart (one liter) of coolwater. Apply with a swab, directly on the mildewstain. Dab repeatedly with clear, cool water, and blotdry.

Cab Appearance

22.3

23

Headlight AimingPreliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

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

• Check that the hood is closed and latched.

• Remove any large amounts of mud or ice fromthe underside of the fenders.

• Check the springs for sagging or brokenleaves.

• Check the suspension for proper functioning ofthe leveling mechanism. On cabs with air sus-pensions, make sure that the height is properlyadjusted.

• Check for damage to the hood and hinge as-sembly. Repair as necessary.

• With the vehicle unloaded, check that the tiresare inflated to the recommended air pressure.

• Clean the headlight lenses. Use a soft clothwith mild, non-caustic soap or detergent, andwater.

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

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

2. Each headlight has a height adjusting dot. SeeFig. 23.1. Measure the distance from the groundto the height adjusting dot on each headlight(Fig. 23.2, Item A). Note those distances.

3. On the screen or wall, mark the locations of eachheadlight bulb center using the distances foundin step 2. See Fig. 23.2, Items 2 and 3.

4. Turn on the low-beam headlights.

5. Check the vertical adjustment of the low beams.The center of each beam projection should fallon or near the marks made during step 3. SeeFig. 23.3.

6. Use Table 23.1 to determine the maximum verti-cal distance allowable between the marks on thewall and the center of each low-beam projection.

If the distance between either projection centerand the mark made on the wall or screen isgreater than the maximum distance given in

Table 23.1, adjust the vertical positioning of thatheadlight.

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

The adjusting screw is located on the lower outsidecorner of the headlight assembly. See Fig. 23.4. Turnthe adjusting screw clockwise to raise the beam andcounterclockwise to lower it, until the beam patternmeets the acceptable standard.

01/23/2012 f545869

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

Fig. 23.1, Headlight Beam Height Adjusting Dot

Headlight Aiming

23.1

f545850a01/10/2012

B

B

1

23

25 ft (7.6 m)

AA

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

3. Center of Left-Hand Headlight Projection

Fig. 23.2, Headlight Aiming Screen/Wall

01/10/2012 f545851a

A

12

3

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

3. Low-Beam Angle Lower Limit

Fig. 23.3, Vertical Low-Beam Headlight Variation Limits

Headlight Aiming

23.2

Vertical Low-Beam Headlight Variation LimitsDistance Between Ground

and Headlight: in (mm)Desired Variation (Fig. 23.3,

Item 2): in (mm)Upper Limit (Fig. 23.3, Item

1): in (mm) upLower Limit (Fig. 23.3, Item

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

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

Table 23.1, Vertical Low-Beam Headlight Variation Limits

06/18/2007 f545076

Fig. 23.4, Headlight Adjusting

Headlight Aiming

23.3

24

In an EmergencyHazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Filter Replacement, Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.7

Hazard Warning LightsThe hazard warning light switch is located on thedash in what is referred to as the master module.See Fig. 24.1. The hazard lights can be activatedregardless of the ignition switch position.

To activate the hazard lights, push the center of theswitch once. The switch will blink at the same ratethat the hazard lights flash. Push the switch again toturn them off. All the turn signal lights on the vehicleand trailer, as well as the turn signal indicators in theICU, flash simultaneously when the hazard lights areactivated.

Fire ExtinguisherA fire extinguisher is located either in the cab by thedriver’s door, or in the baggage compartment.

Emergency Kit, OptionalAn optional emergency kit is located in the cab. Thekit includes one or more of the following: a first aidkit, a reflective vest, a triangular reflector, a flare kit,and (on vehicles with a Davco fuel/water separator) aspin-on fuel filter element.

If there is an emergency while driving, cautiously pulloff the road. Turn on the hazard warning lights. Placethe flares and reflector along the side of the road toalert other drivers that an emergency situation exists.

WARNINGUse extreme care when placing flares in emer-gency situations that involve exposure to flam-mable substances such as fuel. An explosion orfire could occur causing serious personal injury.

Emergency FilterReplacement, DavcoIf the filter cover on the Davco fuel/water separator isbroken, it will not be possible to operate the vehicle.A standard spin-on filter will correct this problem.

Refer to the Davco web site (www.davcotec.com)for additional information.

To replace the filter on all Davco fuel/water separa-tors, follow this procedure:

1. Drain the fuel until it is below the level of the col-lar. See Fig. 24.2 for the model 232/233 fuel/water separator and Fig. 24.3 for the model 382fuel/water separator.

2. Remove the vent and seal.

NOTE: The vent and seal are not needed in theemergency replacement. They should be re-tained for later installation at the time when thecover is replaced.

3. Remove the collar using the DAVCO fuel-waterseparator wrench. Do not use pliers or channel-lock pliers.

4. Remove the cover, cover seal, and spring. Re-tain them for later assembly.

5. Remove the filter element and dispose of it prop-erly.

NOTE: Remove the rubber grommet from thestud.

6. Install the standard engine spin-on filter (includedin the emergency kit) on the threaded stud.

7. Install the cover, cover seal, and spring, as re-moved.

8. Install the collar over the cover. Tighten the collarfinger-tight.

9. Start the engine and run it at increased rpm forone minute to purge air from the fuel lines.

03/20/2007 1 f6108552

1. Hazard Warning Switch2. Panel Lamps Switch

Fig. 24.1, Master Module

In an Emergency

24.1

www.davcotec.com

Emergency Starting WithJumper CablesWhen using jumper cables, follow the instructionsbelow.

WARNINGBatteries release explosive gas. Do not smokewhen working around batteries. Put out all flamesand remove all sources of sparks or intense heat

in the vicinity of the battery. Do not allow the ve-hicles to touch each other. Do not lean over thebatteries when making connections, and keep allother persons away from the batteries. Failure tofollow these precautions could lead to severepersonal injury as a result of an explosion oracid burns.

CAUTIONMake sure both electrical systems are the samevoltage. Electronic devices on both vehicles can

f47041611/14/2001

1

2

3

4

5

6

7

8

10

9

1. Vent2. Seal3. Collar4. Cover

5. Cover Seal6. Spring7. Filter Element

8. Threaded Stud9. Fuel Port10. Drain

Fig. 24.2, Davco Model 232 and 233 Fuel/Water Separator

In an Emergency

24.2

be damaged when connected to a vehicle with adifferent operating voltage.

NOTE: On vehicles equipped with optional un-derhood jump start posts, connect to theseposts instead of the batteries.

1. Apply the parking brakes and turn off the lightsand all other electrical devices.

2. Remove the battery box cover by pulling on theend of each hold-down latch until the end clearsthe catch, then pivoting the latches out of theway, and lifting off the cover. See Fig. 24.4.

CAUTIONAlways connect the battery, jumper cables, andcharger correctly (positive-to-positive andnegative-to-negative). Connecting a charging de-vice backwards (positive-to-negative) can se-verely damage the vehicle electrical content andcause non-warrantable failures.

3. Connect the positive (+) jumper cable to thepositive battery post on the Cascadia needingthe jump start, then connect the other end of thepositive jumper cable to the positive battery or

f470417

1

2

4

6

7

5

8

11/14/2001

3

9

11

10

1. Collar2. Vent3. Seal4. Cover

5. Cover Seal6. Spring7. Filter Element8. Threaded Stud

9. Fuel Port10. Drain11. Bottom-Plate Collar

Fig. 24.3, Davco Model 382 Fuel/Water Separator

In an Emergency

24.3

jump start post of the vehicle providing the jump.See Fig. 24.5.

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a spark

could occur near a battery, possibly resulting insevere personal injury from explosion or acidburns.

4. Connect one end of the second jumper cable tothe negative terminal of the booster battery, andconnect the other end of the cable to to thenegative battery post of the Cascadia needingthe jump start.

5. Start the engine of the vehicle with the boosterbatteries, and let the engine run a few minutes tocharge the batteries of the other vehicle.

6. Attempt to start the engine of the vehicle with thebatteries receiving the charge. Do not operatethe starter longer than 30 seconds, and wait atleast two minutes between starting attempts toallow the starter to cool.

7. When the engine starts, let it idle a few minutes.

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting insevere personal injury from explosion or acidburns.

8. Disconnect the grounded cable from the frame orother non-battery location, then disconnect theother end of the cable.

9. Disconnect the remaining cable from the newlycharged battery (or jump-start post if equipped)first, then disconnect the other end.

10. Install the cover; be sure it is positioned properlybefore fastening the latches.

TowingWhen it is necessary to tow the vehicle, make surethe instructions below are closely followed to preventdamage to the vehicle.

WARNINGDo not tow an unbraked vehicle if the combinedweight of both vehicles is more than the sum of

06/12/2007 f545070

Fig. 24.4, Battery Compartment

+

−

+

−

f54511107/06/2007

+

−

+

−

A B

C D

A. – Battery Cable to VehicleB. + Battery Cable to VehicleC. + Jumper Cable (connect first and disconnect last)D. – Jumper Cable (connect last and disconnect first)

Fig. 24.5, Jumper Connections

In an Emergency

24.4

the gross axle weight ratings (GAWR) of the tow-ing vehicle. Otherwise brake capacity will be in-adequate, which could result in personal injury ordeath.

Front Towing Hookup1. Disconnect the battery ground cables.

NOTICEFailure to remove the axle shafts when towingthe vehicle with the rear wheels on the groundwill result in damage to the transmission andother drivetrain components.

2. Remove both drive axle shafts. On dual driveaxles, if the vehicle is to be lifted and towed, re-move only the rearmost drive axle shafts.

On vehicles equipped with an air fairing, removeboth the forward and rearmost drive axle shafts ifthere is insufficient towing clearance.

3. Cover the ends of the hubs with metal plates orplywood cut to fit the axle opening, and drilled tofit the axle shaft studs. This prevents lubricantfrom leaking out and will keep contaminants fromgetting into and damaging the wheel bearingsand axle lubricant.

NOTICEFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.

4. On dual drive axles, if the vehicle is to be liftedand towed, chain the forward rear-axle assemblyto the vehicle frame. Use protection to keep thechains from damaging the frame.

5. Remove the bumper end caps and chrome bum-per (if equipped).

6. Attach the towing device. Do not pass a sling (forexample, a rope or chain) from one tow hook toanother to fasten for towing. Known as reeving,this practice is not permissible in most industrialapplications of towing and hoisting. Reeving canoverload the hooks and result in damage to thevehicle. See Fig. 24.8.

7. Lift the vehicle and secure the safety chains. Ifextra towing clearance is needed, remove thefront wheels.

NOTE: Due to the many variables that exist intowing, positioning the lifting and towing deviceis the sole responsibility of the towing-vehicleoperator.

8. Connect the clearance lights, taillights, and sig-nal lights. Connect any special towing lights re-quired by local regulations.

WARNINGFailure to chock the tires or connect the towtruck’s air brake system before releasing thespring parking brakes could allow the disabledvehicle to suddenly roll. This could cause prop-erty damage or personal injury.

9. Chock the tires on the disabled vehicle and con-nect the towing vehicle’s air brake system to thevehicle being towed. Then, release the springparking brakes and remove the chocks.

Rear Towing Hookup

NOTICEUsing a rear towing hookup on a vehicleequipped with a roof fairing could cause damageto the cab structure.

If reverse towing at speeds above 45 mph (70kph) is necessary, note the following precau-tions:

• Remove the rubber flex extenders (for sideextenders equipped with middle brackets)or the side extender assemblies (withoutmiddle brackets). Failure to do so couldcause damage to the side extenders and/orloss of the rubber flex extenders.

• Hold down the cab with tension strapslooped over the cab shocks and under theframe rails. Failure to do so could allow thewind load to lift the cab unexpectedly, re-sulting in damage to the air springs andother components.

1. If the vehicle is equipped with side extenders,and reverse towing at speeds above 45 mph (70

In an Emergency

24.5

kph) is necessary, prepare the side extenders asfollows:

• If middle brackets are installed on the sideextenders, as shown in Fig. 24.7, removethe rubber flex extenders.

• If middle brackets are not installed on theside extenders, remove the side extendersfrom the cab.

2. If the vehicle is equipped with cab air suspen-sion, and reverse towing at speeds above 45mph (70 kph) is necessary, hold down the cab asfollows:

2.1 Drain the air from the cab air springs.

2.2 Loop a 2-inch (5-cm) ratchet-style tensionstrap (rated 2000 lb [900 kg] minimumwork load) over the top of the cab shockand under the frame rail. See Fig. 24.8.Tighten the strap for a snug fit. If the cabis equipped with two or more shocks, re-strain the aftmost shock on each side ofthe vehicle.

3. Place the front tires straight forward and securethe steering wheel in this position.

4. Disconnect the battery ground cables.

NOTICEFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.

5. On dual drive axles, using protection to keep thechains from damaging the vehicle frame, chainthe forward-rear drive axle to the frame.

6. Attach the towing device.

NOTE: Due to the many variables that exist intowing, positioning the lifting and towing deviceis the sole responsibility of the towing-vehicleoperator.

7. Lift the vehicle and secure the safety chains. Ifextra clearance is needed, remove the bumperextension if equipped.

07/05/2007

OK

OK

1

1

2

f880793

IMPORTANT: Do not reeve when towing.

1. Tow Hook 2. Chain

Fig. 24.6, Reeving

In an Emergency

24.6

8. Connect the clearance lights, taillights, and sig-nal lights. Also connect any special towing lightsrequired by local regulations.

Fire in the CabThe incidence of fire in heavy- and medium-dutytrucks is rare, according to data from the NationalHighway Traffic Safety Administration. Federal MotorVehicle Safety Standard #302 limits the flammabilityof specified materials used inside the cab, but de-spite this, most materials will burn. The cab of thisvehicle contains urethane foam, which is of concernin this respect.

WARNINGUrethane foam is flammable! Do not allow anyflames, sparks, or other heat sources such ascigarettes or light bulbs to contact urethanefoam. Urethane foam in contact with such heatsources could cause a serious, rapid fire, whichcould result in death, severe burns, or gas poi-soning, as well as damage to the vehicle.

In Case of a Cab FireAs quickly as possible, bring the vehicle to a safestop, apply the parking brake, turn off the ignition,and get out of the vehicle.

01/05/2010 f602410

Fig. 24.7, Side Extender Middle Bracket

05/13/2014 f602527

Fig. 24.8, Tension Strap Installed to Hold Down the Cab

In an Emergency

24.7

25

Natural Gas VehiclesNatural Gas Vehicles, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1Natural Gas Vehicles, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1Natural Gas Fuel Tank Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3Natural Gas Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5Natural Gas Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.9Major Repairs and Replacement of Natural Gas Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.10

Natural Gas Vehicles, GeneralInformationThe vehicle can be equipped with a compressednatural gas (CNG) fuel system, or a liquefied naturalgas (LNG) fuel system. CNG is made by compress-ing natural gas to less than 1% of its volume at stan-dard atmospheric pressure. LNG is created by con-densing natural gas into a liquid by cooling it toapproximately -259°F (-162°C).

When vaporized at ambient temperatures, naturalgas is less dense than air, and it rises and disperses.However, LNG is initially heavier than air due to itscryogenic temperature. When released in largeamounts, it may drop or pool on the ground beforeits temperature rises enough to vaporize. Cold at-mospheric conditions may prevent natural gas fromdispersing quickly when released in large amounts.

Natural gas is nontoxic, but it can cause asphyxiationif present in very large concentrations.

CNG often contains an odor-producing chemical,while LNG does not have any odor. Users of natural-gas-fueled vehicles should never expect to detectnatural gas leaks by scent.

For natural gas to burn, it must first vaporize, thenmix with air in the proper proportions (flammablerange is 5 to 15% by volume in air), and then beignited.

A typical natural gas fuel system consists of:

• Fuel supply cylinders that store compressedgas at high pressure (CNG), or a tank thatstores liquefied gas at an extremely low tem-perature (LNG).

• A vaporizer or heat exchanging device thatchanges LNG to gaseous form (LNG fuel sys-tems only).

• Pressure relief and manual fuel shutoff valves.

• A filling connection with a check valve that pre-vents the gas from flowing back out of the fuelfilling line.

• High-pressure and low-pressure fuel filters.

• A pressure control regulator that reduces thehigh fuel tank or cylinder pressure to the lowerpressure needed for the engine.

• A fuel contents gauge that indicates the fuelsupply in the tank or cylinders.

Figure 25.1 shows the locations of various compo-nents of a CNG installation.

Natural Gas Vehicles, SafetyPrecautions

DANGERNatural gas is highly flammable. Failure to ob-serve the following safety precautions could leadto the ignition of the natural gas, which couldcause serious bodily injury or death.

CNG systems should be maintained and inspectedexclusively by trained personnel with certifications inaccordance with the applicable codes. As with allpressure vessels, CNG storage and fuel delivery sys-tems are inherently dangerous and should be treatedas such. Individuals involved in any aspect of CNGfuel system maintenance, emergency response, ser-vicing, or testing must be properly trained and certi-fied. Individuals who are not trained and certified inall aspects concerning CNG fuel delivery systemsare not permitted to service, maintain, test, or inspecta system in any way.

Follow these safety precautions when operating orrepairing a natural gas vehicle.

• Only certified LNG personal can fuel LNGtrucks.

• Do not start the engine if a natural gas leak isdetected.

• Transferring fuel is only allowed as long as anon-static hose is used. if a non-approvedhose is used, static can build up and ignite thefuel. A correct hose can be obtained throughAgility fuel systems.

• Do not attempt to cut any fuel supply pipingcomponents.

• Avoid open flames or sparks near a naturalgas vehicle.

• Cover eyes and exposed skin when working ona natural gas fuel system or fueling a naturalgas vehicle.

Natural Gas Vehicles

25.1

1

2

3 4

5

6

7

01/21/2014 f470613

1. Sleeper Leak Sensor (zone 3)2. Engine Compartment Leak Sensor (zone 2)3. Leak Detection Control Panel (zone 1) (overhead

console)4. Cylinder Shutoff Valve (back-of-cab box)

5. Shutoff Valve, Right Side Cylinder6. Shutoff Valve and System Components, Left Side

Cylinder7. Fill Panel

Fig. 25.1, CNG Component Locations


25.2

• Permit no smoking or other ignition sources in,or within thirty feet of, a natural gas vehicle.

• Have CO2 fire extinguishers (ABC minimum)located in a highly visible and easily accessiblelocation.

• Use Purple-K powder (PKP) or a similar drypowder to extinguish an LNG fire. Do not at-tempt use water around an LNG fire.

• Always purge the fuel lines before performingmaintenance or repairs on a natural gas fuelsystem. Refer to the system manufacturer’sservice manual or the vehicle’s workshopmanuals for the proper purging procedure.

• Always use a natural gas detector to test thesystem for leaks, whether an odor is present ornot. Routinely inspect the fuel filtering andregulating mechanisms, and the fuel lines. Anapproved natural gas bubble solution can beused to pinpoint the exact location of leaks. Donot use soap and water. Soap and water cancause premature failure of the O-rings in thesystem.

• Make sure black caps are always on the PRDvent lines to reduce water build up in lines.

• Do not store a natural gas vehicle indoors forany extended period of time. Do not bring anatural gas vehicle indoors unless the work-shop is equipped with a methane detection andventilation system.

In Case of EmergencyIf a vehicle has sustained damage or a leak hasbeen discovered:

1. Turn the ignition switch off, and set the parkingbrake.

2. Exit the vehicle leaving as many doors and win-dows open as possible. Get at least 30 feet fromthe vehicle, and allow it to vent until it is safe todo the steps below.

3. Remove all ignition sources from the area sur-rounding the vehicle.

4. If it is safe to do so, close all fuel shutoff valves.

5. Use a natural gas detector, or approved NGbubble solution, to identify leaks in the fuel sys-tem.

Natural Gas Fuel Tank FillingProceduresCNG Vehicle FuelingCNG is moved from the fuel station storage tanks tothe vehicle cylinders through a metered dispenser.During fueling, as pressure inside of the vehicle cyl-inders increases, so does the temperature. The dis-penser shuts off when it determines the CNG cylin-ders are full.

CNG fuel cylinders cannot be filled to their full capac-ity of 3600 psi (24 800 kPa) in cooler weather. Sincetemperature change causes gas to expand and con-tract, less pressure in the cylinders on a cold day isequal to the same amount of gas at a higher pres-sure on a warm day. The fuel station dispenser has atemperature-pressure compensating device, whichaccounts for ambient temperature during fueling. SeeTable 25.1 for approximate full cylinder pressures atvarious temperatures.

CNG Temperature/Pressure Compensation Values

Temperature:°F (°C)

Fill Station Pressure Set Point3000 psi (20 684kPa) Set Point

3600 psi (24 821kPa) Set Point

100 (37.8) 3415 (23 546) 4086 (28 172)90 (32.2) 3276 (22 587) 3909 (26 952)80 (26.7) 3138 (21 636) 3754 (25 883)70 (21.1) 3000 (20 684) 3600 (24 821)60 (15.6) 2861 (19 726) 3445 (23 752)50 (10) 2723 (18 774) 3288 (22 670)40 (4.4) 2584 (17 816) 3131 (21 587)30 (-1.1) 2446 (16 865) 2973 (20 498)20 (-6.7) 2307 (15 906) 2814 (19 402)

10 (-12.2) 2169 (14 955) 2655 (18 306)0 (-17.8) 2031 (14 003) 2495 (17 202)

-10 (-23.3) 1893 (13 052) 2336 (16 106)-20 (-28.9) 1755 (12 100) 2180 (15 031)-30 (34.4) 1616 (11 142) 2024 (13 955)-40 (-40) 1477 (10 184) 1868 (12 879)

Table 25.1, CNG Temperature/Pressure CompensationValues

Use the following steps to fuel a CNG vehicle.

1. Shut down the engine and apply the parkingbrake.


25.3

IMPORTANT: Close all windows and doors dur-ing the fueling process. Keeping windows anddoors closed allows for easier leak detectioninside the cab after fueling.

NOTE: If the fuel system has only back of cabtanks, the fuel fill is located behind the fuel ac-cess panel on the lower part of the cabinet, orbelow the tank cabinet in a separate box. Iftruck has saddle mount tanks, the fuel panel islocated on the back end of the left side tank.Vehicles with back-of-cab cabinets and saddletanks are have the fuel fill panel on the backend of the left side tank. See Fig. 25.2 for sidetanks, or Fig. 25.3 for back-of-cab cabinetmounted fuel panel.

WARNINGNatural gas fuel tanks, lines, and valves are al-ways pressurized. Always observe safety precau-tions. Failure to do so could lead to loss of con-trol over a filling hose or to ignition of the naturalgas, which could cause serious bodily injury,death, or severe property damage.

2. Ensure all fuel cylinder shutoff valves are open.See Fig. 25.2.

3. Ensure the vehicle fuel system main shutoffvalve is open.

4. If equipped, open the CNG fuel panel accessdoor and remove the dust cap from the vehiclefuel fill port.

5. Ensure the O-ring is present inside the fuel fillport. If the O-ring has been dislodged or is miss-ing, the station dispensing nozzle will not con-nect securely to the fill port.

6. Turn the selector knob on the service pump tothe VENT position, if equipped.

7. Connect the quick coupling on the dispensingnozzle securely to the vehicle fuel fill port.

8. Turn the selector knob on the service pump tothe FILL position, if equipped.

IMPORTANT: If at any time the service pump orvehicle begins to vent CNG uncontrollably, notifya station attendant or activate the service sta-

tion emergency shut-off switch to cease the flowof CNG.

01/21/2014 f470615

2

13

4

1. High-Pressure Gauge2. Fuel Cylinder Information Sticker3. Manual Shutoff Valve4. Fuel Fill Port

Fig. 25.2, CNG Fuel Cylinder Fill Panel (side tankshown)

HIGH PRESSURE PRESSURELOW

CYLINDERSINSPECT CYLINDERS

EVERY 36 MONTHSOR 36000 MILES

WHICHEVER OCCURS FIRST

NATURALGAS

VEHICLE110 PSIG

ON

MANUAL

SHUT O

FFVALV

EOPEN VALVE

SLOWLY3600 PSIG MAX.

SERVICE PRESSURE

REGULATOR

FILTER

INSPECT PRESSURERELIEF DEVICE

EVERY 2000 MILES

DRAIN HOUSINGEVERY 1500 MILESREPLACE ELEMENTEVERY 3000 MILES

1 2

34

04/30/2010 f470556

1. High Pressure Gauge2. Low Pressure Gauge3. Manual Fuel Shutoff Valve4. Fuel Fill Port and Dust Cap

Fig. 25.3, CNG Under Cabinet Fuel Panel (undercabinet shown)


25.4

9. Switch on the service pump. A slight hissingnoise may be heard as the fuel cylinders fill.

10. Watch the pressure gauge on the service pump.When the gauge reads approximately 3600 psi(24 800 kPa), or when the fill pressure stopsclimbing, the CNG cylinders are full. The servicepump will shut itself down automatically. SeeTable 25.1 for pressure compensation valuesbased on ambient temperatures.

11. Move the selector knob on the service pump tothe VENT position, if equipped. A short hiss willbe heard as a small amount of natural gas isvented into the hose.

WARNINGDo not attempt to remove the fill station nozzlefrom the tank fill fitting until venting of pressureis noted. If no venting occurs, ask for assistancefrom the station attendant. Removing an un-vented coupling could result in an uncontrolledhose, which could lead to property damage orpersonal injury.

12. Remove the station dispensing nozzle from thevehicle fill port.

NOTE: Some fill ports and dust caps contain amagnetic start interrupt sensor to prevent atruck from being started and driven away withthe fill hose connected. These caps must beinstalled correctly or vehicle will not start.

13. Install the dust cap on the vehicle fuel fill portand close the fuel panel access door, ifequipped.

LNG Vehicle FuelingOnly certified LNG fueling personnel are authorizedto fuel an LNG vehicle.

Natural Gas Detection SystemA gas detection system is standard in all DaimlerTrucks natural-gas-fueled vehicles. This system hasa sensor in the engine compartment, one in the cab,and one in the sleeper (if equipped), all situated inhigh areas to detect natural gas buildup as a resultof leaks.

The AMGaDS III Plus is a natural gas detection sys-tem. This device is meant to serve as a supplemen-tal warning only. It is not intended to replace stan-dard safety practices that should be conductedaround flammable gases.

IMPORTANT: To function properly, the gas de-tection system must be powered at all times.The gas detection system is directly powered bythe batteries, and can only be powered off bydisconnecting the batteries. When servicing anatural-gas-fueled vehicle, disconnect the bat-teries only when necessary, and do not leavethe batteries disconnected for extended periodsof time.

The lower flammability limit (LFL) is the smallestamount of the gas that supports a flame when mixedwith oxygen and ignited. Zero percent (0%) LFL indi-cates a gas-free atmosphere. One hundred percent(100%) LFL indicates that gas concentration hasreached its lower flammability limit (5% gas in air byvolume). The red warning light and audible alarmlocated in the overhead console activate when a sen-sor detects gas fumes in concentrations above 50%LFL, and should allow ample time to utilize safetyprocedures. However, individuals with special needsshould review the system with a professional safetyengineer.

Alarm ProcedureBefore operating the vehicle, the driver must be fa-miliar with the procedures as shown on the interiorsticker on the overhead panel (See Fig. 25.4) andthe exterior sticker on the door (See Fig. 25.5).

IMPORTANT: If an audible alarm activates, donot operate any electrical switch, includinglights. Avoid causing sparks and stay away fromarcing switches and equipment. Do not use atelephone, including cellular phones or anytypes of portable communication or electronicdevices that have a battery.

If the vehicle is in motion when the audible alarmactivates, bring it to a safe stop, shut down the en-gine, and exit the vehicle. Do not open the hood.

If outside the vehicle when the audible alarm acti-vates, do not open the cab door or hood.

In the event of an audible alarm, immediately followthese procedures, as allowed by conditions:


25.5

1. Immediately shut off all engines. Extinguish anycigarettes, pilot lights, flames, or other sources ofignition in the area and adjacent areas.

2. Exit the vehicle leaving as many doors and win-dows open as possible, and move at least 30feet away from vehicle. If the vehicle is parked,stay at lease 30 feet away until it is safe to dothe following.

3. Manually close all fuel shutoff valves, includingthose on the LNG tank or CNG cylinders.

4. If the vehicle is indoors (as in a service shop),immediately open shop windows and doors toprovide extra ventilation to the area. Do not startthe engine or any other type of equipment untilthe gas leak is corrected and the area cleared ofnatural gas.

5. Evacuate the area.

6. After the area is cleared of natural gas and thealarm is no longer active, have the vehicle in-spected by a qualified technician.

IMPORTANT: Do not consider the area clearuntil all alarm indicators are off, and the alarmpanel light returns to green.

SensorsGas detection sensors are located on the cab over-head console (zone 1), in the engine compartmenton the frontwall (zone 2), and in the sleeper, ifequipped (zone 3). The sensors are located in highareas, where rising gas vapors will pass by or accu-mulate. On some vehicles, there is a sensor locatedunder the cab floor (zone 4). Zone 4 is not used onDTNA vehicles.

If the system detects that one of the sensors hasbeen disconnected or has malfunctioned, the sensorfault light for that zone will illuminate. A failed sensormay trigger and lock on an alarm. If this happenshave a qualified technician troubleshoot the systemand make appropriate repairs.

The sensors are sensitive to all hydrocarbon vapors.An alarm may be triggered by the use of chemicalssuch as cleaners, paint, polish, lacquer, gasoline,silicone, silicone spray, or other harsh chemicals.The sensors will also detect hydrogen fumes from anovercharged battery. If a sensor sends an alarm, butno gas fumes are present, check for recent use ofchemicals or a battery charger.

04/28/2009 f080157

Fig. 25.4, Interior Warning Sticker

04/28/2009 f080158

Fig. 25.5, Exterior Warning Sticker


25.6

NOTICESilicone-based chemicals and cleaners will per-manently disable the sensors. When cleaning thevehicle, cover the sensors with a plastic cover-ing. Keep the sensors covered until the area hasbeen cleared of any cleaning fumes.

Harsh chemicals, including some high alcoholcotenant washer fluids, and extremely high tem-peratures may damage the sensor.

Puncture of or damage to the seal located insidethe sensor housing will significantly shorten thesensor life.

Frequent exposure to high concentrations of gaswill accelerate sensor deterioration.

Overhead ConsoleThe overhead console consists of an alarm panel onthe right side and the control module on the left side.

The alarm panel has a green light, a red light, abuzzer, and a sensor. See Fig. 25.6. It is locatedwithin view from outside of the vehicle. The largegreen light is continuously illuminated during normaloperating conditions.

Before entering the vehicle, always verify that thegreen light is illuminated. If the green light is not illu-minated, do not enter the vehicle. Complete thealarm procedure previously outlined.

The alarm panel meets the California Highway PatrolTitle 13-2008 and NFPA 52 2010 requirements. Alldrivers and technicians using it should be trained re-garding the red and green lights, and the audiblewarning.

The control module, located on the center of theoverhead console, contains the status lights and con-trol buttons for the system. The areas that the sen-sors monitor are defined as Zone 1 (cab), Zone 2(engine compartment), and Zone 3 (sleeper, ifequipped). The control module has lights assigned toeach zone that will illuminate if a sensor detects atrace level leak (between 20% and 30% LFL), a sig-nificant level leak (above 50% LFL), or if a sensor isdisconnected or malfunctioning.

• Trace Level: If either sensor detects gas fumesat a concentration greater than 20% to 30%LFL (1% gas in air by volume), the amber lightnext to the Trace indicator for that zone will

flash. There is no buzzer alarm for a tracelevel detection, and the large green light on thealarm panel will remain illuminated.

• Significant Level: If either sensor detects gasfumes at a concentration greater than 50% to60% LFL (2.5% gas in air by volume), thesmall red light next to the SIGNIFICANT indi-cator for that zone will flash. After approxi-mately 15 seconds, the large green light on thealarm panel will switch off, the red light will illu-minate, and the buzzer will sound. All alarmindicators will remain on as long as fumes aredetected.

• Sensor Fault: If the system detects that eitherof the sensors has been disconnected or hasmalfunctioned, an amber light next to the Sen-sor Fault indicator for that zone will illuminate.

The control module also has buttons used to test orreset the the control module after an alarm. Redlights next to each button indicate when they are en-gaged.

• Shutdown Reset: If an alarm has been acti-vated and the Relay Engaged light is illumi-nated, the Shutdown Reset button will resetthe internal relay. Press the Shutdown Resetbutton only after the gas has cleared, thebuzzer has turned off, and the alarm panellight has returned to green.

• Push To Silence: If an alarm has been acti-vated, the Push To Silence button will silencethe buzzer.

See Table 25.2 for the functions of all lights and but-tons on the overhead console.

TestingDaimler Trucks North America strongly recommendsthat all operators follow California Code of Regula-tions (CCR) inspection requirements, regardless ofwhere the vehicle is operated. Per Title 13 CCR §

935 (2), gas detection systems should be testedthree times per calendar year at equal intervals. Thetesting procedure should simulate the same operat-ing environment in which the vehicle is used, with thesame gaseous fuel.


25.7

Control Module FunctionsItem Display Function Action Required

Green Power Light

Illuminated System is on. None required.

Unlit Detection system is notfunctioning.

Ensure the batteries areconnected and replace any blownfuses. If the gas detection systemis still not functioning, replace thesystem immediately.

SIGNIFICANT GasConcentration Lights Red (illuminated) Dangerous gas concentration

detected.

Suspend vehicle operationimmediately and follow alarmprocedures.

Trace Gas ConcentrationLights Amber (flashing) Minor gas concentration detected.


Sensor Fault LightsOff Sensor is functioning properly. None required.On Sensor has malfunctioned. Replace the sensor immediately.

02/06/2014 f470614

1 3 42

10

11

1214

13

9

5

678

1. Green Light2. Red Light3. Sensor4. Buzzer Alarm5. Test Button

6. Sensor Fault Indicator Lights7. Zone Numbers8. Trace Leak Indicator Lights9. Significant Leak Indicator Lights10. Silence Engaged Light

11 Silence Button12. Relay Reset Button13. Relay Engaged Light14. Power Indicator Light

Fig. 25.6, AMGaDS III Overhead Console


25.8

Control Module FunctionsItem Display Function Action Required

Shutdown Reset Button — Resets the system after an alarmactivation.

Press to reset the system onlyafter the gas has cleared, thebuzzer has turned off, and thealarm panel light has returned togreen.

Relay Engaged LightOn Relay is engaged and test or

alarm is being cleared. Press the Shutdown Reset button.

Off Normal condition. None required.

Test Button — Tests the overhead consoleoperation and circuitry.

Press and hold for one minute toto activate a test of all overheadconsole components.

Silence Button — Silences the alarm buzzer. Press to silence the alarm buzzer.

Silence Engaged LightOn Indicates the buzzer is active but

silenced.


Off Normal condition. None required.

Table 25.2, Control Module Functions

Test results validating the performance of the gasdetection system within the parameters establishedby the component manufacturer and NFPA 52 2010should be maintained as a permanent part of the ve-hicle service records. Use of alcohol, propane, andother harsh liquids or gases are not acceptablemethods for testing.

Always test the system and sensors after any com-ponent has been replaced, or if the vehicle has beeninvolved in an accident or fire. Ensure that the gasdetection system is wired directly to the battery.

It is recommended that the highest level of safetyvalidation be utilized if there are multiple validationrequirements in the state or locality where the vehicleis operated or domiciled.

Overhead Console TestPress and hold the Push To Test button for one min-ute. The system will proceed with a self-diagnostictest that will include illumination of the Trace and Sig-nificant gas concentration lights, and the sensor faultlights. Verify the large red light and buzzer activate,and that all lights illuminate or flash to ensure that allbulbs are operational.

Sensor TestThe gas detection system sensors must be testedusing qualified test gas, which can be purchased aspart of a test kit. Testing with alcohol or heavy gases

such as butane or propane does not satisfy CCR §

935 (2) or NFPA 52 regulations.

Expose each sensor to qualified test gas for at least30 seconds. The system will proceed through thealarm procedure consistent with a significant leakand the buzzer will sound after approximately 15seconds. If a sensor fails to respond after exposureto the test gas, replace the sensor.

Natural Gas Engine StartingNOTE: Before starting the engine, read Chap-ter 4 for detailed information on how to read theinstruments and Chapter 5 for detailed informa-tion on how to operate the controls. Read theoperating instructions in the engine manufactur-er’s operation manual before starting the en-gine.

1. Before engine start-up, complete the engine pre-trip and post-trip inspections and maintenanceprocedures in Chapter 21.

2. Ensure the fuel shutoff valve is open.


4. Ensure that the transmission shift control is inNeutral (N), Park (P), or the Park Brake (PB) po-sition.


25.9

5. Without starting the engine, turn the ignitionswitch to the ON position (Fig. 25.7). The elec-tronic gauges on the instrumentation control unit(ICU) will complete a full sweep of their dials, thewarning and indicator lights will illuminate, andthe buzzer will sound for three seconds.

6. Turn the ignition switch to the START position.

Press down on the clutch pedal, if equipped, butdo not press down on the accelerator pedal.

Release the key the moment the engine starts.

7. Bring the engine up to operating speed graduallyas it warms up and develops stable oil pressure.If the vehicle has not been operated previously ina 24-hour period, allow the vehicle to idle for fiveminutes.

NOTICEDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the enginewithin approximately ten seconds to avoid enginedamage.

8. Check the oil pressure gauge for any drop in lu-bricating oil pressure or mechanical malfunctionin the lubricating oil system.

Major Repairs andReplacement of Natural GasComponentsIMPORTANT: All repairs to natural gas systemand components must be performed by certifiedtechnicians.

If a natural-gas-fueled vehicle is involved in an acci-dent, remove the fuel tank or cylinders from serviceand have them inspected by a qualified technician.Replace any leaking or damaged fuel tanks/cylindersand fuel lines; repair or replace leaking or damagedfittings. Install parts and components in accordancewith the manufacturer’s instructions.

07/19/2006 f610805

Fig. 25.7, Ignition Switch Positions


25.10

26

SpecificationsFuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1Replacement Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.3Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.4

Fuses and Relays

CAUTIONThis vehicle may be equipped with a roof-mounted Citizens’ Band (CB) antenna. Operationof an amplified CB radio with output powergreater than FCC limits (4W AM/12W SSB) is ille-gal, and may expose vehicle occupants to radiofrequency (RF) radiation that exceeds FCC maxi-mum permissible RF exposure limits. Vehicle oc-cupants with electronic medical devices shouldconsult the device manufacturer’s user manual ora physician for information on RF radiation expo-sure limit guidelines.

SAM Cab FusesPart Name AMPF1 Power FD Spare 1 & 3 30

F2Cab/Slpr HVAC Ctrl

Trans Shift Pnl15

F3 Power FD Spare 2 & 4 30F4 MSF 15

F5OBD J1939

OBD DCDI10

F6 Dash Power Recp 1 15F7 Dash Power Recp 2 15F8 Phone/Radio 15F9 Amplifier Power 20

F10 Cab HVAC Motor 30F11 Sleeper HVAC Motor 30F12 Door Controls, L 20

F13Door Lock

Coll Warn Sys20

F14Fleet Mgm Sys

CB25

F15 Sleeper Power Recp 3 20F16A Aux Cab Heater Enable 3F16B Aux Coolant Heater 20F17 Power Recp 4 20

F18

GPS

Tire Press Monitor

Antitheft Warn

AuxiliaryTelematics

15

F19 Heated Seat 20

SAM Cab FusesPart Name AMPF20 CGW 2F21 Area Light 15

F22ICU

Horn Switch5

F23

GPS

Driver Info Sys

Fleet Mgmt Sys

Pyrometer, Axle Temp, EngOil Temp Gauges

15

F24Diagnostic Conn

ICU7.5*

F25

Trans Temp Gauge/ShiftSelect

Phone

Collision Warn Sys

10†

F26 SRS Airbags 5F27 Mirror Heat, L 10F28 Mirror Heat, R 10F29 SAM Relay Coils 3F30 Power Recp 6 20F31 Power Recp 5 20F32 Power FD Spare 5 & 6 25F33 Spotlight 20F34 Baggage Comp Lamp 3F35 Dome Lamp 15

F36Aux Circulation Fan

Road Lamps15

F37

Clock (cab & sleeper)

Driver Info Sys

CD Player

Keyless Entry

15

F38 Door Controls, R 20F39 Power Window, R 15F40 Power Window, L 15F41 Aux Mirror Heat 10

* F24 value on assemblies -005 and lower is 10 amps.† F25 value on assemblies -005 and lower is 7.5 amps.

Table 26.1, SAM Cab Fuses

Specifications

26.1

SAM Cab RelaysPosition Function Source

BR21Power FD Spare 1 & 3

Dash Power Recp 1BAT

BR22Power FD Spare 2 & 4

Slpr Power Recp 3BAT

R3 Heated Seats IGN

BR23

Dash Power Recp2

Fleet Mgmt Sys

CB

Aux Cab Heater

Aux Coolant Heater

BAT

R7

GPS

Driver Info Sys

Fleet Mgmt Sys

Pyrometer, Axle Temp, EngOil Temp Gauges

IGN

R8

Diagnostic Conn

ICU

Trans Temp/Shift Select

Phone

Coll Warn Sys

SRS Airbags

IGN

R9 Amplifier Power ACCR10 Mirror Heat (L, R, & Aux) ACC

BR24

Power Recp6

Area Lighting

Baggage Comp Lamp

Dome Lamp

BAT

BR25

Power Recp 4 & 5

Aux Circulation Fan

Reading Lamp

BAT

R15 Power Windows ACC

Table 26.2, SAM Cab Relays

SAM Chassis FusesPart Name AMP

F1 Elec Air Process. Unit(EAPU) 20

F2 Fuel/Water Separator Heat 20F3 ABS Bat 1 20F4 ABS Bat 2 10F5 Trailer Left-Turn Lamp 20F6 ABS 15

F7EAPU/WIF

Rear Camera10

F8 Trailer Right-Turn Lamp 20F9 Trailer Marker Lamps 30

F10 SAM Relay Coils 5F11 Trailer ABS 30F12 Trailer Stop Lamps 30F13 Trailer Tail Lamps 20F14 Trailer Power 30

Table 26.3, SAM Chassis Fuses

SAM Chassis RelaysPosition Function

R1 Fuel/Water Separator HeatR2 Trailer Left-Turn Lamp

R3

ABS

EAPU/WIM

Rear CameraR4 Trailer Right-Turn LampR5 Trailer Marker LampsR6 Trailer ABSR7 Trailer Stop LampsR8 Trailer PowerR9 Trailer Tail Lamps

Table 26.4, SAM Chassis Relays

MEGA Fuse Junction Block (MFJB) Fuses, EPA07Only

Part Name AMPF1 Powertrain PDM 175F2 SAM Cab 175F3 SAM Chassis 125

F4 Chassis-Mounted TrailerPDM 125

Specifications

26.2

MEGA Fuse Junction Block (MFJB) Fuses, EPA07Only

Part Name AMPF5 Inverter 200

Table 26.5, MEGA Fuse Junction Block (MFJB) Fuses,EPA07 Only

Powernet Distribution Box (PNDB) Fuses, EPA10 andNewer

Fuse Function AMP

A Aftertreatment ControlModule 30

B Emergency Power 20C Radio/Clock 5D Alternator Remote Sense 51 Powertrain PDM 1752 SAM Chassis 1253 SAM Cab 175

Table 26.6, Powernet Distribution Box (PNDB) Fuses,EPA10 and Newer

Trailer PDM Fuses and RelaysPosition Function AMP

F1 Trailer Power Fuse 30F2 Taillight Fuse 30F3 Left-Turn Lamp Fuse 20F4 Right-Turn Lamp Fuse 20F5 Marker Lamp Fuse 30F6 Stop Lamp Fuse 30R1 Taillight RelayR2 Right-Turn RelayR3 Stop Lamp RelayR4 Trailer Power RelayR5 Left-Turn RelayR6 Marker Lamp Relay

Table 26.7, Trailer PDM Fuses and Relays

Replacement Bulbs

Replacement BulbsLamp Assembly Replacement Bulb

Headlight Hi/Low Beam, Foglight, Driving Light

WEE 12362LLBA(H11)

Turn/Marker Lamp (in headlightassy) GE 3457

Incandescent Auxiliary Turn (onfender) GE 2058U

Integral Stop/Tail/Backup Lights GE 1157/GE 1156Utility Light WEE 199Cab Dome Lamp, Clear,Outboard GN12 BUL 050 R5WC

Cab Dome Lamp, Clear, Inboard GN12 BUL 049 R10WCab Dome Lamp (Red) GN12 BUL 050 R5WRSleeper Reading Lamp GRLSAP270Sleeper Dome Lamp GRLBUL049R10WSleeper Writing Desk Lamp GRLBUL027578Sleeper Bunk Lamp GRLBUL0142112Footwell Lamp (Red) GRLBUL042W5W

Table 26.8, Replacement Bulbs

Specifications

26.3

Fluids and Lubricants

NOTICEDetroit transmissions use synthetic lubricant thatmeets the requirements of the MB 235.11 specifi-

cation, such as Detroit Synth 75W-90. Using lu-bricant that does not comply with this specifica-tion will result in damage to the transmission.

Type Approved Fluid or Lubricant

Engine OilEngines compliant with EPA07 or newer regulations: Engine lube oil with a sulfated ash level lessthan 1.0 wt %; currently referred to as CJ-4 oil. See the engine manufacturer’s manual forspecifications.

FuelEngines compliant with EPA07 or newer regulations: Ultralow-sulfur diesel (ULSD) with 15 ppmsulfur content or less, based on ASTM D2622 test procedure. See the engine manufacturer’smanual for specifications.

Power Steering Fluid ATF must meet TES 389 or Dexron III specificationsHydraulic Clutch Fluid DOT 4

Detroit AutomatedManual TransmissionLubricant

Detroit Synth 75W-90; synthetic lubricant that meets the requirements of the MB 235.11specification.

Do not mix types or brands of fluid. Multi-weight and extreme-pressure gear fluids are notrecommended.

Manual TransmissionLubricant

MobilTrans SHC 50 (RN 2952 E-5), SAE 50WSynthetic transmission lubricant approved by Eaton, SAE 50W

Call 1-800-826-4357 for a complete list of Eaton approved lubricants.

Do not mix types or brands of fluid. Multi-weight and extreme-pressure gear fluids are notrecommended.

Antifreeze Refer to the engine manufacturer’s service literature for antifreeze requirements.

Drive Axle Lubricant

Recommended SAE Viscosity Grade Ambient Temperature Range75W –40°F to –15°F (–40°C to –26°C)

75W—80 –40°F to 80°F (–40°C to 27°C)75W—90 –40°F to 100°F (–40°C to 38°C)

75W—140 –40°F and above (–40°C and above)80W—90 –15°F to 100°F (–26°C to 38°C)

80W—140 10°F and above (–12°C and above)

Table 26.9, Approved Fluids and Lubricants

Specifications

26.4

Subject Page

AAccessory Heaters . . . . . . . . . . . . . . . . . . . . . . . . 8.6

Espar Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8.6Webasto Heater . . . . . . . . . . . . . . . . . . . . . . . 8.7

Adjustable Steering ColumnControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20

Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 23.1Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . 13.1

Automatic Slack Adjusters . . . . . . . . . . . . . . . . 13.3Brake System Components . . . . . . . . . . . . . . . 13.1Brake System General

Information . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Brake System Operation . . . . . . . . . . . . . . . . . 13.1

Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . 19.1

BBack-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . 2.4

Climbing Down from Back-of-Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Entering Back-of-Cab . . . . . . . . . . . . . . . . . . . . 2.5

CCab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Power Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Radio and CB . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Cab Climate Control Panel . . . . . . . . . . . . . . . . . . 8.1Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Mode Control Switch . . . . . . . . . . . . . . . . . . . . 8.2Temperature Control Switch . . . . . . . . . . . . . . . . 8.1

Cab Door Locks and Handles . . . . . . . . . . . . . . . . 2.1Cab Washing and Polishing . . . . . . . . . . . . . . . . . 22.1Cab-to-Sleeper Access . . . . . . . . . . . . . . . . . . . . . 2.3Canadian Motor Vehicle Safety

Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 22.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 22.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 22.1Cascadia 2.0 High-Back Seat . . . . . . . . . . . . . . . . 7.2

Armrest Angle . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Bottom Cushion Extension . . . . . . . . . . . . . . . . 7.3Fore/Aft Isolator . . . . . . . . . . . . . . . . . . . . . . . . 7.2Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 7.2Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 7.2Recline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Seat Fore/Aft Slide . . . . . . . . . . . . . . . . . . . . . . 7.3Seat Heating/Ventilation . . . . . . . . . . . . . . . . . . 7.2

Subject Page

Seat Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Shock Absorber Adjustment . . . . . . . . . . . . . . . . 7.2

Cascadia High-Back Seat . . . . . . . . . . . . . . . . . . . 7.3Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Bottom Cushion Extension . . . . . . . . . . . . . . . . 7.3Fore/Aft Isolator . . . . . . . . . . . . . . . . . . . . . . . . 7.3Fore/Aft Seat Slide . . . . . . . . . . . . . . . . . . . . . . 7.3Front Cushion Height . . . . . . . . . . . . . . . . . . . . 7.3Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 7.3Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 7.3Rear Cushion Height . . . . . . . . . . . . . . . . . . . . 7.3Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . 7.3

Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 23.1Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1

Daily Pretrip InspectionChecklists . . . . . . . . . . . . . . . . . . . . . . . . . 20.1

Monthly Post-trip InspectionChecklists . . . . . . . . . . . . . . . . . . . . . . . . . 20.2

Weekly Post-trip InspectionChecklist . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2

Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . 5.19Cab Climate Control . . . . . . . . . . . . . . . . . . . . 5.19Sleeper Climate Control . . . . . . . . . . . . . . . . . 5.20

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5Clutch Maintenance . . . . . . . . . . . . . . . . . . . . 14.7Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 14.6General Information . . . . . . . . . . . . . . . . . . . . 14.5

Component GWR Label . . . . . . . . . . . . . . . . . . . . 1.1Component Information Label . . . . . . . . . . . . . . . . 1.1Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

Cruise Control ("CC") Limiter . . . . . . . . . . . . . . 5.13Descent Control and

Deceleration Modes,Detroit™ AutomatedTransmissions . . . . . . . . . . . . . . . . . . . . . . . 5.13

Run Smart PredictiveCruise™ . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

DDaily Pretrip Inspection and

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1Cab Inspection . . . . . . . . . . . . . . . . . . . . . . . 21.6Engine Compartment

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.4Natural Gas Fuel System

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.8Saddle Tank Areas

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.4Suspension and Slack

Adjuster Inspection . . . . . . . . . . . . . . . . . . . 21.1Wheel and Tire Inspection . . . . . . . . . . . . . . . . 21.2

Index

I-1

Subject PageDashboard Care . . . . . . . . . . . . . . . . . . . . . . . . 22.2Dash-Mounted Brake Controls . . . . . . . . . . . . . . . 5.14

Antilock Braking System . . . . . . . . . . . . . . . . . 5.15Parking Brake Control Valve . . . . . . . . . . . . . . . 5.14Trailer Air Supply Valve . . . . . . . . . . . . . . . . . . 5.14Trailer Brake Lever . . . . . . . . . . . . . . . . . . . . . 5.15

Detroit Assurance Radar . . . . . . . . . . . . . . . . . . . 6.11Active Brake Assist (ABA) . . . . . . . . . . . . . . . . 6.14Adaptive Cruise Control

(ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11Driver Message Center . . . . . . . . . . . . . . . . . . 6.11

Detroit Connect Tablet . . . . . . . . . . . . . . . . . . . . . 6.21Detroit™ Automated

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Clutch Abuse Protection . . . . . . . . . . . . . . . . . 15.4Creep Mode . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Detroit™ Multifunction

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Driving Modes . . . . . . . . . . . . . . . . . . . . . . . . 15.2eCoast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Engine Overspeed Alerts . . . . . . . . . . . . . . . . . 15.4Gear Display Window . . . . . . . . . . . . . . . . . . . 15.2Low Transmission Air

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4Power Up and Shift into

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2Selected Gear . . . . . . . . . . . . . . . . . . . . . . . . 15.3Suggested Shift . . . . . . . . . . . . . . . . . . . . . . . 15.3

Diesel Exhaust Fluid and Tank,EPA10 and Newer Engines . . . . . . . . . . . . . . . . 12.3DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4DEF Warnings and Engine

Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 12.3Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . 12.4

Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . 16.1Driver-Controlled Differential

Lock (DCDL) . . . . . . . . . . . . . . . . . . . . . . . . 16.1Single Drive Axles with

Traction Equalizer . . . . . . . . . . . . . . . . . . . . 16.2Tandem Drive Axles with

Interaxle Differential Lock . . . . . . . . . . . . . . . 16.1Driver Message Center . . . . . . . . . . . . . . . . . . . . 4.12

ICU3/ICU4 . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12ICU4Me . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19ICU4M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

EEaton Fuller 10-Speed Range-

Shift Transmissions . . . . . . . . . . . . . . . . . . . . . 14.4General Information, Eaton

Fuller Range-Shift . . . . . . . . . . . . . . . . . . . . 14.4

Subject Page

Operation, Eaton FullerRange-Shift . . . . . . . . . . . . . . . . . . . . . . . . 14.4

Eaton Fuller 13-Speed and 18-Speed Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . 14.1General Information, Eaton

Fuller Splitter and Range-Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

Operation, Eaton FullerSplitter and Range-Shift . . . . . . . . . . . . . . . . 14.1

Eaton Fuller AutoShiftAutomated Transmissions . . . . . . . . . . . . . . . . 15.11General Information,

AutoShift . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11Operation, AutoShift with

SmartShift . . . . . . . . . . . . . . . . . . . . . . . . . 15.11Eaton Fuller UltraShift PLUS . . . . . . . . . . . . . . . 15.14

Auto Neutral . . . . . . . . . . . . . . . . . . . . . . . . 15.17Auto Start Gear Selection

and Override . . . . . . . . . . . . . . . . . . . . . . . 15.17Automatic Mode (AUTO) . . . . . . . . . . . . . . . . 15.14Automatic Traction Control . . . . . . . . . . . . . . . 15.17Clutch Abuse Protection . . . . . . . . . . . . . . . . 15.15Coasting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17Creep Mode . . . . . . . . . . . . . . . . . . . . . . . . 15.16Engine Overspeed

Protection . . . . . . . . . . . . . . . . . . . . . . . . . 15.16Hill Start Aid . . . . . . . . . . . . . . . . . . . . . . . . 15.16Load-Based Shifting . . . . . . . . . . . . . . . . . . . 15.17Low (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15Manual Mode (MAN) . . . . . . . . . . . . . . . . . . . 15.15Power Down . . . . . . . . . . . . . . . . . . . . . . . . 15.14Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14Reverse (R) . . . . . . . . . . . . . . . . . . . . . . . . . 15.14Shuttle Shifting . . . . . . . . . . . . . . . . . . . . . . 15.16Skip Shifting . . . . . . . . . . . . . . . . . . . . . . . . 15.17

Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . 15.6General Information,

UltraShift DM . . . . . . . . . . . . . . . . . . . . . . . 15.6Operation, UltraShift DM . . . . . . . . . . . . . . . . . 15.6Ultrashift Diagnostics . . . . . . . . . . . . . . . . . . 15.10

Electrical Power Distribution . . . . . . . . . . . . . . . . . . 3.1Cab Load Disconnect Switch . . . . . . . . . . . . . . . 3.3Circuit Protection Features . . . . . . . . . . . . . . . . 3.1MEGA Fuse Junction Block,

EPA07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Power Distribution Modules . . . . . . . . . . . . . . . . 3.1Powernet Distribution Box,

EPA10 and Newer . . . . . . . . . . . . . . . . . . . . . 3.1Emergency Filter Replacement,

Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . 24.1Emergency Power Supply . . . . . . . . . . . . . . . . . . . 3.3

SAM Cab Fault . . . . . . . . . . . . . . . . . . . . . . . . 3.4

Index

I-2

Subject Page

SAM Chassis Fault . . . . . . . . . . . . . . . . . . . . . 3.4Emergency Starting With

Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 24.2Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Aftertreatment SystemIndicators Label . . . . . . . . . . . . . . . . . . . . . . 1.1

Certified Clean Idle Label . . . . . . . . . . . . . . . . . 1.4EPA Noise Emission Control

Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3Vehicle Emission Control

Information Label . . . . . . . . . . . . . . . . . . . . . 1.4Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5

Engine Brake Operation . . . . . . . . . . . . . . . . . 13.6Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . 11.2

California Engine IdleLimiting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . 11.2Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 10.2

Cold-Weather Operation . . . . . . . . . . . . . . . . . 10.3Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . 10.3High-Altitude Operation . . . . . . . . . . . . . . . . . . 10.4Normal Operation . . . . . . . . . . . . . . . . . . . . . . 10.3Safety and Environmental

Considerations . . . . . . . . . . . . . . . . . . . . . . 10.2Engine Protection—Warning

and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 10.4Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Cold-Weather Starting . . . . . . . . . . . . . . . . . . . 10.2Starting After Extended

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2Enhanced Stability Control . . . . . . . . . . . . . . . . . . 6.20EPA-Regulated Emissions

Aftertreatment Systems . . . . . . . . . . . . . . . . . . . 12.1ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 12.3EPA07 Engines . . . . . . . . . . . . . . . . . . . . . . . 12.1EPA10 and Newer Engines . . . . . . . . . . . . . . . 12.1Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 12.3Regeneration . . . . . . . . . . . . . . . . . . . . . . . . 12.2

FFederal Motor Vehicle Safety

Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . 18.1

Fontaine and Holland FifthWheels Coupling . . . . . . . . . . . . . . . . . . . . . 18.1

Jost Fifth Wheel Coupling . . . . . . . . . . . . . . . . 18.3Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . 18.7

Air Slide Operation . . . . . . . . . . . . . . . . . . . . . 18.9Manual Slide Operation . . . . . . . . . . . . . . . . . . 18.7

Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . 18.4Air-Actuated Uncoupling . . . . . . . . . . . . . . . . . 18.5

Subject Page

Manual Uncoupling . . . . . . . . . . . . . . . . . . . . . 18.4Fifth Wheels, General

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Air-Suspension Dump Valve . . . . . . . . . . . . . . . 18.1Fifth Wheel Lubrication . . . . . . . . . . . . . . . . . . 18.1

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 24.1Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 24.7

In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 24.7Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . 26.4Freightliner SmartShift Shift

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5General Information,

SmartShift . . . . . . . . . . . . . . . . . . . . . . . . . 15.5Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . 26.1

GGrab Handles and Access

Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Entering the Driver Side . . . . . . . . . . . . . . . . . . 2.2Entering the Passenger Side . . . . . . . . . . . . . . . 2.2Exiting the Driver Side . . . . . . . . . . . . . . . . . . . 2.2Exiting the Passenger Side . . . . . . . . . . . . . . . . 2.2

Greenhouse Gas Emissionsand Fuel ConsumptionStandards . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . 24.1Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . 19.1

General Information . . . . . . . . . . . . . . . . . . . . 19.1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.5To Return the Hood . . . . . . . . . . . . . . . . . . . . . 2.5To Tilt the Hood . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7

IIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . 5.1Instrumentation Control Units . . . . . . . . . . . . . . . . . 4.1

Audible Alerts . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 4.1

Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Air Intake Restriction Gauge . . . . . . . . . . . . . . . 4.8Application Air Pressure

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9Coolant Temperature Gauge . . . . . . . . . . . . . . . 4.9

Index

I-3

Subject Page

Drive Axle Oil TemperatureGauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . 4.9Engine Oil Temperature

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10Fuel Gauge, Pre-EPA10 . . . . . . . . . . . . . . . . . 4.10Fuel/Diesel Exhaust Fluid

(DEF) Gauge, EPA10 andNewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

Primary and Secondary AirPressure Gauges . . . . . . . . . . . . . . . . . . . . . 4.10

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 4.11Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11Tire Pressure Monitoring

System (TPMS) . . . . . . . . . . . . . . . . . . . . . . 4.11Transmission Fluid

Temperature Gauge . . . . . . . . . . . . . . . . . . . 4.11Turbocharger Boost

Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 4.11Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

Inverter/Charger . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

LLane Departure Warning (LDW) . . . . . . . . . . . . . . 6.17

Activating or Deactivating . . . . . . . . . . . . . . . . 6.18Cleaning the Distance

Sensor and the Camera . . . . . . . . . . . . . . . . 6.18Functions and Activation

Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 6.17Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . 6.17

Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Exterior Lighting Controls . . . . . . . . . . . . . . . . . 5.2Interior Lighting Controls . . . . . . . . . . . . . . . . . . 5.6

MMajor Repairs and

Replacement of Natural GasComponents . . . . . . . . . . . . . . . . . . . . . . . . . 25.10

Meritor WABCO® AntilockBraking System . . . . . . . . . . . . . . . . . . . . . . . . 13.3Automatic Traction Control . . . . . . . . . . . . . . . . 13.4ECAS Automatic Load

Transfer (ECAS only) . . . . . . . . . . . . . . . . . . 13.4Trailer ABS Compatibility . . . . . . . . . . . . . . . . . 13.4

Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Monthly Post-Trip Inspections

and Maintenance . . . . . . . . . . . . . . . . . . . . . . 21.13Brake Component Inspection . . . . . . . . . . . . . 21.13Engine Compartment

Inspection andAdjustments . . . . . . . . . . . . . . . . . . . . . . . 21.15

Saddle Tank AreasInspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.14

Subject Page

NNatural Gas Detection System . . . . . . . . . . . . . . . 25.5

Alarm Procedure . . . . . . . . . . . . . . . . . . . . . . 25.5Overhead Console . . . . . . . . . . . . . . . . . . . . . 25.7Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.6Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.7

Natural Gas Engine Starting . . . . . . . . . . . . . . . . . 25.9Natural Gas Fuel Tank Filling

Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3CNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . 25.3LNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . . 25.5

Natural Gas Vehicles, GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Natural Gas Vehicles, SafetyPrecautions . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1In Case of Emergency . . . . . . . . . . . . . . . . . . 25.3

OOnGuard™ Collision Safety

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7Adaptive Cruise Control

(ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9Additional Features . . . . . . . . . . . . . . . . . . . . 6.10Collision Warning System

(CWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8Error Screens . . . . . . . . . . . . . . . . . . . . . . . . 6.10OnGuard Display Unit . . . . . . . . . . . . . . . . . . . . 6.8System Limitations . . . . . . . . . . . . . . . . . . . . . . 6.7

Optimized Idle® . . . . . . . . . . . . . . . . . . . . . . . . . 11.2Overhead Instrument Panel . . . . . . . . . . . . . . . . . 4.24

PParkSmart™ HVAC System . . . . . . . . . . . . . . . . . . 8.3

Standard VehicleConfiguration . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Vehicles with Detroit DieselOptimized Idle . . . . . . . . . . . . . . . . . . . . . . . 8.5

Periodic Inspections andMaintenance, GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1

Power Steering System GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1

Power Steering Systems . . . . . . . . . . . . . . . . . . . 17.1Rack and Pinion Steering

System . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1Steering Gear System . . . . . . . . . . . . . . . . . . . 17.1

Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . 11.2Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 5.7

Aftertreatment SystemRegen Switches . . . . . . . . . . . . . . . . . . . . . . 5.7

Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

Index

I-4

Subject Page

Engine Brake Switch . . . . . . . . . . . . . . . . . . . . 5.8Engine Fan Switch . . . . . . . . . . . . . . . . . . . . . . 5.9Hill Start Aid Override Switch . . . . . . . . . . . . . . . 5.9PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Transmission Controls . . . . . . . . . . . . . . . . . . . 5.9

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 23.1Progressive Low Voltage

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

RReplacement Bulbs . . . . . . . . . . . . . . . . . . . . . . 26.3Roll Stability System . . . . . . . . . . . . . . . . . . . . . . 6.18

Hard-Braking Advisor . . . . . . . . . . . . . . . . . . . 6.20Roll Stability Advisor . . . . . . . . . . . . . . . . . . . . 6.18Roll Stability Control . . . . . . . . . . . . . . . . . . . . 6.19Trip/Leg Totals . . . . . . . . . . . . . . . . . . . . . . . . 6.20

RollTek Rollover ProtectionSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Inspection and Service . . . . . . . . . . . . . . . . . . 7.11Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

SSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . 21.1Sears Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

Armrest Angle . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4Bottom Cushion Tilt . . . . . . . . . . . . . . . . . . . . . 7.5Fore/Aft Seat Slide . . . . . . . . . . . . . . . . . . . . . . 7.4Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 7.4Seat Extension . . . . . . . . . . . . . . . . . . . . . . . . 7.5Suspension Inflation/

Deflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 7.5

Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 7.6Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 7.6

Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20Seats, General Information . . . . . . . . . . . . . . . . . . 7.1Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Baggage CompartmentDoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Power Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Sleeper Access Door . . . . . . . . . . . . . . . . . . . . 9.2Sliding Side Window . . . . . . . . . . . . . . . . . . . . 9.3

Sleeper Climate Control Panel . . . . . . . . . . . . . . . . 8.2Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Smartway Certified Parked

Heater Operation . . . . . . . . . . . . . . . . . . . . . . 8.3

Subject Page

Temperature Control Switch . . . . . . . . . . . . . . . . 8.3Sleeper Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Sleeper Luggage Door . . . . . . . . . . . . . . . . . . . . . 2.4Steering Wheel Air Bag . . . . . . . . . . . . . . . . . . . . . 7.8

Inspection and Service . . . . . . . . . . . . . . . . . . . 7.9Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

Suspension/Trailer ConnectionControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16Air Suspension Dump

Control Switch . . . . . . . . . . . . . . . . . . . . . . . 5.16ECAS Dash Switches . . . . . . . . . . . . . . . . . . . 5.16ECAS Remote Control Unit . . . . . . . . . . . . . . . 5.17Fifth Wheel Slide Control

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18Trailer Auxiliary Switch . . . . . . . . . . . . . . . . . . 5.18

TTowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4

Front Towing Hookup . . . . . . . . . . . . . . . . . . . 24.5Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 24.5

Two-Speed Drive Axles . . . . . . . . . . . . . . . . . . . . 16.2Axle Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2

VVelour Upholstery Cleaning . . . . . . . . . . . . . . . . . 22.3

Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 22.3Grease and Oil-Based Stains . . . . . . . . . . . . . . 22.3Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3Sugar and Water-Based

Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 22.2

Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 22.3Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 22.2Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 22.3Nail Polish and Nail Polish

Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 22.2Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 22.2Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 22.3Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 22.2Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 22.2

VORAD VS-400 System . . . . . . . . . . . . . . . . . . . . 6.1Collision Warning System . . . . . . . . . . . . . . . . . 6.4Driver Interface Unit . . . . . . . . . . . . . . . . . . . . . 6.1Failure Display Mode/Fault

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6Side Object Detection . . . . . . . . . . . . . . . . . . . . 6.5SmartCruise . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5Special Road Situations . . . . . . . . . . . . . . . . . . 6.6

Index

I-5

Subject Page

WWarning and Indicator Lights . . . . . . . . . . . . . . . . . 4.3

Engine Protection System . . . . . . . . . . . . . . . . . 4.7Weekly Post-Trip Inspections

and Maintenance . . . . . . . . . . . . . . . . . . . . . . 21.10Engine Compartment

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.10Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Windshield Wiper/Washer

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15

Index

I-6

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