s2 chassis operator's manual - fcccrv.com chassis operator’s manual ... freightliner chassis...
TRANSCRIPT
S2 CHASSIS
Operator’s Manual
Part Number A24-01453-000Publication Number STI-479-6
IntroductionThis manual provides information needed to operateand understand the chassis 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.
Freightliner chassis are equipped with various chas-sis and cab components; not all of the informationcontained in this manual applies to every vehicle. Ifparts on your chassis differ from those shown, theymay have been installed by the vehicle final-stagemanufacturer.
The safety or performance of your vehicle could beadversely affected by the installation of nonstandardcomponents. Note the limitations and specificationsprovided in the vehicle and chassis manuals, andconsult your selling dealer before making any altera-tions to the vehicle or chassis.
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 Custom Chassis Corporation re-serves the right to discontinue models and tochange specifications or design at any timewithout notice and without incurring obligation.Descriptions and specifications contained in thispublication provide no warranty, expressed orimplied, and are subject to revisions and edi-tions 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 systemsperformed. 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 S2 Chassis 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 greenhouse
Foreword
STI-479-6 (2/18)A24-01453-000
Printed in U.S.A.
gas 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 maintaincompliance with federal and local jurisdictional regu-lations. Components including, but not limited to, low-rolling resistance tires are specifically designed andmanufactured to exacting standards for regulatoryfuel efficiency and greenhouse gas emissions compli-ance. It is important that these components are al-ways replaced with components that meet or exceedthe performance of the originally installed compo-nents.
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 week-ends, for dealer referral, vehicle information, break-down coordination, or Fleetpack assistance. Ourpeople are knowledgeable, professional, and commit-ted to keeping your vehicle moving.
Reporting Safety DefectsIf you believe that your vehicle has a defect thatcould cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying Freightliner Custom ChassisCorporation.
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 Freightliner CustomChassis Corporation.
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 also
obtain other information about motor vehicle safetyfrom www.safercar.gov.
Canadian customers who wish to report a safety-related defect to Transport Canada, Defect Investi-gations and Recalls, may telephone the toll-freehotline 1-800-333-0510, or contact TransportCanada by mail at: Transport Canada, ASFAD,Place de Ville Tower C, 330 Sparks Street,Ottawa, Ontario, Canada K1A 0N5.
For additional road safety information, please visitthe Road Safety website at: www.tc.gc.ca/roadsafety.
© 2007–2018 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.FreightlinerChassis.com.
Foreword
ContentsChapter Page
Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Emissions and Fuel Efficiency Compliance,Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword
1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Heater, Ventilating, and Air Conditioner (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Exhaust Aftertreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
10 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111 Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.112 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.113 Hydraulic and Air Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.114 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.115 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.116 Cleaning and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.117 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.118 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.119 Propane Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.120 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1
1
Vehicle IdentificationComponent Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 manufac-turer, month and year of manufacture, vehicle identifi-cation number (VIN), gross vehicle weight rating(GVWR), front and rear gross axle weight ratings(GAWR), and tire and wheel information. It also indi-cates if the vehicle has been certified as compliantwith Federal Motor Vehicle Safety Standard(FMVSS). See Fig. 1.1.
The tire and rim portion of the component informationlabel 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.
Incomplete chassis intended for service in the U.S.have an incomplete vehicle certification label at-tached by the final-stage manufacturer. This label willbe attached to the incomplete vehicle document in-cluded with the vehicle, and certifies that the vehicleconforms to all applicable FMVSS regulations in ef-fect on the date of completion.
Vehicle Identification NumberThe chassis vehicle identification number (VIN) isstamped on a metal plate permanently attached tothe vehicle, and the last six digits (designating thechassis serial number) are stamped into the metalframe. See Fig. 1.2. A VIN label is also mounted bythe body builder. Mounting locations vary, to includethe glove box. See Fig. 1.3.
NOTE: Always include the chassis serial num-ber (last six digits of the VIN) when communi-cating to Daimler Trucks North America.
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.
A reference label included with the driver’s documen-tation package contains important warning indicatorsin the instrument cluster that pertain to the ATS. SeeFig. 1.4.
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 with
09/11/2002 f080123
Fig. 1.1, Component Information Label
GAFFNEY, SOUTH CAROLINA, USA4UZA4FVC0TC748531
f080061a04/18/2005
Fig. 1.2, Vehicle Identification Number, Typical
Vehicle Identification
1.1
certification 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.
Vehicle Emission Control InformationLabelModel year 2013 and later vehicles meet additionalrequirements as specified by federal greenhouse gas
12/04/2001 f080122
Fig. 1.3, Vehicle Identification Number Label, Typical
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. 1.4, ATS Indicators
Vehicle Identification
1.2
and fuel efficiency regulations (GHG14). Model year2017 and later vehicles meet similar requirements asspecified by GHG17 requirements. These vehiclesare equipped with components that increase fuel effi-ciency and reduce GHG emissions. Componentsmay include, but are not limited to, low-rolling resis-tance tires.
A Vehicle Emission Control Information Label indi-cates compliance with GHG14 regulations. SeeFig. 1.5. It is the owner’s responsibility to maintainthe vehicle so that it conforms to EPA and NHTSA
regulations.
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–December31, 2015
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.
From January 1, 2016GHG17: GHG14 components plus OBD16 instrumentation and sensor upgrades, andcomponent technology that meets NHTSA and EPA 2017 fuel efficiency andgreenhouse gas emission standards (GHG17) requirements.
* 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
03/02/2012 f080183
Fig. 1.5, Vehicle Emission Control Information Label
Vehicle Identification
1.3
2
Vehicle AccessBattery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Battery AccessBattery CompartmentThe battery compartment is located behind thedriver’s area, attached to the frame rail. To open thebattery access door, insert and turn the key, then pullthe access door open. Pull the pull-pin spring latchesout to slide the battery tray forward. See Fig. 2.1.
With the battery access door open, it is easy to getaccess to the battery terminals for cleaning, charg-ing, or emergency jump starting.
To return the battery to the compartment, slide thebattery tray in until the pin spring latch is in thelocked position. Lock the battery access door withthe key.
Battery Disconnect Switch, OptionalA battery disconnect switch, if so equipped, cuts offall battery power to the vehicle. It is also used when-ever the vehicle is placed out of service for extendedperiods to prevent battery discharge. The battery dis-connect switch is located on the side of the batterybox. See Fig. 2.2.
NOTICEThe batteries must be disconnected if the vehicleis not in use for a period exceeding two weeks,or the vehicle may not start, and permanent bat-tery damage could occur.
Hood Opening and ClosingA torsion spring helps to raise and lower the hood.Hood restraint cables prevent the hood from over-travel. An optional hood damper limits the closingspeed. In the operating position, the hood is securedto the half-fenders by a hold-down latch on eachside.
Tilting the Hood1. Apply the parking brakes.
2. Release both hood hold-down latches by pullingthe ends outward. See Fig. 2.3.
12/05/2003 f544365
1
2 23
4
1. Battery Access Door2. Pull-Pin Spring Latch
3. Battery Tray4. Battery
Fig. 2.1, Battery Access
01/18/95 f600150a
Fig. 2.2, Battery Disconnect Switch
10/24/2001 f880555
1
2
3
4
1. Fender2. Latch Hook
3. Latch Handle4. Half-Fender
Fig. 2.3, Hood Hold-Down Latch
Vehicle Access
2.1
NOTICEDo not let the hood free-fall to the fully open po-sition. To do so could damage the hood or hoodstraps.
3. Standing in front of the hood, tilt the rear of thehood upward until it reaches the over-center po-sition (45-degrees from vertical). Then slowlybring it to a stop.
Closing the Hood1. Push the hood over center.
2. As the hood goes over center, the damper (ifequipped)automatically slows its rate of descent.If needed, you can also slow the rate of descentwith your hand.
3. Make sure the hood is flush with the cowl, thensecure the hood by engaging both hood hold-down latches.
IMPORTANT: Make sure that both hold-downlatches are fully engaged before operating thevehicle.
Vehicle Access
2.2
3
InstrumentsInstrumentation Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Warning and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Instrumentation Control UnitFigure 3.1 and Fig. 3.2 show a typical set of instru-ments for vehicles equipped with the S2 ChassisICU3 instrument cluster.
NOTE: This instrument cluster is shown with theU.S. speedometer, which shows miles per hour(mph) more prominently than kilometers perhour (km/h).
The ICU3 instrument cluster receives informationfrom the datalink and sensors installed on the ve-hicle, and sends that information to electronicgauges.
There can be up to eight gauges on the driver’s in-strument panel (six electronic and two mechanical).Only the air gauges operate mechanically.
The S2 Chassis instrument clusters have the capabil-ity to drive independent stand-alone gauges such asthose installed on the auxiliary dash panel.
Dash Message CenterThe dash message center houses all of the standardand optional warning and indicator lamps. Warningmessages and diagnostic fault codes will appear inthe driver display screen.
Ignition SequenceWhen the ignition is turned on, all the electronic
gauges complete a full sweep of their dials, thewarning and indicator lamps illuminate, and thebuzzer sounds for 3 seconds.
NOTE: The air gauges do not sweep.
The following lamps illuminate during the ignition se-quence:
• fasten seat belt warning
• low battery voltage warning
10 f611047
1 2 4 5
7
9
8
11
3
12
13
07/08/2011
6
1. Engine Oil Pressure Gauge2. Dash Message Center3. Headlight High-Beam Indicator4. Dash Driver Display Screen5. Fuel Level Gauge
6. Diesel Exhaust Fluid (DEF) Gauge7. Primary Air Pressure Gauge8. Mode/Reset Switch9. Secondary Air Pressure Gauge
10. Speedometer11. Tachometer12. Transmission Temperature Gauge13. Coolant Temperature Gauge
Fig. 3.1, Gauge Layout (typical, U.S.), EPA10 and Newer Engines
Instruments
3.1
• high coolant temperature warning
• low engine oil pressure warning
• low air pressure warning
• parking brake on indicator
• all engine indicator/warning lights, includingcheck engine and stop engine
• all ABS indicator/warning lights, includingwheel spin, and tractor ABS (if installed)
NOTE: While the engine and ABS warninglamps illuminate during the ignition sequence,they are not controlled by the instrument clusterbut by their own system electronic control unit(ECU).
When the ignition switch is turned on, the ICU per-forms a self-test, looking for active faults. During thefirst half of the self-test, all segments of the displayilluminate as follows:
• First line (odometer): 888888.8
• Second line (units): TRIP MI KM HOURS
• Third line (voltmeter): 38.8 VOLTS
• Fourth line: SERVICE ENGINE
During the second half of the self-test, the softwarerevision level is displayed.
If there are no active faults, the driver display screendisplays the odometer.
If however, the instrument cluster has received activefault codes from other devices, it displays them oneafter the other until the parking brake is released, orthe ignition switch is turned off. Once the parkingbrake is released, the dash message center displaysthe odometer again.
NOTE: If active faults are present, take the ve-hicle to an authorized Freightliner service facilityas soon as possible.
If the fault requires immediate attention, the stop en-gine system will activate. In most cases, the checkengine lamp will also illuminate.
9 f610837b
1 2 4 5
WATER
100
150 200
250
F°
0 100
50
PSI
OIL
E F
1/2
FUEL
AIR
0 150
50
PSI
100
AIR
0 150
50
PSI
100
6
8
PUSH−MODEHOLD−RESET
7
OPT
ABS ABS
BRAKE
CHECK STOP
0
5
10
1520
30
RPM
25
X100
10
3
5
15
2535
4555
65
75
85
MPHkm/h
30
5070
90
130
110
10
10/26/2006
OPTOPTOPTOPTOPTOPTOPTOPT
TRANS
100
225
350
F°
11
12
1. Engine Oil Pressure Gauge2. Dash Message Center3. Headlight High-Beam Indicator4. Dash Driver Display Screen
5. Fuel Level Gauge6. Primary Air Pressure Gauge7. Mode/Reset Switch8. Secondary Air Pressure Gauge
9. Speedometer (U.S. version)10. Tachometer (optional)11. Coolant Temperature Gauge
Fig. 3.2, Gauge Layout (typical, U.S.), EPA07-Compliant
Instruments
3.2
Some examples include:
• high coolant temperature
• low air pressure
• low coolant level
• low engine oil pressure
NOTE: The check engine lamp does not illumi-nate for a low air pressure fault.
The legend SERVICE ENGINE can appear on thedriver display screen as an active fault code. If thislegend appears, it means the trip miles (or hours)have gone beyond the next required service interval,as set by the vehicle operator.
IMPORTANT: If the legend SERVICE ENGINEdoes appear on the driver display screen whileoperating the vehicle, bring the vehicle to anauthorized Freightliner service facility whenconvenient.
OdometerThe odometer is a seven-digit display with a decimalpoint, until the vehicle has traveled 999,999.9 milesor kilometers (km). At one million miles (km), theodometer resets itself to 1,000,000, without the deci-mal point, and can continue up to 9,999,999. Theodometer only displays significant figures (no leadingzeros).
The odometer is set to display in either miles or kilo-meters, depending on the primary scale of thespeedometer. The legend, either MI or KM, illumi-nates between the odometer and the volts displaywhen the engine is running or the headlights areturned on.
Mode/Reset SwitchThe mode/reset switch, shown in Fig. 3.3, is locatedon the right side of the instrument cluster. The mode/reset switch is used to scroll through the displays onthe message display screen, and to reset the trip dis-tance and trip hours values to zero.
When the odometer reading is displayed and theparking brake is applied:
• Press the mode/reset switch once and the tripdistance will display.
• Press the mode/reset switch a second timeand the trip hours (engine hours) will display.
• Press the mode/reset switch a third time andthe SELECT screen and the current units, MIor KM, will display.
• Press the mode/reset switch a fourth time toreturn to the odometer reading.
To reset trip miles and/or trip hours to zero, press themode/reset switch for 1 second or longer. To togglebetween MI (miles) or KM (kilometers), press themode/reset switch while in the SELECT screen.
Warning and Indicator LampsThere can be up to 27 warning and indicator lamps(telltales) installed in the dash message center. SeeFig. 3.4 and Fig. 3.5.
The instrument cluster has an emergency buzzer thatsounds when serious conditions that require immedi-ate attention occur.
A description of the standard warning and indicatorlamps are listed below.
Check Engine WarningThe check engine warning indicator illuminates whencertain faults are detected. If a critical engine condi-tion exists (for example, low oil pressure or highcoolant temperature), the check engine indicator willilluminate to alert the driver to correct the conditionas soon as possible. If the condition gets worse, thestop engine indicator will illuminate.
NOTE: If the check engine indicator illuminatesduring vehicle operation, take the vehicle di-rectly to an authorized Freightliner service facil-ity.
Stop Engine WarningThe stop engine warning indicator illuminates whenthe protection system available for the engine has
09/25/99
PUSH− MODE HOLD− RESET
f610340
Fig. 3.3, Mode/Reset Switch
Instruments
3.3
been activated. On some engines, the engine elec-tronic control unit (ECU) will derate the engine, allow-ing it to run, but at lower rpm and slower vehiclespeed. The vehicle may be driven to a safe location.
The engine ECU will derate the engine. The drivermust safely bring the vehicle to a stop on the side ofthe road.
NOTICEBecause operating the engine when the stop en-gine indicator is illuminated can lead to severeengine damage, the driver must move the vehicleto a safe location as quickly as possible.
To restart the engine turn the ignition switch to OFF,leave it there a few seconds, and turn the switch toSTART.
IMPORTANT: Do not attempt to restart the en-gine while the vehicle is moving. Bring the ve-hicle to a safe stop and restart the engine withthe vehicle stopped.
Malfunction Indicator Lamp (MIL)The malfunction indicator lamp (MIL) indicates anengine emissions-related fault. See the engine op-eration manual for details.
ABS WarningThe ABS indicator illuminates when there is a mal-function in the vehicle antilock brake system (ABS).
NOTE: For more information about this indicatorand the ABS system, see Chapter 13.
07/08/2011
OPT
ABS ABSCHECK STOP
f611066
1 2 3 4
8 9 1014 15
5 6
11 12 1320 211817
7
OPTOPTOPTOPTOPTOPTOPTOPT
16 19
1. Optional Indicator2. Check Engine Warning3. Stop Engine Warning4. Malfunction Indicator Lamp (MIL)5. ABS Warning6. Transmission Overheat Warning7. Trailer ABS Indicator (not used)8. Low Oil Pressure Warning9. High Coolant Temperature Warning10. Fasten Seat Belt Warning11. Parking Brake On Warning12. Diesel Particulate Filter (DPF) Lamp13. High Exhaust System Temperature (HEST) Lamp14. Left-Turn Indicator15. Low Battery Voltage Warning16. Water In Fuel Indicator17. Dash Driver Display Screen18. Headlight High-Beam Indicator19. Cruise Control Indicator20. Low Air Pressure Warning21. Right-Turn Indicator
Fig. 3.4, ICU3 Warning and Indicator Lights, EPA10 andNewer Engines
09/28/2006
OPT
ABS ABS
BRAKE
CHECK STOP
f610838
1 2 3 4
8 9 1014 15
5 6
11 12 1318 191716
7
OPTOPTOPTOPTOPTOPTOPTOPT
1. Optional Indicator2. Check Engine Warning3. Stop Engine Warning4. Malfunction Indicator Lamp5. ABS Warning6. Transmission Overheat Warning7. Trailer ABS Indicator (not used)8. Low Oil Pressure Warning9. High Coolant Temperature Warning10. Fasten Seat Belt Warning11. Parking Brake On Warning12. Diesel Particulate Filter (DPF) Lamp13. High Exhaust System Temperature (HEST) Lamp14. Left-Turn Indicator15. Low Battery Voltage Warning16. Dash Driver Display Screen17. Headlight High-Beam Indicator18. Low Air Pressure Warning19. Right-Turn Indicator
Fig. 3.5, Warning and Indicator Lights, EPA07-Compliant
Instruments
3.4
Transmission Overheat WarningThe transmission overheat indicator illuminates whenthe temperature of the transmission fluid goes abovethe preset level set by the transmission manufac-turer.
For more information, see the transmission manufac-turer’s manual provided with the vehicle.
Low Oil Pressure WarningThe low oil pressure warning indicator and emer-gency buzzer activate whenever the engine oil pres-sure goes below the preset minimum specified by theengine manufacturer. See Table 3.1.
Oil Pressure Specifications*
Engine ModelPressure at
Idle RPMPressure atRated RPM
Mercedes-BenzMBE900†
50 psi (345kPa) 50 psi (345 kPa)
Cummins ISB 10 psi (69 kPa) 30 psi (207 kPa)* 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.† EPA07 MBE900 engines are equipped with an oil pressure switch.
When above minimum pressure, the dash gauge will display the valueslisted in this table. If below minimum oil pressure, the dash gauge willread 0 psi.
Table 3.1, Oil Pressure Specifications
High Coolant Temperature WarningThe high coolant temperature indicator and emer-gency buzzer activate whenever the coolant tem-perature goes above a preset maximum specified bythe engine manufacturer. See Table 3.2.
Maximum Coolant TemperatureEngine Model °F (°C)
Mercedes-Benz MBE900 221 (105)Cummins ISB 220 (104)
Table 3.2, Maximum Coolant Temperature
Fasten Seat Belt WarningThe fasten seat belt warning indicator (seat belt icon)illuminates for 3 seconds after the ignition switch isturned on.
When the engine is operating, if the driver’s seat beltis unfastened and the park brake is not set, the seatbelt warning indicator illuminates and a warning
chime activates. The warning chime will remain ac-tive for 10 seconds. The warning indicator remainsilluminated until the driver’s seat belt is fastened.
Parking Brake On WarningThe parking brake on indicator activates when theparking brake is engaged.
If the vehicle is moving at a speed of 2 mph (3 km/h)or more, the emergency buzzer will sound until theparking brake is released.
Diesel Particulate Filter (DPF) LampA solid illumination indicates a regeneration is re-quired. Change to a more challenging duty cycle,such as highway driving, to raise exhaust tempera-tures for at least 20 minutes, or perform a stationaryregeneration. See the engine operator’s manual fordetails.
A blinking lamp indicates that a stationary regenera-tion is required immediately. An engine derate andshutdown will occur. See the instructions in the en-gine operator’s manual to perform a stationary regen-eration.
High Exhaust System Temperature(HEST) LampThe high exhaust system temperature (HEST) lampalerts the operator of high exhaust temperature dur-ing the regen process when the speed is below 5mph (8 km/h), or during a manual regen. The HESTlamp does not signify the need for any kind of ve-hicle or engine service; it only alerts the vehicle op-erator to high exhaust temperatures.
IMPORTANT: Make sure the engine exhaustpipe outlet is not directed at any person, or atany surface or material that will melt, burn, orexplode.
Left-Turn IndicatorThe left-turn indicator flashes on and off when theleft-turn signal lights are flashing.
Both turn signal indicators flash when the hazardwarning flasher is turned on.
Low Battery Voltage WarningThe low battery voltage warning indicator (batteryicon) illuminates when the battery voltage dropsbelow 12 volts.
Instruments
3.5
Water In Fuel IndicatorThe water in fuel indicator notifies the driver the fuelmay contain water. Drain any water collected in thefuel/water separator.
NOTICEWater in the fuel/water separator will appear asbeads. With the engine off, drain the separatoronly enough to remove the water; about two tea-spoons at a time. Do not drain the separatorcompletely or it will be necessary to prime thefuel system before the vehicle can be startedagain.
Headlight High-Beam IndicatorThe high-beam indicator (sideways beam icon) illumi-nates when the headlight high beams are on.
Cruise Control IndicatorThe cruise control indicator illuminates when thecruise control is activated.
Low Air Pressure WarningThe low air pressure warning indicator (BRAKE icon)and emergency buzzer activate when the engine isturned on if air pressure in the primary or secondaryair reservoir is below 65 to 75 psi (448 to 517 kPa),and remain on until air pressure rises above thatlevel in both reservoirs.
Right-Turn IndicatorThe right-turn indicator flashes on and off when theright-turn signal lights are flashing.
Both turn signal indicators flash when the hazardwarning flasher is turned on.
Emergency BuzzerThe emergency buzzer sounds during the ignitionsequence and whenever one of the following condi-tions exists:
• The engine oil pressure falls below the presetlevel shown in Table 3.1.
• The coolant temperature rises above the pre-set level shown in Table 3.2.
• The air pressure falls below the preset level,which is 65 psi (448 kPa).
• The parking brake is set with the vehicle mov-ing at a speed greater than 2 mph (3 km/h).
Optional Warning and IndicatorLampsA description of some commonly used optional warn-ing and indicator lamps are listed below.
Air Filter WarningThe air filter warning indicator (AIR FILTER legend)illuminates when the air cleaner filter element isclogged, restricting the intake air flow. See Table 3.3.
If the air filter indicator light is steadily illuminated forany period of time, check the air intake restrictiongauge. If needed, replace the air filter, and reset theair intake restriction gauge.
Air Intake Maximum Restriction Values (inH2O)
Engine Pre-EPA07Engines
EPA07 andNewer Engines
Cummins 25 25Mercedes-Benz 22 22
Table 3.3, Air Intake Maximum Restriction Values(inH2O)
IMPORTANT: Never attempt to clean the air fil-ter.
Alternator No Charge IndicatorThe alternator no charge indicator lamp (NOCHARGE legend) illuminates when the alternator isnot charging properly.
Check Transmission Warning (dieselengine only)
NOTE: Although it appears in the row of op-tional indicators, the check transmission indica-tor is a standard indicator.
The check transmission indicator, shown in Fig. 3.6,notifies the driver of three things. Any of the followingitems could be the cause for activating the indicator:
• the oil needs to be changed
• the filter(s) need to be changed
• clutch maintenance is required
Instruments
3.6
When the check transmission indicator illuminates,refer to the Allison Operator’s Manual or contact cus-tomer support at Allison Transmission to determinethe specific cause activating the indicator.
Speedometer and TachometerSpeedometerThree kinds of speedometer faces are available. TheU.S. version of the speedometer registers speed inboth miles per hour (mph) and kilometers per hour(km/h), with mph in larger numbers. See Fig. 3.7.
The NAFTA version (not shown) of the speedometerface reverses this arrangement, with km/h in largernumbers. The metric only version (not shown) showskm/h exclusively.
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. See Fig. 3.7.
Standard InstrumentsEngine Oil Pressure Gauge
NOTICEA sudden decrease or absence of engine oilpressure may indicate mechanical 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.
See Fig. 3.8 for an example of the engine oil pres-sure gauge. If the engine oil pressure falls below thepreset levels shown in Table 3.1, first the check en-gine lamp will illuminate, and, if the condition doesnot improve, the stop engine lamp will also illuminateand the buzzer will sound. At this point, the enginewill derate or shut down, depending on the type ofengine protection system installed.
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). See Fig. 3.9. If the temperature remains
f61111502/28/2011
Fig. 3.6, Check Transmission Indicator
10/09/2001
0
5
10
1520
30
RPM5
15
2535
4555
65
75
85
MPHkm/h
25
X100
30
5070
90
130
110
10
1 2f610527
1. Tachometer 2. Speedometer
Fig. 3.7, Speedometer and Tachometer
10/09/2001
0 100
50
PSI
OIL
f610528
Fig. 3.8, Engine Oil Pressure Gauge
Instruments
3.7
below 160°F (71°C), or exceeds the maximum tem-perature shown in Table 3.2, inspect the cooling sys-tem to determine the cause. See Group 20 of the S2Chassis Workshop Manual.
If the coolant temperature rises above the preset lev-els shown in Table 3.2, first the check engine warn-ing indicator will illuminate, and, if the condition doesnot improve, the stop engine warning indicator willalso illuminate and the buzzer will sound. At thispoint, the engine will derate or shut down, dependingon the type of engine protection system installed.
Fuel/Diesel Exhaust Fluid (DEF)GaugeFor engines that are EPA10-compliant or newer, thefuel and DEF levels are measured in a dual purposefuel/DEF gauge. See Fig. 3.10.
The diesel fuel level is indicated at the top of thegauge, with a low-level warning lamp that illuminateswhen the diesel fuel level registers 1/8th of capacity.One fuel gauge is standard. If equipped with a sec-ond (optional) fuel gauge, each fuel tank level is indi-cated on a separate gauge.
The DEF level is indicated in the lower portion of thegauge. There is a low DEF level warning lamp thatilluminates when the DEF level reaches 10% of ca-pacity. See Chapter 9 for details of the DEF gaugefunctions.
Figure 3.11 shows a fuel gauge installed on EPA07vehicles.
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
10/09/2001 f610565
WATER
100
150 200
250
F°
Fig. 3.9, Coolant Temperature Gauge
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. 3.10, Fuel/DEF Gauge, EPA10
10/09/2001 f610566
E F
1/2
FUEL
Fig. 3.11, Fuel Level Gauge, EPA07 Vehicles
Instruments
3.8
with the engine running is 100 to 120 psi (690 to 827kPa) in both systems. See Fig. 3.12.
Air pressure gauges are required on all vehicles withair brakes. A low-air-pressure warning lamp andbuzzer, connected to both the primary and secondarysystems, activate when air pressure in either systemdrops below a minimum pressure of 65 to 75 psi(448 to 517 kPa).
When the engine is started, the warning lamp andbuzzer remain on until air pressure in both systemsexceeds minimum pressure.
VoltmeterThe voltmeter is a digital readout located on the bot-tom line of the driver display screen whenever theignition switch is turned on.
It indicates the vehicle charging system voltage whenthe engine is running and the battery voltage whenthe engine is stopped. By monitoring the voltmeter,the driver can be aware of potential charging systemproblems and have them fixed before the batteriesdischarge enough to create starting difficulties.
The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltage
of a fully charged battery is 12.7 to 12.8 volts whenthe engine is stopped. Battery voltage under 12.0volts is considered a low battery, and a completelydischarged battery will produce only about 11.0 volts.The voltmeter will indicate lower voltage as the ve-hicle is being started or when electrical devices inthe vehicle are being used.
If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at a repairfacility.
Optional InstrumentsOptional instruments are not found on every vehicle.They are stand-alones, not driven by the instrumentcluster, and are usually located on the auxiliary dashpanel. They are listed here in alphabetical order, tomake the information easier to find.
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. See Fig. 3.13. As an optionfor easier viewing, the intake-air restriction indicatorcan be mounted on the dash, usually on the right-hand control panel.
Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with a gradu-ated indicator or a restriction gauge on the dash,
10/22/2009 f610567
1
2
1. Primary Air Pressure Gauge2. Secondary Air Pressure Gauge
Fig. 3.12, Air Pressure Gauges
10/10/2001 f610568
Fig. 3.13, Air Intake Restriction Indicator
Instruments
3.9
check the gauge with the engine off. If the yellowsignal stays locked in the red zone once the engineis shut down, or is at or above 25 inH2O, the aircleaner element needs to be replaced.
NOTE: Rain or snow can wet the filter andcause a temporarily higher than normal reading.
AmmeterAn optional ammeter measures current flowing toand from the battery. See Fig. 3.14. When the batter-ies are being charged, the meter needle moves tothe plus side of the gauge; when the batteries arebeing discharged, the needle moves to the minusside. A consistent negative reading when the engineis running indicates a possible problem with thecharging system.
Axle Oil Temperature Gauge, Rear
NOTICEA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the vehicle until the cause hasbeen determined and corrected.
During normal operation, the optional rear axle oiltemperature gauge should read between 160 and220°F (71 and 104°C) for Detroit™ and Meritor™ driveaxles. See Fig. 3.15.
Under heavy loads, such as when climbing steepgrades, temperatures up to a maximum of 250°F(121°C) are not unusual.
Digital ClockThe optional digital clock has black characters on aconstantly backlighted green display, with a bright-ness that automatically adjusts for day or night. Theclock has a 24-hour alarm, with a three-minutesnooze feature. See Fig. 3.16.
1. To set the time of day:
1.1 Push the Run/Set (lower) switch to theright (TIME-SET position).
NOTE: When the hour setting is for a timebetween noon and midnight, the small lettersPM will appear in the lower left corner of thedisplay; no PM display indicates an AM set-ting.
10/10/2001 f610573
Fig. 3.14, Ammeter
10/10/2001 f610571
Fig. 3.15, Axle Oil Temperature Gauge
10/11/2001 f610576
Fig. 3.16, Digital Clock
Instruments
3.10
1.2 Advance the hour setting to the correctnumber by pushing and releasing the hourbutton as many times as needed. Or if thebutton is pressed and held in for longerthan 2 seconds, the numbers will continueto advance until the button is released.
1.3 Advance the minute setting by repeatedlypushing, or pushing and holding the min-ute button as needed.
1.4 Push the Run/Set switch to the middle(RUN) position.
2. To set the alarm time:
2.1 Push the Run/Set switch to the left(ALARM-SET position).
2.2 Set the alarm time by using the same pro-cedure used to set the time of day; re-member to set the hour for AM (no lettersin the corner of the display), or PM as de-sired.
2.3 Return the Run/Set switch to the middle(RUN) position; the readout will return tothe time-of-day setting.
3. To operate the alarm:
3.1 With the alarm time set, push the alarm(upper) switch to the left. An alarm "wave"symbol and the letters AL will appear inthe upper left corner of the display whenthe alarm is on.
3.2 When the displayed time of day coincideswith the alarm time, the alarm will sound.If the SNOOZ button is not pushed or thealarm switch is not moved, the alarm willautomatically stop sounding after 1 minuteand will not sound again for 24 hours.
3.3 If desired, press the SNOOZ button whilethe alarm is sounding to shut the alarm offfor 3 minutes. The alarm symbol will flashin the display when the button is pushedand will continue to flash until the alarmswitch is moved or the alarm has soundedfor one minute. The snooze procedure canbe done as many times as desired.
3.4 Move the alarm switch to the right whenyou wish to shut off or cancel the alarm;the alarm symbol will disappear.
Engine Oil Temperature Gauge
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 in the following tempera-ture range:
• 180 to 225°F (82 to 107°C) for Cummins ISBengines
• 177 to 203°F (81 to 95°C) for Mercedes-BenzMBE900 engines
NOTE: Under heavy loads, such as when climb-ing steep grades, temperatures that exceed thenormal oil temperature range for a short periodare not unusual. If the temperature returns tonormal when the load decreases, there is noproblem. See Fig. 3.17.
Transmission Fluid TemperatureGaugeDuring normal operation, the transmission fluid tem-perature gauge reading should not exceed 250°F(121°C) at the sump. See Fig. 3.18.
10/10/2001 f610569
Fig. 3.17, Engine Oil Temperature Gauge
Instruments
3.11
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.
NOTE: Under heavy loads, such as when climb-ing steep grades, temperatures may climbabove those given here for limited periods.
Turbocharger Boost Pressure GaugeA turbocharger boost pressure gauge measures thepressure in the intake manifold, in excess of atmos-pheric pressure, being created by the turbocharger.See Fig. 3.19.
10/30/2001 f610600
TRANS
125 350
F
275200
Fig. 3.18, Transmission Fluid Temperature Gauge
10/10/2001 f610574
Fig. 3.19, Turbo Boost Pressure Gauge
Instruments
3.12
4
ControlsIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Multifunction Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Aftertreatment System (ATS) Regen Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6Braking Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Ignition Switch and KeyThe ignition switch can be turned to four positions:ACCESSORY, OFF, ON, and START. See Fig. 4.1.
The key can be inserted and removed only in theOFF position. The headlights (low beams), taillights,brake lights, road lights, clearance lights, turn sig-nals, hazard warning lights, horn, CB radio, clock,and electric oil pan heater operate with the ignitionswitch in the OFF position, regardless of whether thekey is inserted.
All of the components that are operable in the OFFposition are operable in the ACCESSORY position,as well as the radio (if so equipped), mirror heat, airdryer, and backup lights.
Turn the key fully clockwise to the START position tostart the engine. When the engine starts, release thekey.
All electrical systems are operable in the ON posi-tion. The warning lights and the buzzer for low airpressure and low oil pressure operate until minimumpressures are built up.
Lighting ControlsThe lighting controls are operated with two types ofswitches located on the dash:
• Paddle switches—a single paddle located inthe center of the switch that can be raised orlowered to perform a function.
• Rocker switches—can be pressed up or downto perform a function. Certain rocker switchesare guarded to prevent them from beingswitched on or off accidentally.
Headlight/Parking Light SwitchThe headlights and parking lights are operated with apaddle switch, shown in Fig. 4.2. When the paddle islowered, the parking lights (front turn signals, markerand identification lights, and the taillights) illuminate.When the paddle is raised, the low-beam headlightsilluminate, along with all of the parking lights. To turnoff all lights, return the paddle to the center position.
NOTE: The front turn signal is the amber lens ineach headlight unit. The low-beam headlight isthe top clear lens in each headlight unit.
When the headlights or parking lights are on, thepanel lights also illuminate. A light in the switch back-lights either the top icon (for headlights and parkinglights) or the bottom icon (for parking lights only).
Daytime Running LightsTurning on the ignition and releasing the parkingbrakes automatically activates the daytime runninglights, if so equipped. The daytime running lights willoperate until the parking brakes are applied or theheadlights are turned on.
The daytime running lights illuminate at about two-thirds of normal power.
Panel Light Increase/Decrease SwitchWhen the panel lights are on, they can be brightenedor dimmed by using the INCR/DECR switch, justbelow the headlight switch. When the panel lights areon, both legends of the switch are backlit. SeeFig. 4.3. Push the top of the switch to increase thepanel brightness. Push the bottom of the switch todim.
09/12/2001 f610509
Fig. 4.1, Ignition Switch Positions
10/15/2001 f610580
Raise the paddle to illuminate the low-beam headlights.
Lower the paddle to illuminate the parking lights.
Fig. 4.2, Headlight/Parking Light Switch
Controls
4.1
Marker Lamp Interrupt SwitchThe optional marker lamp interrupt (MRKR INT)paddle switch temporarily deactivates the markerlamps and taillights. See Fig. 4.4.
With the vehicle lights on, raise and hold the paddleswitch to briefly turn off the marker lamps and tail-lights. When the paddle switch is released themarker lamps and taillights return to normal opera-tion. With the vehicle lights off, raise the paddleswitch to momentarily turn the marker lamps and tail-lights on.
Multifunction Turn SignalLeverThe multifunction turn signal lever has the followingfunctions:
• turn signals
• windshield wipers and washers
• high-beam headlights
• hazard warning lights
See Fig. 4.5 for the multifunction switch and its com-ponent parts.
Turn Signal LeverMoving the multifunction turn signal lever down acti-vates the left turn signal lights; moving it up activatesthe right turn signal lights. See Fig. 4.6 for an ex-ample of the multifunction turn signal lever.
f61059810/29/2001
Fig. 4.3, Panel Light Increase/Decrease Switch
05/09/2002 f610581
Raise the paddle to flash the marker lights.
Fig. 4.4, Marker Light Interrupt Switch
f820386
12
3
4
5
11/16/2001
Press down on the upper part of the rocker switch toactivate the hazard warning lights.1. Washer Button2. Wiper Control Dial3. Turn Signal Lever4. Hazard Warning Light Rocker Switch (red)5. Multifunction Switch Module
Fig. 4.5, Multifunction Turn Signal Lever
10/17/2001 f820384
Move the lever down to activate the left turn signals.
Move the lever up to activate the right turn signals.
Fig. 4.6, Turn Signal Controls
Controls
4.2
When a turn signal is activated, a green indicatorarrow flashes at the far left or far right of the instru-ment panel.
The lever automatically returns to the neutral position(self-cancels the switch) when the steering wheelreturns to the straight ahead position after a turn. Tocancel the signal manually, move the lever to theneutral position.
Windshield Wiper/Washer Controls
NOTICEDo not move the wiper arms manually. Wipermotor damage will occur if the arms are moved.
The wipers are operated by a rotary switch in thewiper control dial, located on the end of the turn sig-nal lever. See Fig. 4.7. There are five delay settings,marked on the dial by lines of increasing length, andtwo steady speed settings, LO and HI.
Rotating the control dial forward (in a counterclock-wise direction) turns the wipers on. If they are al-ready on, rotating the handle further forward in-creases the speed of the wipers through the variousdelay settings, and to the LO and HI settings.
Rotating the control dial in the opposite direction(clockwise) reduces the speed of the wipers. Rotat-ing the control dial clockwise as far as it will go (tothe OFF setting) turns the wipers off.
The washers are operated by a button at the veryend of the turn signal lever. To operate the washers,press the button in and hold it.
High-Beam HeadlightsNOTE: The ignition switch must be on for thehigh beams to work.
To activate the high-beam headlights, push the turnsignal lever forward, towards the windshield. Pull thelever back to its original position to turn the high-beam headlights off. See Fig. 4.8. The low beamsremain on during high beam operation.
When the high-beam headlights are on, a blue lightilluminates on the instrument panel. For vehicles builtfor domicile in the United States, the road lights turnoff when the high beams are activated.
To flash the high beams momentarily, pull the leverbackward, towards the steering wheel.
Hazard Warning LightsTo activate the hazard warning lights, press down onthe upper part of the rocker switch located on the topof the multifunction switch module (towards the
f820383
1 3
2
4
5
10/29/2001
Rotate the control dial forward to turn the wipers on, orincrease their speed.
Rotate the control dial backward to decrease the wipersspeed, or turn them off.1. Washer Button2. OFF Position3. Delay Positions4. Wipers On, Low Speed5. Wipers On, High Speed
Fig. 4.7, Wiper/Washer Controls
10/17/2001 f820385
1
2
Move the lever forward to activate the high-beamheadlights. Move the lever back to its original position toturn the high-beam headlights off.
Move the lever back toward the steering wheel to flashthe high beams momentarily.
1. Turn Signal Lever 2. Boot
Fig. 4.8, Headlight High Beams
Controls
4.3
dash). See Fig. 4.5. When the rocker switch ispushed down, all of the turn control lights will flash.To cancel the hazard warning lights, press down onthe lower part of the rocker switch (towards thesteering wheel).
Aftertreatment System (ATS)Regen SwitchNOTE: Alternative fueled vehicles are notequipped with a regeneration (regen) switch.
A regen switch, located on the dash, allows thedriver to control three states. See Fig. 4.9. Theseinclude:
• request regeneration
• default (automatic regeneration)
• inhibit regeneration
See the engine operation manual for details on op-eration of the regen switch.
Horn ControlsNOTE: It is possible to have both the electricand the air horn installed on one vehicle.
A single electric horn is standard. Dual electric hornsare available as an option.
Electric HornThe button for the horn is located in the center of thesteering wheel. To sound the horn, press the centerof the steering wheel pad. See Fig. 4.10.
Air HornSingle and dual air horns are available as options.
The air horn is controlled by a wire lanyard hangingdown just inboard on the driver’s door. See Fig. 4.11.Pull downward on the lanyard to sound the air horn.
Cruise ControlCruise Control Switch
WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as 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.
f61119906/19/2012
Fig. 4.9, Regen Switch
10/17/2001 f461918
1
1. Horn Button
Fig. 4.10, Electric Horn Control
10/17/2001 f610592
To sound the air horn, pull down on the lanyard (arrow).
Fig. 4.11, Air Horn Control
Controls
4.4
NOTICEIf equipped with a manual transmission, do notattempt to shift gears without using the clutchpedal when the cruise control is engaged. Failureto follow this precaution will result in a temporar-ily uncontrolled increase in engine speed; trans-mission damage and gear stripping could result.
NOTE: Maximum cruise control speed variesaccording to vehicle specifications, but cannotbe higher than 75 mph (121 km/h).
On standard models, cruise control is activated bytwo dash switches. See Fig. 4.12. On some models,the cruise control can be activated by a button on thetransmission shift knob.
• The On/Off Switch—this two-position rockerswitch bears the legend SPD CNTL on thelower half of the switch. When the cruise con-trol is on, an amber light illuminates in the toppart of the switch.
• The Set/Resume Switch—this three-positionpaddle switch bears the legend RES/ACC
above the paddle and SET/CST below thepaddle.
1. To cruise at a particular speed:
1.1 Press the upper half of the On/Off rockerswitch.
1.2 Hold the accelerator pedal down until thespeedometer reaches the desired speed.
1.3 Momentarily lower the Set/Resume switchpaddle.
2. To disengage the cruise control:
2.1 Depress the brake pedal (on automatic ormanual transmission) or
Depress the clutch pedal (on manualtransmission only)
2.2 Press the lower half of the On/Off rockerswitch.
3. To resume a preselected cruise speed:
3.1 If the On/Off rocker switch is off, turn it on.
3.2 Momentarily raise the paddle of the Set/Resume switch to RES/ACC. Cruise willreturn to the last speed selected.
NOTE: If the ignition is shut off, the speedmemory will be lost.
4. To adjust cruise speed up, raise and hold thepaddle of the Set/Resume switch to RES/ACCuntil the vehicle accelerates to the desiredspeed.
5. To adjust the cruise speed down, lower and holdthe paddle of the Set/Resume switch to SET/CST until the vehicle decelerates to the desiredspeed.
NOTE: For more information about cruise con-trol operation, see the engine manufacturer’sservice manual.
Fast Idle SystemIf the vehicle is equipped with this option, it is avail-able for use only with cruise control. There are threepreset speeds available: 800, 900, or 1000 rpm.
The fast idle system can be used to increase engineidle speed whenever the following conditions aremet.
• The brake pedal is not pressed.
09/13/2001
1
2
f610510
To turn the cruise control on, press the upper half of theOn/Off (rocker) switch. To turn cruise control off, pressthe lower half of the On/Off (rocker) switch.1. Cruise Control On/Off (rocker) Switch2. Cruise Control Set/Resume (paddle) Switch
Fig. 4.12, Cruise Control Switches, Dash-Mounted
Controls
4.5
• The vehicle must not be moving and thethrottle must not be pressed.
Fast Idle Operation1. To enable the fast idle system, press and release
the cruise control On/Off rocker switch.
2. For the preset fast idle, press and release thecruise control set switch. This will set the presetfast idle speed.
IMPORTANT: The fast idle system does nothave any type of light activation in the instru-ment panel. The only light that will be illumi-nated is the cruise indicator.
Any of the following actions will turn off the fast idlesystem:
• Applying the brake.
• Moving the transmission shifter out of Park (P)or Neutral (N); this will engage the transmis-sion.
• Pressing and releasing the cruise control On/Off rocker switch when it is on.
Powertrain ControlsFor complete transmission operating instructions seeChapter 10.
Automatic TransmissionsVehicles equipped with a standard Allison On-Highway series automatic transmission, have aT-handle shift selector. See Fig. 4.13.
When the transmission is in D (drive), the vehicle willoperate in 4th and 5th gear as needed. To shift downinto a lower gear, pull the lower half of the T-handleselector up. Select the gear needed and release thelower half of the T-handle selector.
On vehicles with an Allison MD Series automatictransmission or an Eaton Autoshift automated trans-mission, a push-button shift selector, shown inFig. 4.14, provides four, five, or six forward rangesand one reverse range. See Chapter 10 for moreinformation about the push-button shift selector.
Transmission Mode SwitchSome vehicles are equipped with a transmissionmode switch, shown in Fig. 4.15. The transmissionmode switch is a fuel conservation option that allowsthe driver to choose either performance or economy
shifting. When the switch is in the on position (thetop of the rocker switch is pushed down), the trans-mission shift pattern changes from primary (perfor-mance) shift mode to secondary (economy) shiftmode. When the transmission mode switch is in theoff position (the bottom of the rocker switch ispushed down), the transmission reverts back to theprimary shift mode.
NOTE: Primary and secondary shift mode cali-bration varies by vehicle.
09/21/2012 f270165
Fig. 4.13, T-Handle Shift Selector
Controls
4.6
Axle SwitchesAll axle switches contain a red LED that illuminatesthe switch when it is turned on (the upper part of therocker is pressed). The legend under the LED, if any,is not visible until the switch is turned on. For moreinformation on axle switch function, see Chapter 11.
IMPORTANT: A guard is positioned around allaxle switches to prevent unintentional activation.
Differential Lock Switch
NOTICEDifferential lock should only be engaged whenthe vehicle is stopped or moving slowly at lowthrottle. This will prevent internal axle damage.
The optional differential lock switch is a two-positionguarded rocker switch. It causes the wheels on eachaxle governed by the switch to rotate together. It isalso known as side-to-side wheel lock. SeeFig. 4.16.
To lock the wheels together, press the upper half ofthe rocker switch momentarily. To turn off differentiallock, press the upper half of the rocker switch again.
When the panel lights are on, the double-axle icon isbacklit in green.
IMPORTANT: The differential lock switch isguarded to prevent unintentional switch activa-tion. If the LED in the switch begins to blink dur-ing normal operation, when the switch has notbeen activated, this indicates an error condition.Take the vehicle to an authorized Freightlinerdealer as soon as possible.
Manual Dump ValveOn vehicles equipped with a manual dump valve,there are two ways to deflate the rear suspension.With the key in the OFF position, toggle the dumpvalve into the "lower" position. If the key is in the ONposition, the parking brake must be set (ON) beforethe dump valve is toggled into the "lower" position.
NOTE: If the key is turned to the ON positionand the parking brake is not engaged, the over-ride will cause reinflation of the air ride system.
1
2
3
f61080407/27/2006
4
1. Digital Display2. Mode Identification Label3. Mode Indicator LED4. Mode Button
Fig. 4.14, Push-Button Shift Selector
01/21/2016 f611330
Fig. 4.15, Transmission Mode Switch
10/26/2001 f610596
Fig. 4.16, Differential Lock Switch
Controls
4.7
Braking ControlsParking Brake Control KnobAll pneumatic-braked vehicles are equipped with adiamond-shaped parking brake control knob. SeeFig. 4.17. Pull the knob to apply the parking brake.In air brake systems, before the parking brake canbe released, the air pressure in either brake systemmust be at least 65 psi (448 kPa).
See Chapter 13 for further information about thebrake system.
Meritor™ WABCO® Antilock BrakingSystem (ABS)The Meritor WABCO ABS has an indicator lamp(ABS legend) and, if equipped with automatic tractioncontrol (ATC), a wheel spin indicator lamp (WHEELSPIN legend). See Fig. 4.18.
See the brake system operating instructions in Chap-ter 13 for more information about ABS.
Exhaust Brake SwitchAn exhaust brake is an optional auxiliary braking sys-tem that assists, but does not replace the servicebrake system. The exhaust brake is controlled by adash-mounted rocker switch to help slow the vehiclewhen the accelerator is released.
To turn the exhaust brake on, press the upper part ofthe rocker switch. The exhaust brake turns off auto-matically. See Fig. 4.19.
03/30/2010 f421624
Fig. 4.17, Parking Brake Control Knob
ABS ABS
BRAKE
CHECK STOP
BRAKEAIR
WAIT TO
START
CHECK
TRANS
LOW
WATER
WHEEL
SPINOPT 1 OPT 8 OPT 9
DEF
QUALITY
RANGE
INHIBIT
1 206/19/2012 f611198
1. Wheel Spin Indicator 2. Tractor ABS Indicator
Fig. 4.18, ABS Indicator Lights
f61058911/28/2001
Fig. 4.19, Exhaust Brake Switch
Controls
4.8
5
Cab FeaturesWindows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
WindowsStandard windows operate mechanically using ahand crank.
Power windows are optional, and can be installed onone side or both sides. One power window switch(window icon) will be installed on the dash for eachwindow. See Fig. 5.1. If your vehicle is equipped withpower windows, press up to raise the window; pressdown to lower the window. Releasing the switchcauses the window to stop.
Standard vent (wing) windows do not open. Operat-ing vent windows are optional. To open the operatingvent window, turn the latch on the window and pushthe window open. See Fig. 5.2.
MirrorsThe standard outside mirrors are mounted on thedoor frame. There is a primary rear view mirror and aconvex mirror.
Mirror Heat Switch, OptionalOne or both outside door mirrors can be heated tokeep them clear of fog, frost, and ice.
To heat the mirrors, press the upper part of the mir-ror heat switch (MIRR HEAT) on the dash. SeeFig. 5.3. When the mirror heat switch is on, anamber indicator light illuminates inside the switch.
The mirror heat switch is a smart switch (fully multi-plexed).
Power Mirrors, OptionalThe main outside mirrors, if heated, can be equippedwith an electrical remote control located on thedriver’s door. See Fig. 5.4.
To select the mirrors on the left-hand side, press theleft side of the mirror select switch. To select the mir-rors on the right-hand side, press the right side of themirror select switch.
The keypad has four arrow keys, pointing up, down,left, and right. To adjust the mirror position, press thekeypad in the direction you want the mirror to move.
Down View Mirror, OptionalA down view mirror can be installed on the top of thepassenger door frame to allow the driver a view ofthe area adjacent to the right side of the cab. SeeFig. 5.5.
10/09/2001 f610522
Press up to raise the window; press down to lower thewindow. Releasing the switch causes the window to stop.
Fig. 5.1, Power Window Switch
10/05/2001 f670096
1
2
1. Latch 2. Vent Window
Fig. 5.2, Operating Vent Window (optional)
MIRRHEAT
10/09/2001 f610524
To heat the mirrors, press up; press down to turn off theheat.
Fig. 5.3, Mirror Heat Switch
Cab Features
5.1
SeatsGeneral Information
WARNINGKeep hands, tools, and other objects away fromthe scissor points under the seats. Failure to doso could cause personal injury.
Unless otherwise noted, all seat adjustments shouldbe made while seated and before the engine isstarted.
Due to the high degree of adjustability found in high-back air suspension seats, it is possible to set theseat back recline adjustment and the seat slide ad-justment in such a combination that the seat back
will come into contact with the rear wall of the cab. Itis the responsibility of the driver to adjust the seat toprevent damage to the seat and the cab interior.
The following is a description of adjustments that areavailable on one or more seats. Not all seats have allof the adjustments listed below.
1. Seat Slide (fore-and-aft): When this adjustment ismade, the entire seat moves forward or back-ward on its track. See Fig. 5.6.
2. Isolator: This feature (also referred to as back-slap isolator or Chugger-Snubber®) reduces theamount of road shock by isolating the occupantfrom the motion of the vehicle, and allowing theupper seat to move in a simple pendulum mo-tion. Whenever the isolator is not desired, it canbe locked out. See Fig. 5.6.
3. Lumbar Support: Lumbar support changes theshape of the seat back to give more or less sup-port to the occupant’s lumbar (lower back) area.This adjustment is either mechanical or air con-trolled, depending on the make and model of theseat. See Fig. 5.7.
4. Headrest: When this adjustment is made, theupper part of the backrest (back cushion)changes angle to provide head and upper backsupport as shown in Fig. 5.7.
5. Backrest Tilt: This adjustment pivots the backrestforward or backward as shown in Fig. 5.8.
10/05/2001 f610523
1
2
To adjust the mirror position, press the keypad on thedoor in the direction you want the mirror to move.
1. Mirror Select Switch 2. Keypad
Fig. 5.4, Power Mirror Switch Pad
10/05/2001 f720396
1
1. Mirror
Fig. 5.5, Down View Mirror (optional)
10/05/2001 f910482
A
B
A. Seat Slide (fore-and-aft) AdjustmentB. Isolator Feature
Fig. 5.6, Seat Slide Adjustment and Isolator Feature
Cab Features
5.2
6. Seat Cushion Tilt: This adjustment raises or low-ers the front and/or back of the seat (bottom)cushion. This adjustment is easier to performwhen all weight is removed from the seat. SeeFig. 5.8.
7. Seat Tilt: When this adjustment is made, the seatassembly, both backrest and seat cushion, tiltsforward or backward as shown in Fig. 5.8.
8. Ride Height Adjustment: The entire seat movesup or down when adjusting the ride height. Theadjustment is either manual or air controlled, de-pending on the make and model of the seat. SeeFig. 5.9.
9. Damper: When you sit on the seat, a levelingvalve places you in the center of the ride zone.When the damper is adjusted properly under nor-mal driving conditions, the seat should not top orbottom against the limits of the vertical travel.
10. Ride Firmness: A firmer ride gives a better feelfor the road but less protection against uneven-ness in the road surface. A softer ride smoothsout the bumps.
Bostrom SeatSeat Slide AdjustmentMove the seat slide and isolator lever, shown inFig. 5.10, to the left and hold it there to slide theseat forward or backward to the desired position.
IsolatorTo engage the isolator, put the seat slide and isolatorlever in the center position. Lock out the isolator bymoving the lever to the right.
10/05/2001
A
B
f910483
A. Lumbar Support B. Headrest Adjustment
Fig. 5.7, Lumbar Support and Headrest Adjustment
A
B
10/05/2001 f910484
A. Backrest Tilt B. Seat Cushion Tilt
Fig. 5.8, Cushion Tilt Adjustments
10/05/2001
A
f910485
A. Ride Height
Fig. 5.9, Ride Height Adjustment
Cab Features
5.3
Lumbar SupportTo increase lumbar support, rotate the lumbar sup-port knob forward. To decrease lumbar support, ro-tate the knob rearward.
On seats equipped with air lumbar support, press thecontrol valve upward to increase lumbar support.Press the control valve downward to decrease lum-bar support.
Seat Cushion TiltRotate the seat cushion tilt knob to increase or de-crease seat cushion tilt.
Backrest TiltTo tilt the backrest, lean forward slightly to removepressure from the cushion and hold the backrest tiltlever rearward. Lean backward slowly to the desiredposition and release the lever to lock the backrest inplace.
Ride Height and Damper AdjustmentTo raise the seat, press the upper portion of theheight adjustment switch. To lower the seat, pressthe lower portion of the switch.
Press the damper adjustment switch to adjust thedamper.
National 2000 Series SeatSeat Slide AdjustmentMove the seat slide lever, shown in Fig. 5.11, to theleft and hold it there to slide the seat forward orbackward to the desired position. Move the leverback to its original position to lock the seat in place.
IsolatorTo use the isolator feature, turn the isolator handle tothe horizontal position. Turn the isolator handle downto lock out the isolator.
1
23
45
6
7
10/10/96 f910131
1. Backrest Tilt Lever2. Air Lumbar Support Control Valve (optional)3. Damper Adjustment Switch4. Height Adjustment Switch5. Seat Cushion Tilt Knob6. Seat Slide and Isolator Lever7. Lumbar Support Knob (standard)
Fig. 5.10, Bostrom Seat
11/14/2000
1
234
5
f910445
6
7
1. Backrest Tilt Knob2. Lumbar Support Switch3. Height Adjustment Switch4. Seat Slide Lever5. Front Cushion Height Adjustment Handle6. Isolator Handle7. Rear Cushion Adjustment Knob
Fig. 5.11, National 2000 Series Seat
Cab Features
5.4
Lumbar SupportTo adjust the lumbar support, use the lumbar supportswitch on the side of the seat to give more or lesssupport to your lower back.
Backrest TiltTo tilt the backrest, turn the backrest tilt knob untilthe desired position is reached.
Seat Cushion AdjustmentTo adjust the height of the front of the seat cushion,lift the front cushion height adjustment handle, andpull forward or push back to the desired setting.
To adjust the height of the rear of the seat cushion,remove your weight from the seat and turn the rearcushion adjustment knob to one of three positions.
Ride Height AdjustmentTo raise or lower the height of the seat, use theheight adjustment switch on the side of the seat.
Sears SeatSeat Slide AdjustmentPush the seat slide (fore-and-aft adjustment) lever,shown in Fig. 5.12, all the way to the left and slidethe seat forward or backward, as desired. Releasethe lever to lock the seat in the desired position.
IsolatorTo engage the isolator (if installed), move the seatslide and isolator lever shown in Fig. 5.13 all the wayto the right. To lock out the isolator, move the isolatorlever to the center position.
Lumbar SupportMove the three-position lumbar support lever upwardto increase lumbar support (firmer). Move the leverdownward to decrease lumbar support (less firm).
NOTE: This three-position lever (see inset) doesnot rotate a full 360 degrees.
For seats with air support, use the aft rocker switchon the control panel on the left-hand side of the seat.See Fig. 5.14. Press up to make the seat firmer;press down to make the seat less firm.
10/08/2001 f910487
1
2
34
5
1. Seat Slide Lever2. Seat Cushion Tilt Adjustment3. Ride Height Knob4. Lumbar Support Lever5. Backrest Lever
Fig. 5.12, Sears Low Profile Seat
10/09/2001 f910486
1
2
3
4
56
7
8
NOTE: Armrests are optional.1. Lumbar Support Lever2. Backrest Lever3. Ride Height Knob4. Shock Absorber Bracket (ride firmness)5. Pin (ride firmness)6. Snap Ring (ride firmness)7. Seat Slide and Isolator Lever8. Seat Cushion Adjustment
Fig. 5.13, Sears Fleetmaster Seat (with isolator)
Cab Features
5.5
Seat Cushion TiltTo raise the seat cushion, lift upward on the front ofthe seat cushion, and then push it rearwards. Tolower the seat cushion, pull forward on the front ofthe seat cushion, and then push downwards.
Backrest AdjustmentTo adjust the backrest, push downwards on the back-rest lever just below the bottom of the backrest cush-ion. With the lever down, lean forward or backwardto the desired position. Release the lever to lock thebackrest in place.
Ride Height AdjustmentPush the ride height knob inwards to inflate the aircylinder, raising the height of the seat. Pull the rideheight knob outwards to deflate the air cylinder, low-ering the height of the seat.
For seats with air support, use the forward rockerswitch on the control panel on the left-hand side ofthe seat. See Fig. 5.14. Press up to raise the seat;press down to lower the seat.
Ride Firmness AdjustmentFor a softer ride, remove the snap ring and pin fromthe shock absorber bracket (see inset). Relocate thepin in the other set of holes in the bracket and se-cure it with the snap ring.
Seat Belts and Tether BeltsGeneral InformationSeat belt assemblies are designed to secure personsin the vehicle to help reduce the chance of injury orthe amount of injury resulting from accidents or sud-den stops. For this reason, Freightliner CustomChassis Corporation (FCCC) urges that the driverand all passengers, regardless of age or physicalcondition, use seat belts when riding in the vehicle.
WARNINGAlways use the vehicle’s seat belt system whenoperating the vehicle. Failure to do so can resultin severe personal injury or death.
Seat belt assemblies in FCCC 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 in mo-tion.
In addition to seat belt assemblies, tether belts areinstalled on suspension-type seats. Tether belts helpsecure the seat to the floor and are intended to re-strain the seat and seat belt in case of an accident orsudden stop.
IMPORTANT: Seat belts have a finite life whichmay be much shorter than the life of the vehicle.Regular inspections and replacement as neededare the only assurance of adequate seat beltsecurity over the life of the vehicle.
Seat Belt Inspection
WARNINGInspect and maintain seat belts and tethers asinstructed below. Seat belts and tethers that weredamaged or stressed in an accident must be re-placed, and their anchoring points must be
10/08/2001 f9104881 2
1. Ride Height Switch2. Air Lumbar Support Switch
Fig. 5.14, Air Controls, Sears Seat
Cab Features
5.6
checked. When any part of a seat belt systemneeds replacement, the entire seat belt must bereplaced, both the retractor and the buckle side.Do not attempt to modify the seat belt system;doing so could change the effectiveness of thesystem. Failure to replace damaged or stressedseat belts or any modifications to the systemmay result in personal injury or death.
Inspect the seat belts and tether belts (if soequipped).
1. Check the web for fraying, cuts, or extreme wear,especially near the buckle latch plate and in theD-loop guide area.
2. Check the web for extreme dirt or dust, and forsevere fading from exposure to sunlight.
3. Check the buckle and latch for operation and forwear or damage.
4. Check the Komfort Latch or the Sliding KomfortLatch (if equipped) for function and cracks orother damage.
5. Check web retractor for function and damage.
6. Check the mounting bolts for tightness andtighten any that are loose.
Seat Belt OperationThree-Point Seat Belt With Komfort Latchor Sliding Komfort Latch
WARNINGWear three-point seat belts only as describedbelow. Three-point seat belts are designed to beworn by one person at a time. In case of an acci-dent or sudden stop, personal injury or deathcould result from misuse.
Fasten the seat belts before driving. Fastening athree-point seat belt while driving creates a haz-ard.
When engaged and used properly, the Komfort Latchand the Sliding Komfort Latch, shown in Fig. 5.15and Fig. 5.16 respectively, introduce a small amountof slack into the seat belt, resulting in a more com-fortable ride.
1. Slowly pull the latch end of the three-point seatbelt out of the retractor and pull it across yourlap (from outboard to inboard) far enough to en-gage the buckle. If the retractor locks too soon,
allow the belt to retract slightly, then slowly pull itout again.
2. Fasten the three-point seat belt by pushing thelatch into the buckle. Listen for an audible click.See Fig. 5.17.
03/11/2010 f910620
A B
A. Disengaged B. Engaged
Fig. 5.15, Komfort Latch
11/18/2010 f910621a
Fig. 5.16, Sliding Komfort Latch
Cab Features
5.7
3. Tug on the seat belt to make sure it is securelyfastened. If the buckle unlatches, repeat thisstep. If the problem continues, replace the three-point seat belt.
4. Snug the seat belt to your waist.
5. Position the shoulder strap diagonally acrossyour chest with the adjustable D-loop bracket, ifso equipped. If desired, engage the KomfortLatch or Sliding Komfort Latch as follows.
If equipped with a Sliding Komfort Latch, makesure that the shoulder strap is snug against yourchest. Without loosening the shoulder strap,push the Sliding Komfort Latch switch to the ONposition. See Fig. 5.16. To activate the latch,lean forward until you hear a click. This will allowfor 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. See Fig. 5.18 andFig. 5.19.
6. Unbuckle the three-point seat belt and releasethe Komfort Latch or the Sliding Komfort Latchas follows.
If equipped with a Sliding Komfort Latch, un-buckle the seat belt, then tug on the shoulderbelt to release the Sliding Komfort Latch, orpress the Sliding Komfort latch to the OFF posi-tion, 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.
01/18/95 f910004a
Fig. 5.17, Fastening the Three-Point Belt
f910048a02/03/2017
A
A. 1 Inch (2.5 cm) Maximum
Fig. 5.18, Adjusting Shoulder Harness Clearance,Komfort Latch
f91014402/03/2017
Fig. 5.19, Locking the Komfort Latch
Cab Features
5.8
NOTE: Neither the Komfort Latch nor the SlidingKomfort Latch need to be manually released inan emergency situation. Each will release byitself under rough road or other abnormal condi-tions. Make sure the three-point seat belt iscompletely retracted when it is not in use.
Cab AmenitiesCup HoldersThere are two cup holders molded into the lower partof the auxiliary dash panel, one on either side of theHVAC control head.
Cab StorageThere is a dash storage bin located under the cupholders on the center panel. The bin has a hingedcover and can be used to store sunglasses. There isalso a small storage pocket above the radio.
Overhead StorageVehicles without an overhead console have two stor-age bins located above the windshield.
On vehicles equipped with an overhead console,most vehicles have a storage bin located in the over-head console. See Fig. 5.20. The overhead storagebin is often removed and replaced with a CB radio.
Two map holders with netted openings are locatedoverhead, one on either side of the overhead con-sole.
10/08/2001 f680027
1 2
3
1. Overhead Storage Bin 2. Overhead Console 3. Map Holder Netting
Fig. 5.20, Overhead Storage
Cab Features
5.9
6
Electrical SystemsElectrical System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Power Distribution Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Electrical System GeneralInformationThe S2 Chassis uses an electrical system wheremultiple electrical signals are carried along a simpli-fied set of wires, reducing the size of wiring bundles.There are significantly fewer wires overall, meaningless chance of damage, shorts, and other problems.The information in this chapter is to help familiarizethe driver with the basic electrical system. Servicingthe electrical system requires special skills andequipment and should be performed only by a quali-fied technician. Take the vehicle to an authorizedFreightliner service facility for repairs.
WARNINGDo not attempt to modify, add, splice, or removeelectrical wiring on this vehicle. Doing so coulddamage the electrical system and result in a firethat could cause serious personal injury or prop-erty damage.
Power Distribution ModulesThere are three electrical modules, a main powerdistribution module (PDM) located under the hood onthe driver’s side above the fender, a chassis modulelocated between the frame rails, and a cab modulelocated to the left of the driver under the switchpanel.
The main PDM distributes battery power to the vehi-cle’s control modules and contains the fuses requiredto protect the power feed circuits to the control mod-ules. See Fig. 6.1. While the main PDM providespower to the modules, the modules themselves con-trol power flow and circuit protection to the variouscomponents of the vehicle electrical systems. Be-cause of this, traditional PDM devices such as relaysand circuit breakers are no longer necessary on themain PDM.
Inside the lid of the fuse box there is a sticker thatshows the locations of the fuses and describes thecircuit(s) that each fuse protects. Fuse configurationwill vary depending on the PDM assembly installed.See Fig. 6.2. See Table 6.1 for descriptions of atypical set of fuses.
Because the electrical system is multiplexed, no re-lays are needed. The multiplexing module performsthe functions normally provided by relays.
Main PDM Fuse IdentificationCAV Description FuseF1 Engine VCU (spare) 10AF2 Blower Motor 30AF3 Engine ECU 20AF4 Spare 30AF5 Ignition Switch 5AF6 HydroMax RLY (if equipped with
hydraulic brakes)30A
F7 Bulkhead Module 30AF8 ICU3 10AF9 Transmission ECU 10A
F10 Spare —F11 Spare —F12 Radio/Diagnostic 20AF13 Chassis Module 30AF14 Spare —F15 Bulkhead Module 30AF16 ABS ECU 25AF17 Chassis Module 30AF18 Bulkhead Module 30AF19 Chassis Module 30AF20 Bulkhead Module 30AF21 Spare —F22 Bulkhead Module 30AF23 Spare —
09/25/2001 f543935
1
2
1. Bulkhead Module 2. Main PDM
Fig. 6.1, Location of the Main PDM (under driver sidehood, above fender)
Electrical Systems
6.1
Main PDM Fuse IdentificationCAV Description FuseF24 Hydraulic Pump and RLY (if equipped
with hydraulic brakes)25A
F25 Spare —F26 Spare —
Table 6.1, Main PDM Fuse Identification
12/19/2003 f544381
1
2
3 4
5
6
1. Battery Power Mega Fuse 12. Battery Power Mega Fuse 2
3. Engine Harness (green)4. Forward Chassis Harness (blue)
5. Forward Chassis Harness (gray)6. Frontwall Harness (black)
Fig. 6.2, Main PDM (top view)
Electrical Systems
6.2
7
Heater, Ventilating, and AirConditioner (HVAC)
Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Climate Control PanelThe climate control panel controls the HVAC for thedriver. The climate control panel without air condition-ing is shown in Fig. 7.1. The climate control panelwith air conditioning is shown in Fig. 7.2.
Standard controls consist of an eight-speed fanswitch, an air selection switch, and a temperaturecontrol switch. See Fig. 7.1. On vehicles with airconditioning, the panel also contains a telltale lightemitting diode (LED) and an air recirculation button.
NOTE: The vehicle may be equipped with a We-basto heating system. The Webasto heatingsystem warms the engine prior to starting thevehicle, and also assists in generating additionalheat for the passengers during operation. Foroperating instructions see the Webasto Opera-tor’s Manual.
Fan SwitchThe fan switch controls the fan speed and forcesfresh or recirculated air through the air outlets. Thefan switch has eight fan speeds and an off position.
To increase airflow, turn the fan switch clockwise to ahigher number. To decrease the airflow, turn theswitch counterclockwise to a lower number.
Air Selection SwitchThe air selection 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. Nine air selection modes are avail-
able on a system without air conditioning. SeeFig. 7.3. A system with air conditioning has 11 airselection modes, four of which are air conditioningmodes. See Fig. 7.4.
Air Selection Switch Without AirConditioning1. Face Mode: Directs all airflow through the face
or instrument panel outlets.
2. Selection between Face Mode and Bi-LevelMode: Directs 75 percent of the airflow throughthe face outlets and 25 percent through the flooroutlets.
3. Bi-Level Mode: Directs the airflow equally to theface outlets and the floor outlets.
4. Selection between Bi-Level Mode and FloorMode: Directs 25 percent of the airflow through
the face outlets and 75 percent through the flooroutlets.
5. Floor Mode: Directs all airflow through the flooroutlets.
6. Selection between Floor Mode and Floor/Defrost Mode: Directs 75 percent of the airflowthrough the floor outlets and 25 percent throughthe defrost outlets.
7. Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets.
8. Selection between Floor/Defrost Mode andDefrost Mode: Directs 75 percent of the airflow
231
40
1 2 3
f831452a06/17/2003
1. Fan Switch 2. Air Selection Switch 3. Temperature Control Switch
Fig. 7.1, Climate Control Panel Without Air Conditioning
Heater, Ventilating, and Air Conditioner (HVAC)
7.1
through the defrost outlets and 25 percentthrough the floor outlets.
9. Defrost Mode: Directs all airflow through thedefrost outlets.
1 2 3
5 4 f831453a06/18/2003
231
40
1. Fan Switch2. Air Selection Switch
3. Temperature Control Switch4. Recirculation Button
5. Recirculation Indicator
Fig. 7.2, Climate Control Panel With Air Conditioning
06/17/2003
1
2
34
5
6
7
8
9
f831455
1. Face Mode2. Selection Between Face Mode and Bi-Level Mode3. Bi-Level Mode4. Selection Between Bi-Level Mode and Floor Mode5. Floor Mode6. Selection Between Floor Mode and Floor/Defrost
Mode7. Floor/Defrost Mode8. Selection Between Floor/Defrost Mode and Defrost
Mode9. Defrost Mode
Fig. 7.3, Air Selection Switch Without Air Conditioning
f831462
1
2
3
4
56
7
8
9
10
1106/18/2003
A
A. Air Conditioning Modes1. Air Conditioning Face Mode2. Selection Between Air Conditioning Face Mode and
Air Conditioning Bi-Level Mode3. Air Conditioning Bi-Level Mode4. Selection Between Air Conditioning Bi-Level Mode
and Face Mode5. Face Mode6. Selection Between Face Mode and Floor Mode7. Floor Mode8. Selection between Floor Mode and Floor/Defrost
Mode9. Floor/Defrost Mode10. Selection between Floor/Defrost Mode and Defrost
Mode11. Defrost Mode
Fig. 7.4, Air Selection Switch With Air Conditioning
Heater, Ventilating, and Air Conditioner (HVAC)
7.2
Air Selection Switch With AirConditioning1. Air Conditioning Face Mode: Directs all airflow
through the face or instrument panel outlets.
2. Selection between the Air Conditioning FaceMode and the Air Conditioning Bi-LevelMode: Directs 75 percent of the airflow to theface outlets and 25 percent to the floor outlets.
3. Air Conditioning Bi-Level Mode: Directs theairflow equally to the face outlets and the flooroutlets.
4. Selection between the Air Conditioning Bi-Level Mode and the Face Mode: Directs 25percent of the airflow to the face outlets and 75percent to the floor outlets.
5. Face Mode: Directs all airflow through the faceoutlets.
6. Selection between Face Mode and FloorMode: Directs the airflow equally through theface outlets and the floor outlets.
7. Floor Mode: Directs all airflow through the flooroutlets.
8. Selection between Floor Mode and Floor/Defrost Mode: Directs 75 percent of the airflowthrough the floor outlets and 25 percent throughthe defrost outlets.
9. Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets. Therecirculation button will not work in this mode.
10. Selection between Floor/Defrost Mode andDefrost Mode: Directs 75 percent of the airflowthrough the defrost outlets and 25 percentthrough the floor outlets. The recirculation buttonwill not work in this mode.
11. Defrost Mode: Directs all airflow through thedefrost outlets. The recirculation button will notwork in this mode.
Temperature Control SwitchThe temperature control switch is used to select thedesired temperature. Turn the switch to the left(counterclockwise) for cool air, or to the right (clock-wise) for hot air. There are 21 positions on the tem-perature control switch ranging from full cool air tofull hot air.
Fresh Air ModeFresh air, or outside air, is circulated through theheating and air conditioning system unless the recir-culation mode, if equipped, is turned on.
Recirculation ModeThe recirculation mode is only available on vehicleswith air conditioning.
The recirculation mode limits the amount of outsideair entering the cab. Press the recirculation button toprevent dusty or smoky air from entering the cab.The recirculation mode can also be used to decreasethe time required to cool or heat the cab interior dur-ing extreme outside temperature conditions. Whenthe recirculation mode is on, the recirculation indica-tor will illuminate. See Fig. 7.2.
The recirculation mode is not available when the airselection switch is in one of the following modes:
• floor/defrost mode
• selection between floor/defrost mode and de-frost mode
• defrost mode
When the recirculation mode is turned on, it will stayon for 20 minutes, or until the recirculation button ispressed again, or the air selection switch is turned toa defrost mode.
IMPORTANT: The HVAC system enters a partialrecirculation mode for five minutes after being infull recirculation mode for 20 minutes. This cyclerepeats every 20 minutes.
DefrostingBefore using any of the defrost modes, clear thescreen at the base of the windshield if snow or ice ispresent.
Air ConditioningThere are four air conditioning modes on the air se-lection switch. The air conditioning settings on the airselection switch are blue, in addition to the selectionbetween the air conditioning bi-level mode and theface mode.
IMPORTANT: Operate the air conditioner atleast five minutes each month, even during coolweather. This helps prevent drying and cracking
Heater, Ventilating, and Air Conditioner (HVAC)
7.3
of the refrigerant compressor seals and reducesthe chance of refrigerant leaks in the system.
NOTE: The heating and air conditioning systemhas a brushless blower motor with a protectionor shutdown mode to prevent damage due tooverheating and overcurrent conditions. If thebrushless blower motor goes into a protectionmode, the motor will operate at a slower speed.If the overheating or overcurrent condition con-tinues, the motor will shut down and stop com-pletely.
The motor will resume proper operation after themotor has cooled or the overcurrent conditionhas been resolved. It will be necessary to cyclethe fan switch off, and then on, to reset themotor. If the problem appears repeatedly, takethe vehicle to an authorized Freightliner dealerfor repairs.
Heater, Ventilating, and Air Conditioner (HVAC)
7.4
8
EnginesEngine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Engine StartingFor cold-weather starting, refer to the Cummins orMercedes-Benz engine manufacturer’s operator’smanual, as applicable, for detailed instructions.
General InformationNOTE: Before starting the engine, read Chap-ter 3 and Chapter 4 in this manual for detailedinformation on how to read the instruments andoperate the controls.
Before operating the vehicle, perform the engine pre-trip inspection and daily maintenance checks inChapter 14 and Chapter 15 of this manual.
NOTICEWhen starting a vehicle equipped with a manualtransmission and clutch lockout switch, theclutch pedal must be fully depressed during theentire start sequence. Failure to do so can causethe pinion to release and re-engage, which couldcause ring gear and starter pinion damage.
If a vehicle does not start on the first attempt,make sure that the engine has completelystopped rotating before reapplying the starterswitch. Failure to do so can cause the pinion torelease and re-engage, which could cause ringgear and starter pinion damage.
Moving a vehicle with the starter and/or using thestarter to bump the engine for maintenance pro-cedures is strictly prohibited. Use of these meth-ods to bump the engine over or move the vehiclecan cause the pinion to release and re-engage,which could cause ring gear and starter piniondamage.
NOTICENever attempt to start any Cummins orMercedes-Benz engine using ether or any otherstarting fluid. Serious engine damage could re-sult.
1. Set the parking brake.
2. Turn the ignition switch to the ON/RUN position.The low air pressure and low oil pressure warn-ing lights (or messages) and buzzer operate untilthe engine is started and pressure is built up.
IMPORTANT: On vehicles equipped with an in-take air preheater, the INTAKE HEATER indica-tor stays on for a minimum of two seconds, re-gardless of coolant temperature. Wait until theINTAKE HEATER indicator goes out before at-tempting to start the engine.
NOTE: On vehicles equipped with a neutral startswitch, the transmission must be in neutral be-fore the engine can be started.
3. For manual transmissions, place the transmis-sion in neutral and depress the clutch pedal.
For automatic transmissions, make sure that thetransmission shift control is in Neutral (N), or ifso equipped, the Park (P) or Park Brake (PB)position.
IMPORTANT: Do not depress the throttle pedalwhile starting the engine.
4. Turn the ignition switch to the START position.After the engine starts, release the key.
NOTICEDo not crank the engine for more than 30 sec-onds at a time. Wait two minutes after each try toallow the starter to cool. Failure to do so couldcause starter damage.
NOTE: Some starters are equipped with op-tional overcrank protection. If overcranking oc-curs, a thermostat breaks the electrical circuit tothe starter motor until the motor has cooled.
5. Bring the engine up to operating speed graduallyas it warms up and develops stable oil pressure.
IMPORTANT: When the engine is started, ittakes a short time to build up a lubricating oilfilm between the shafts and bearings, and be-tween the pistons and cylinder walls. The oilpressure gauge indicates any drop in lubricatingoil pressure within 15 seconds of engine startup.See the applicable engine manufacturer’s op-erator’s manual for minimum idle oil pressurespecifications.
Starting After Extended Shutdown orOil ChangeNOTE: An engine in storage for an extendedperiod of time (over winter, for example) may
Engines
8.1
accumulate water in the oil pan. Oil diluted bywater cannot provide adequate bearing protec-tion at start-up. For this reason, change the en-gine oil and filters after extended storage.
Do the following steps after an oil change orafter the engine has been shut down for morethan three days:
1. Make sure the transmission is filled with the cor-rect type of fluid, as recommended by the trans-mission manufacturer.
2. Make sure the fuel tank is full. If air has enteredthe fuel system, prime the fuel system, using theengine manufacturer’s instructions.
3. If the engine is equipped with a fuel/water sepa-rator, drain off any accumulated water.
4. Check the drive belts to make sure they are ingood condition and properly adjusted. Replaceany drive belts that are cracked, worn, or glazed.
5. Check the turbocharger for signs of oil or ex-haust leaks. Correct any problems before startingthe engine.
6. Check the engine mounting bolts for tightness.Retighten them if necessary.
7. Make sure the battery cable connections areclean and tight. Check that the batteries arecharged.
8. Start the engine. See the "Engine Starting" head-ing in this chapter.
Engine OperationIMPORTANT: For cold-weather starting, enginebreak-in, and cold-weather operation, refer tothe Cummins or Mercedes-Benz engine manu-facturer’s operator’s manual, as applicable, fordetailed instructions.
Operating vehicles in areas where there are concen-trated flammable vapors (such as diesel, gasoline, orpropane fumes) can create a hazardous situation.These vapors can be drawn into the engine throughthe air intake, and cause engine overspeed. Be es-pecially cautious of low-lying or closed-in areas, andalways check for signs that flammable vapors maybe present.
DANGERDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut down the engine when in anarea where flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.
All diesel engines have been built to 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. Good operating practices, regularmaintenance, and correct adjustments are factorsthat will help to stay within the regulations.
Adequate maintenance of the engine, which is theresponsibility of the owner/operator, is essential tokeep the emission levels low.
The driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifthe engine malfunctions. If the driver doesn’t under-stand how the warning system works, an engineshutdown could occur, causing a safety hazard. SeeChapter 3 for information on the control panel forthese engines.
Follow the directions in the Cummins or Mercedes-Benz engine manufacturer’s operator’s manual andin this manual for trouble-free, economical vehicleengine operation.
NOTICEStop the engine at the first sign of malfunction.Almost all malfunctions give some warning to theoperator before significant damage occurs. Manyengines are saved because alert operators heedthe warning signs (sudden drop in oil pressure,unusual noises, etc.) and immediately shut downthe engine.
1. Cummins and Mercedes-Benz diesel engines aredesigned to operate successfully at full throttleunder transient conditions down to rated rpm.This is consistent with recommended operatingpractices.
2. Depending on the vehicle gearing, the postedspeed limit can sometimes allow operation in ei-ther of the top two gears; however, for improvedoperating efficiency (fuel economy and enginelife), operate in the top gear at reduced rpm
Engines
8.2
rather than in the next lower gear at the maxi-mum rpm.
3. Cruise at partial throttle whenever road condi-tions and speed requirements permit. This driv-ing technique permits operating within the mosteconomical power range of the engine.
4. When approaching a hill, open the throttlesmoothly to start the upgrade at full power, thenshift down as desired to maintain the optimumvehicle speed. The high torque of the enginemay permit topping some grades without shifting.
5. Engines are designed to operate over a widespeed range. More frequent shifting than neces-sary does not allow proper utilization of this flex-ibility. The driver who stays in top gear and usesthe wider speed range will achieve the best fueleconomy.
6. The Cummins and Mercedes-Benz engines areeffective as a brake on downhill grades, but takecare not to overspeed the engine going downhill.The governor has no control over engine speedwhen the engine is being pushed by the loadedvehicle.
NOTICEDo not allow the engine to exceed its governedspeed, or serious engine damage could result.
7. Never turn the ignition switch to the OFF positionwhile going downhill. With the engine still in gear,fuel pressure will build up against the shutdownvalve and can prevent it from opening when theignition switch is turned to the ON/RUN position.
8. Use a combination of brakes and gears to keepthe vehicle under control at all times, and tokeep the engine speed below the rated governedrpm.
9. Check the coolant temperature and oil pressuregauges frequently.
NOTICEContinuous operation below 140°F (60°C), above212°F (100°C), or with the oil pressure below 10psi (69 kPa), can damage the engine.
10. Do not idle the engine for more than 10 minutes.Long periods at low idle can damage the engine.
NOTE: Long periods of idling are not good foran engine because the combustion chamber
temperatures drop so low that the fuel may notburn completely. This will cause carbon to clogthe injector spray holes and piston rings, andcan result in stuck valves.
11. If the engine starts to overheat, reduce thepower output of the engine. Do one, or both, ofthe following: (1) Release pressure on the accel-erator pedal; (2) Shift to a lower gear. If the tem-perature does not return to normal, shut downthe engine.
High Idle OptionsNOTE: To operate the high idle options listedbelow, the vehicle must be stopped, the trans-mission shift lever placed in the Neutral (N) orPark (P) position, and the parking brake set.
IMPORTANT: Do not idle the engine for exces-sively long periods. The extreme heat can causethe bearings to seize or the oil seals to leak.
High Idle with Cruise Control1. Place the shift lever in Neutral (N) or Park (P)
and set the parking brake.
2. Press the cruise switch located on the dash tothe ON position. Press the RESUME switch toaccelerate the engine revolutions per minute(rpm) to the minimum set speed. To increase theengine rpm, press and hold the RESUME switch.To decrease the engine rpm, press and hold theSET switch.
NOTE: The rpm can also be increased by de-pressing the throttle pedal until the desired rpmis met, and then pressing the SET switch.
3. Disengage the cruise control by depressing theservice brake pedal, or by moving the ON/OFFswitch to the OFF position.
Voltage-Based Auto High Idle1. Place the shift lever in Neutral (N) or Park (P)
and set the parking brake.
2. The idle rpm will automatically increase when thevoltage drops below 12.2 volts. The rpm will in-crementally increase every five seconds until13.4 volts is achieved and maintained.
3. The Voltage-Based Auto High Idle system is dis-engaged by depressing the service brake pedal.
Engines
8.3
IMPORTANT: The Voltage-Based Auto High Idlesystem will not return to normal operation untilone of the following occurs: The parking brakeis depressed and released, the key switch isturned to the OFF position, or the transmissiongears are changed.
Engine ShutdownShut down the engine immediately if:
• the oil pressure gauge needle swings back andforth or falls sharply;
• engine power and rpm fall, even though theaccelerator pedal remains steady;
• the exhaust pipe gives off heavy smoke;
• the coolant and/or oil temperature climb abnor-mally;
• abnormal sounds suddenly occur in the engineor turbocharger.
IMPORTANT: Bearings and seals in the turbo-charger are subjected to the high heat of com-bustion exhaust gases. While the engine is run-ning, this heat is carried away by oil circulation,but if the engine is stopped suddenly, the turbo-charger temperature may rise as much as 115°F(46°C).
1. With the vehicle stopped, place the transmissionin Neutral (N), or if so equipped, the Park (P) orPark Brake (PB) position.
2. Set the parking brake.
3. Idle the engine for three to five minutes beforeshutting it down. This allows the lubricating oiland the coolant to carry heat away from thecombustion chambers, bearings, shafts, etc. Thisis especially important with turbocharged en-gines. The extreme heat can cause bearings toseize or oil seals to leak.
NOTE: Long periods of idling are not good foran engine because the combustion chambertemperatures drop so low that the fuel may notburn completely. This will cause carbon to clogthe injector spray holes and piston rings, andcan result in stuck valves.
NOTICEDo not rev the engine before shutting it down.Revving the engine before shutdown will damagethe turbocharger.
4. Shut down the engine by turning the ignitionswitch to the OFF position.
Engines
8.4
9
Exhaust AftertreatmentSystems
Aftertreatment System, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5EPA07 Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Aftertreatment System, EPA10and Newer EnginesEngines manufactured between January 1, 2010 andDecember 31, 2012 meet EPA10 requirements. En-gines manufactured from January 1, 2013 meetNHTSA and EPA 2014 fuel efficiency and green-house gas emission standards (GHG14) require-ments. Engines manufactured from January 1, 2016meet NHTSA and EPA 2017 fuel efficiency andgreenhouse gas emission standards (GHG17) re-quirements.
Model year 2013 and later vehicles meet additionalrequirements as specified by GHG14 requirements.Model year 2017 and later vehicles meet similar re-quirements as specified by GHG17 requirements.These vehicles are equipped with components thatincrease fuel efficiency and reduce GHG emissions.
IMPORTANT: 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.
Principles of OperationThe 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 aftertreat-ment system (ATS) with an aftertreatment device(ATD) and Selective Catalytic Reduction (SCR) tech-nology to reduce NOx downstream of the engine.
NOTICEFollow these guidelines for engines that complywith EPA10 or newer regulations, or damage mayoccur to the ATD and the warranty may be com-promised.
• 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 CK-4 oil.
• Use only certified diesel exhaust fluid (DEF)in the DEF tank.
NOTICEFA-4 engine lube oil is available, but is not com-patible with all engines. See the engine manufac-turer’s operation manual to determine if FA-4 oilcan be used in your vehicle’s engine. Failure todo so could lead to engine damage and is notwarrantable.
IMPORTANT: Using non-specification fuels oroils can lead to shortened diesel particulate filter(DPF) cleaning or replacement intervals. Forexample, using CK-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.
After exhaust gasses leave the engine, they flow intothe ATS. First they flow into a two-part ATD, com-prised of a diesel oxidation catalyst (DOC), and adiesel particulate filter (DPF). The DPF traps sootparticles, then exhaust heat converts the soot to ashin the DPF, in a process called regeneration (regen).The harder an engine works, the better it disposes ofsoot. When the engine is running under load andregen occurs without input, it is called passive regen.If the engine isn’t running hot enough, the electroniccontrols may initiate an active regen, whereby extrafuel is injected into the exhaust stream before thediesel particulate filter, to superheat the soot trappedin the filter and burn it to ash. Both types of regenoccur without driver input.
WARNINGActive regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (816°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet. See Regen-Inhibit Switch laterin this chapter for instructions on preventing au-tomatic regen if necessary.
Exhaust Aftertreatment Systems
9.1
The exhaust temperature can remain high evenafter the vehicle has stopped. When stopping thevehicle shortly after an automatic regen, ensurethe exhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byexposure to high heat.
Operating at reduced engine load will allow soot toaccumulate in the DPF. When this occurs, the DPFlamp illuminates, indicating that a regen must be per-formed, and the driver must either bring the vehicleup to highway speed to increase the load, or parkthe vehicle and initiate a parked regen. See ParkedRegen, later in this chapter for instructions.
NOTE: Beginning September 2, 2014 somechassis are equipped with an option that allowsa regen to occur at 0 or 1 mph (0 or 2 km/h),instead of the standard 5 mph (8 km/h) thresh-old. Based on the engine programming param-eter, if a regen occurs and vehicle speed is re-duced to either 0 or 1 mph (0 or 2 km/h), theregen process will not be cancelled.
If the vehicle is programmed for the 0 mph (0km/h) parameter, vehicle speed can be reducedto 0 mph (0 km/h) and the regen will continue.Vehicles with this option are equipped with aregen inhibit switch to cancel the regen ifneeded.
If the vehicle is programmed for the 1 mph (2km/h) parameter, vehicle speed can be reducedto 1 mph (2 km/h) and the regen will continue. Ifvehicle speed is less than 1 mph (2 km/h), theregen will be cancelled.
After the exhaust stream passes through the ATD, itflows through another canister housing the SCR de-vice. A controlled quantity of DEF is injected into theexhaust stream, where heat converts it to ammonia(NH3) gas. This mixture flows through the SCR de-vice, where the ammonia gas reacts with the NOx inthe exhaust, to produce harmless nitrogen (N2) andwater vapor (H2O), which then exits out of the tail-pipe.
ATS Warning LampsWarning lamps in the driver’s message center alertthe driver of situations with the ATS.
• An illuminated DPF lamp indicates a regen isneeded. See Fig. 9.1.
• A slow, 10-second flashing of the HEST lampalerts the driver that a parked regen is in prog-ress, but the exhaust temperatures are stillrelatively cool. See Fig. 9.2. It also indicatesthat the high-idle speed is being controlled bythe engine software, not the driver.
• A steadily illuminated HEST lamp alerts theoperator of high exhaust temperatures whenvehicle speed is below 5 mph (8 km/h) while itis performing an automatic regen, and during aparked regen. See Fig. 9.2.
Parked Regen
DANGERDuring parked regeneration, exhaust tempera-tures are very high, and could cause a fire, heatdamage to objects or materials, or personal in-jury to persons near the exhaust outlet.
Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away from
09/25/2006 f610815a
Fig. 9.1, Diesel Particulate Filter (DPF) Status Lamp
09/25/2006 f610816a
Fig. 9.2, High Exhaust System Temperature (HEST)Lamp
Exhaust Aftertreatment Systems
9.2
structures, trees, vegetation, flammable materi-als, and anything else that may be damaged orinjured by prolonged exposure to high heat.
A reference label is included with the driver’s docu-mentation package initially in the glove box, that ex-plains the ATS warnings, and actions required toavoid further engine protection sequences. SeeFig. 9.3.
The regen switch, located on the dash, is used toinitiate a parked regen of the aftertreatment device.See Fig. 9.4.
NOTE: The regen switch can initiate a parkedregen only when the DPF lamp is illuminated(because the engine software is signaling for aparked regen).
The regen-inhibit switch (optional when available)provides additional control over the aftertreatmentregeneration process. Depressing the regen-inhibit
switch will prevent a regen from occurring during adrive cycle. After the vehicle has been shut downand restarted, regens will occur normally unless theinhibit switch is pressed again. See Fig. 9.5.
f080147
EXHAUST AFTERTREATMENT SYSTEM INFORMATION
Switch.
Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended
Filter is reaching
Bring vehicle tohighway speeds to
Filter RegenerationNecessary
Filter is nowreaching maximumcapacity.
To avoid enginederate bring vehicle
Parked RegenerationRequired − EngineDerate
Filter has reachedmaximum capacity.
Vehicle must beparked and a Parked
Parked Regeneration Required −Engine Shut Down
Filter has exceededmaximum capacity
Vehicle must be parked and aParked Regeneration or Service
(Solid) (Flashing) (Flashing)
CHECK CHECK
(Flashing)
INDICATORLAMP(S)
Indicator LampMessage(s)
Diesel ParticulateFilter Condition
Required Action
capacity. .
STOP
See Engine Operator’s Manual for complete Regeneration Instructions.
allow for an AutomaticRegeneration orperform a ParkedRegeneration.
to highway speedsto allow for anAutomaticRegeneration orperform a ParkedRegeneration assoon as possible.
Regeneration mustbe performed −engine will beginderate.
Regeneration must be performed.Check engine operator’s manualfor details −engine will shut down.
For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.
06/29/2009
24−01583−000B
WARNING
HEST (High ExhaustSystem Temperature)
Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.
A regeneration is inprogress.
Flashing
Solid
Fig. 9.3, Exhaust-Aftertreatment Warnings Reference Label
f61119906/19/2012
Fig. 9.4, Regen Switchf61094407/30/2009
Fig. 9.5, Regen Inhibit Switch (optional when available)
Exhaust Aftertreatment Systems
9.3
To initiate a parked regeneration, perform the follow-ing steps.
1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).
2. Set the parking brake. If the parking brake wasalready set, you must release it, then set itagain.
For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.
If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.
IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.
3. Press and hold the regen switch for 4 seconds.The engine will increase rpm and initiate theregen process.
4. After the parked regen has run for 20 to 40 min-utes, the regen cycle is completed. The engineidle speed will drop to normal, and the vehiclemay be driven normally. The HEST lamp may beilluminated, but will go out when the vehiclespeed exceeds 5 mph (8 km/h), or the systemhas cooled to normal operating temperature.
5. To stop a parked regen at any time during theprocess, engage the clutch, brake, or throttlepedal, or turn off the engine.
Shorting PlugNOTE: The DPF lamp must be illuminated be-fore the shorting plug will initiate a parkedregen. See Fig. 9.1.
The shorting plug is used to initiate a parked regenof the ATD. The shorting plug is located under thedash, next to the steering column. Mounting locationsvary. See Fig. 9.6.
To initiate a parked regeneration, perform the follow-ing steps.
1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).
2. Set the parking brake. If the parking brake wasalready set, it must be released, then set again.
For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.
If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.
IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.
3. Disconnect the shorting plug, as follows.
3.1 Slide the secondary red lock away fromthe white cover. See Fig. 9.6, Ref. 2.
3.2 Push the primary lock in. See Fig. 9.6,Ref. 1.
3.3 Pull the plug apart. See Fig. 9.6, Ref. 3.
4. Wait four seconds.
5. Connect the shorting plug.
6. Engine rpm will rise, and initiate the regen pro-cess.
7. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed will drop to nor-mal and the vehicle can be driven normally. TheHEST lamp may be illuminated, but will go outwhen the vehicle speed exceeds 5 mph (8 km/h),or the system has cooled to normal operatingtemperature. See Fig. 9.2. The DPF lamp willshut off.
f54520702/11/2009
1
2
3
1. Primary Lock2. Secondary "Red" Lock
3. Plug
Fig. 9.6, Shorting Plug
Exhaust Aftertreatment Systems
9.4
8. To stop a parked regen at any time during theprocess, engage the clutch, service brake, oraccelerator pedal, or turn off the engine.
DPF MaintenanceEventually ash will accumulate in the DPF and thefilter will require servicing. DPF servicing must beperformed by an authorized technician, following theengine manufacturer’s instructions. A record must bemaintained for warranty purposes, that includes:
• date of cleaning or replacement;
• vehicle mileage;
• particulate filter part number and serial number.
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.
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 locatedbetween the ATS and the fuel tank, or an optionallocation forward of the fuel tank. The DEF tank has a19 mm filler neck inlet that prevents the hose from adiesel outlet from being inserted, and has a blue capfor easy identification.
The DEF tank will require filling a minimum of ap-proximately every second diesel refuel depending onthe DEF tank capacity. The S2 Chassis has an 11.5-gallon tank capacity. DEF consumption is approxi-mately 2% of fuel consumption, dependent on ve-hicle operation. For every 50 gallons of diesel fuelconsumed, approximately 1 gallon of DEF will beconsumed.
Fuel/DEF GaugeThe fuel and DEF levels are measured in a dual pur-pose fuel/DEF gauge. See Fig. 9.7.
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 when the DEF tank is nearempty, and a DEF lightbar that indicates the level inthe DEF tank as follows.
• Four bars illuminated green—Between 75%and 100% full
• Three bars illuminated green—Between 50%and 75% full
• Two bars illuminated green—Between 25%and 50% full
• One bar illuminated green—Between approxi-mately 10% and 25% full
• One bar illuminated amber—DEF low, refillDEF
• One bar flashing red—DEF empty, refill DEF
DEF Warnings and Engine LimitsIMPORTANT: Ignoring the DEF warning lampsand not refilling the DEF will result in limited en-gine power with a speed limit of 5 mph (8 km/h)eventually being applied. See the Cummins Op-eration and Maintenance Manual for further in-formation.
Exhaust Aftertreatment Systems
9.5
DEF Level Low—Initial WarningWhen the DEF level reads low the following warningsstrongly encourage the driver to refill the DEF tank.See Fig. 9.8.
• The CHECK engine lamp flashes for 30 sec-onds when the vehicle is started.
• The DEF warning lamp illuminates.
• One bar of the DEF-level lightbar illuminatessolid amber.
The DEF tank must be filled to cancel the warningsequence.
DEF Level Low—Critical WarningWhen the DEF level reads low, the following warn-ings are activated. See Fig. 9.9.
• The CHECK engine lamp flashes for 30 sec-onds when the vehicle is started.
• The DEF warning lamp illuminates.
• One bar of the DEF-level lightbar flashes red.
Engine performance is limited, with progressivelyharsher engine power limits applied.
The DEF tank must be filled to cancel the warningsequence.
11/08/2010 f611037
B
1/2ULTRA LOW SULFURDIESEL FUEL ONLY
E F
DEF
FE
1/2ULTRA LOW SULFURDIESEL FUEL ONLY
E F
DEF
FE
1/2ULTRA LOW SULFURDIESEL FUEL ONLY
E F
DEF
FE
A C
1 2
A. Green bars—DEF level indicators.B. One bar illuminated amber—DEF low, refill DEF.
C. One bar flashing red—DEF empty, refill DEF.
1. Low Fuel Warning Lamp (amber at 1/8 tank of fuel) 2. Low DEF Warning Lamp
Fig. 9.7, Fuel/DEF Gauge
A
B
07/09/2009 f470537
A. DEF Warning Lamp (illuminates constantly)B. DEF-Level Lightbar (1 bar solid amber)
Fig. 9.8, DEF Level Low—Initial Warning
A
B
07/09/2009 f470537
A. DEF Warning Lamp (illuminates constantly)B. DEF-Level Lightbar (1 bar flashing red)
Fig. 9.9, DEF Level Low—Critical Warning
Exhaust Aftertreatment Systems
9.6
DEF EmptyWhen the DEF level reads empty, the following warn-ings are activated. See Fig. 9.10.
• One bar of the DEF-level lightbar flashes red.
• The DEF warning lamp flashes.
• The CHECK engine lamp illuminates.
Engine performance is limited, with progressivelyharsher engine power limits applied.
The DEF tank must be filled to cancel the warningsequence.
DEF Level Empty and IgnoredIf the empty warning is ignored and the DEF is notrefilled, the DEF warning lamp flashes, one bar ofthe DEF-level lightbar flashes red, and the red STOPengine lamp illuminates in addition to the CHECKengine warning lamp. See Fig. 9.11.
If the DEF tank is not refilled, a 5 mph (8 km/h)speed limit will be applied after the next engine shut-down, or while parked and idling.
DEF Quality or SCR Tampering
NOTICEOnce contaminated DEF or tampering has beendetected in the SCR system, the vehicle must betaken to an authorized service center to checkthe SCR system for damage, and to deactivatethe warning lamp and engine limits.
If contaminated DEF or tampering is detected, theDEF warning lamp flashes, and engine power is lim-ited with progressively harsher limits applied. If the
fault is not corrected, the STOP engine lamp illumi-nates and a 5 mph (8 km/h) speed limit is appliedafter the next engine shutdown, or while parked andidling. See Fig. 9.11.
EPA07 Aftertreatment System(ATS)All on-road diesel engines built after December 31,2006, (EPA07 engines) must meet strict new guide-lines for reduced exhaust emissions of particulatematter and nitrogen oxides (NOx). NOx is limited tojust over 1 gram per brake horsepower hour (g/bhp-hr) and particulate matter cannot exceed 0.01 g/bhp-hr.
EPA07-compliant engines require ultralow-sulfur die-sel (ULSD) fuel, and they should never be run onfuel with sulfur content higher than 15 ppm. In addi-tion, they require low-ash engine oil. The followingguidelines must be followed or the warranty may becompromised.
• Use ultralow-sulfur diesel (ULSD) fuel with 15ppm sulfur content or less, based on ASTMD2622 test procedure.
• Do not use fuel blended with used engine lubeoil or kerosene.
• Engine lube oil must have a sulfated ash levelless than 1.0 wt %; meeting the API CJ-4 indexspecifications.
IMPORTANT: Using non-specification fuels oroils can lead to shortened Diesel Particulate Fil-ter (DPF) cleaning or exchange intervals. Forexample, using CI-4+ oil with 1.3% sulfated ash
A
B
07/09/2009 f470538
NOTE: Engine performance is limited.A. DEF Warning Lamp (flashing)B. DEF-Level Lightbar (1 bar flashing red)
Fig. 9.10, DEF Empty Warning
A
B
11/18/2010 f470540b
NOTE: The STOP engine, CHECK engine, and DEFlamps illuminate, engine power is limited, speed limit of5 mph (8 km/h).A. DEF Warning Lamp (flashing)B. DEF-Level Lightbar (1 bar flashing red)
Fig. 9.11, DEF Empty and Ignored Warning
Exhaust Aftertreatment Systems
9.7
(30% more ash content) may result in the needfor DPF cleaning or exchange 20 to 30% soonerthan would normally be required.
The "exhaust system" in EPA07-compliant vehicles iscalled the aftertreatment system (ATS). The ATS var-ies according to engine manufacturer and vehicleconfiguration, but instead of a muffler, an aftertreat-ment system has a device that outwardly resemblesa muffler, called the aftertreatment device (ATD).
IMPORTANT: See your engine operation manualfor complete details and operation of the after-treatment system.
Inside the ATD, the exhaust first passes over the die-sel oxidation catalyst (DOC), then it passes throughthe DPF, which traps soot particles. If exhaust tem-perature is high enough, the trapped soot is reducedto ash in a process called passive regeneration(regen). Passive regeneration occurs as the vehicleis driven normally under load; the driver is not evenaware that it is happening. The harder an EPA07 en-gine works, the better it disposes of soot, as the ex-haust heat alone is enough to burn the soot to ash.Over the course of a workday, however, passive re-generation cannot always keep the ATD filter clean,so the filter must undergo active regeneration. Inactive regeneration, extra fuel is injected into the ex-haust stream to superheat the soot trapped in theDPF and turn it to ash. Active regeneration happensonly when the vehicle is moving above a certainspeed, determined by the engine manufacturer. Con-sult manufacturers’ documentation for details.
Both active and passive regeneration happen auto-matically, without driver input.
Only when operating conditions do not allow for ATDfilter cleaning by at-speed active or passive regen-eration, the vehicle may require a driver-activatedparked regeneration. The vehicle must be standingstill, and the driver must initiate parked regen. Com-pleting a parked regen takes 20 minutes to an hour,depending on ambient conditions.
DANGERDuring parked regeneration, exhaust tempera-tures are very high, and could cause a fire, heatdamage to objects or materials, or personal in-jury to persons near the exhaust outlet.
Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-
als, and anything else that may be damaged orinjured by prolonged exposure to high heat.
The warning lamps in the driver message center alertthe driver of a regen in progress, of high exhausttemperatures, of the need to perform a parked regeneither soon or immediately, and of an engine faultthat affects the emissions.
A slow (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 driver.
A steadily illuminated HEST lamp alerts the operatorof high exhaust temperature during the regenerationprocess, if vehicle speed is below 5 mph (8 km/h).See Fig. 9.2. The HEST lamp does not indicate theneed for any kind of vehicle or engine service; it onlyalerts the vehicle operator of high exhaust tempera-tures. Make sure the engine exhaust pipe outlet isnot directed at any person, or at any surface or ma-terial that will melt, burn, or combust.
WARNINGWhen the HEST lamp is on, be certain that theexhaust pipe outlet is not directed at combustiblematerial or toward anyone. To do so could causedamage to the vehicle and serious personal in-jury to others.
WARNINGActive regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (816°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet. See Regen-Inhibit Switch laterin this chapter for instructions on preventing au-tomatic regen if necessary.
The exhaust temperature can remain high evenafter the vehicle has stopped. When stopping thevehicle shortly after an automatic regen, ensurethe exhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byexposure to high heat.
IMPORTANT: Due to the high exhaust tempera-ture during the regen process, a diffuser is usedto reduce the temperature at the exhaust pipeoutlet. See Fig. 9.12. If the diffuser is damaged,
Exhaust Aftertreatment Systems
9.8
it must be replaced to ensure proper operationof the vehicle and to reduce the possibility ofdamage or injury.
A steadily illuminated yellow DPF lamp indicates aregen is required soon. Bring the vehicle to highwayspeeds to allow for an active regen, or a parkedregen should be scheduled for the earliest conve-nient time. See Fig. 9.1.
IMPORTANT: Failure to regen could cause en-gine problems, including derate or loss ofpower. As soon as allowed after the DPF lampilluminates, maintain highway speeds to allowautomatic regeneration, or park the vehicle in asafe location and perform a parked regen.
A DPF lamp blinking at the same time as a steadilyilluminated yellow Check Engine lamp indicates thata parked regen must be performed immediately, oran engine derate will occur. If the red Stop Enginelamp illuminates with the blinking DPF lamp and theyellow Check Engine lamp, a parked regen mustoccur or an engine shutdown will occur. Park the ve-hicle and perform a parked regen. See Fig. 9.13 andFig. 9.4.
The DPF regen switch, located on the dash, mayhave three selectable positions:
• Request Regeneration
• Default (can include appropriate normal statecondition—either in an automatic regenerationor inhibit state)
• Inhibit regeneration (optional when available)
NOTE: The regen switch can start a regen onlywhen at least one of two conditions exists: ei-ther the DPF lamp is lit, or the engine softwarecalls for it. If neither of those conditions exist,the regen switch cannot cause a regen to hap-pen.
The function of the switch will vary by the enginemake and model in the vehicle. See the engine op-eration manual for switch operation details.
When diesel particulate filter servicing is needed, itmust be performed by an authorized technician, anda record must be maintained for warranty purposes.The record must include:
• date of cleaning or replacement
• vehicle mileage
• particulate filter part number and serial number
A steadily illuminated Malfunction Indicator Lamp(MIL) indicates an engine fault that affects the emis-sions. The MIL lamp applies to the Mercedes-Benzengine only. See Fig. 9.14.
High-Soot-Load Idle ShutdownExtended idle operation can cause soot to accumu-late in the DPF, which can eventually trigger an ECMfault, cause the Stop Engine lamp to illuminate, andrequire replacement of the DPF. The High-Soot-Load
09/11/2007 f490294
Fig. 9.12, Exhaust Diffuser
07/09/2009 f6110361 2 3
CHECK STOP
1. Malfunction Indicator Lamp (MIL)2. Check-Engine Lamp3. Stop-Engine Lamp
Fig. 9.13, Engine Protection Lamps
09/25/2006 f610814a
Fig. 9.14, Malfunction Indicator Lamp (MIL)
Exhaust Aftertreatment Systems
9.9
Idle Shutdown feature (if equipped), determines if theextended engine idling needs to be shut down beforethere is a triggering of the stop engine warning.
The High-Soot-Load Idle Shutdown feature monitorsthe soot load during the idle or high-idle operation. Ifhigh-soot-load occurs, the DPF lamp will illuminate,then the Check Engine lamp will flash for 30 sec-onds, before the engine shuts down.
Exhaust Aftertreatment Systems
9.10
10
TransmissionDriving Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Allison On-Highway Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Eaton® Fuller® Straight-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Driving PrecautionsThe vehicle operator should use care when acceler-ating or downshifting on slippery road surfaces. Sud-den acceleration or engine braking, caused by shift-ing to a lower gear range, can result in a loss ofvehicle control. This is very important on snow or icecovered roads. See Chapter 13 for information onbrake operation.
If the vehicle is stuck in sand or mud, do not attemptto pull the vehicle out under its own power. Requestprofessional towing assistance.
NOTICEDo not attempt to rock the vehicle. If rocking thevehicle is necessary, even at low speeds, it maycause engine overheating, axle damage, trans-mission damage or failure, or tire damage.
Do not coast the vehicle in neutral. Severe trans-mission damage may result and the vehicle willnot have the benefit of engine braking.
WARNINGTo reduce the risk of personal injury, beforegoing down a steep or long grade, reduce speedand downshift the transmission. Do not hold thebrake pedal down too long or too often whilegoing down a steep or long grade. This couldcause the brakes to overheat, reducing their ef-fectiveness. As a result, the vehicle will not slowdown at the usual rate. Failure to take thesesteps could result in loss of vehicle control.
To avoid skidding on slippery roads, do not downshiftinto L (low) at speeds above 20 mph (32 km/h).
On slippery surfaces, avoid quick movements of thesteering wheel. Decrease speed and allow for extrastopping distance required by these conditions. Fornon-ABS brakes, apply the brakes by pumping thepedal steadily and evenly to avoid wheel lock-up andloss of vehicle control.
Avoid driving through flooded areas unless you aresure the water is no higher than the bottom of thewheel rims. Drive through slowly. Allow adequatestopping distance since wet brakes do not grip well.After driving through water, gently apply the brakesseveral times while the vehicle is moving slowly todry the brakes.
When driving on icy or graveled surfaces, reducespeed. Avoid sharp turning maneuvers.
Allison On-HighwayTransmissionsThe Allison on-highway transmissions are fully auto-matic and include the 2100 Series, B210 Series,2200 Series, B220 Series, 2500 Series, 3000 Series,and B300 Series. Refer to www.allisontransmis-sion.com for additional information.
Safety Precautions2000 and B200 Series
WARNINGDo not leave the vehicle unattended with the en-gine running. If you leave the vehicle and the en-gine is running, the vehicle can move suddenly,which could result in personal injury or propertydamage.
On vehicles with Allison 2000 or B200 series trans-missions, do the following steps if you have to leavethe vehicle with the engine running (for example,when checking the transmission fluid).
Without Auto-Apply Parking Brake1. Bring the vehicle to a complete stop using the
service brake.
2. Ensure that the engine is at low idle rpm.
3. Put the transmission in neutral.
4. Apply the parking brake, and make sure it isproperly engaged.
5. Chock the rear tires and take any other stepsnecessary to keep the vehicle from moving.
With Auto-Apply Parking Brake1. Bring the vehicle to a complete stop using the
service brake.
2. Ensure that the engine is at low idle rpm.
3. Put the transmission in PB (auto-apply parkingbrake).
4. Apply the parking brake (if so equipped), andmake sure it is properly engaged.
5. Chock the rear tires and take any other stepsnecessary to keep the vehicle from moving.
Transmission
10.1
Range Inhibit Indicator, 2000 andB200 SeriesA RANGE INHIBIT indicator is a standard feature ofthe 2000 and B200 series transmissions. TheRANGE INHIBIT indicator comes on to alert thedriver that transmission operation is being inhibitedand that the range shifts being requested by thedriver may not occur. When certain operating condi-tions are detected by the transmission control mod-ule (TCM), the controls will lock the transmission inthe current operating range.
Shift inhibits occur under the following conditions:
• Shifts from neutral to reverse or from neutral toa forward range when the engine is above idle,greater than 900 rpm.
• Forward/reverse directional shifts are typicallynot permitted if appreciable output shaft speedis detected.
• When some types of unusual transmission op-erating conditions are detected by the TCM,the TCM temporarily limits transmission opera-tion until the vehicle can be driven to a servicelocation. When this type of situation is de-tected, the TCM will lock the transmission in asafe gear range.
• The TCM will prevent shifts from park or neu-tral to another range when auxiliary equipmentis in operation.
• If a shift from a higher to a lower gear causesthe engine to overspeed.
Operating Instructions, 2000 andB200 Series Transmissions2000 and B200 series transmissions are electroni-cally controlled. The shift selector provides four for-ward ranges and one reverse range. A T-handle shiftcontrol is used by the driver to select the ranges.See Fig. 10.1.
P (Park)Use park, if so equipped, when turning the engine onor off, to check vehicle accessories, or to operate theengine in idle for longer than 5 minutes. This positionplaces the transmission in neutral and engages thepark pawl of the transmission.
NOTE: This does not apply the parking brake.
The park pawl is standard on the 2200 seriestransmission. The park pawl effectively groundsthe transmission output shaft, thereby prevent-ing rotation of the driveline. Provided the vehicleis stationary, selecting P (park) on the shift se-lector, if so equipped, places the transmission inneutral and engages the park pawl.
PB (Auto-Apply Parking Brake, optionalon 2000 and B200 Series)The auto-apply parking brake places the transmis-sion in neutral and applies the parking brake.
09/21/2012 f270165
Fig. 10.1, T-Handle Shifter (standard)
Transmission
10.2
R (Reverse)Reverse is used to back the vehicle. When the selec-tor is in reverse, the reverse warning signal willsound. Always bring the vehicle to a complete stopbefore shifting from a forward range to reverse, orfrom reverse to a forward range.
Do not idle in reverse for more than 5 minutes. Whentime at idle exceeds 5 minutes, select N (neutral), orif so equipped, P (park) or PB (auto-apply parkingbrake).
NOTE: The shift into reverse may not succeed ifa range inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.
N (Neutral)The neutral position places the transmission in neu-tral. When neutral is selected, the vehicle servicebrakes, parking brake, or emergency brake must beapplied. Selecting neutral does not apply vehiclebrakes unless an auxiliary system to apply the park-ing brake is installed.
This position is used when starting the engine andfor stationary operation. It is also used to shut downthe vehicle when P (park) or PB (auto-apply parkingbrake) are not available on the shifter. In this case,the parking brake must be applied.
Do not let the vehicle coast in neutral. If the vehicleis allowed to coast in neutral, the engine brake willnot work and the driver could lose control of the ve-hicle.
D (Drive)In the drive position, the transmission will initially gointo first range when drive is selected. As vehiclespeed increases, the transmission will upshift auto-matically through each available range up to fourth orfifth range. As the vehicle slows, the transmission willdownshift automatically.
When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, thetransmission may upshift to the next higher range, ifthe engine is exceeding its governed speed in thelower range.
NOTE: The shift into drive may not succeed if arange inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.
3 and 2 (Third and Second Ranges)Use the third or second range for heavy city trafficand for braking on steeper downgrades.
L (Low Range)Use low range when pulling through mud or deepsnow, when maneuvering in tight spaces, or whendriving up or down very steep grades. Low rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect.
NOTE: To have the transmission select theseranges automatically, leave the selector lever inD (drive).
Operating Instructions, 3000 andB300 SeriesThe Allison 3000 and B300 series transmissions areelectronically controlled and have a push-button shiftcontrol that provides five or six forward ranges andone reverse range. The push-button shift selectorhas R (reverse), N (neutral), and D (drive) ranges, upand down arrows, a mode button, and a digital dis-play. See Fig. 10.2.
R (Reverse)Press the R button to select reverse. The digital dis-play will show R when reverse is selected. Always
1
2
3
f61080407/27/2006
4
1. Digital Display2. Mode Identification
Label
3. Mode Indicator LED4. Mode Button
Fig. 10.2, Push-Button Shift Selector
Transmission
10.3
bring the vehicle to a complete stop and let the en-gine return to idle before shifting from a forwardrange to reverse, or from reverse to a forward range.
NOTICEExtended idling in reverse may cause transmis-sion overheating and damage.
Do not idle in reverse for more than 5 minutes. Se-lect neutral when time at idle exceeds 5 minutes.
NOTE: The shift into reverse may not succeed ifa range inhibitor is active. When reverse is se-lected, always be sure that R is not flashing.
N (Neutral)
WARNINGWhen starting the engine, make sure that the ser-vice brakes are applied. Failure to apply the ser-vice brakes may result in unexpected vehiclemovement, which could cause severe personalinjury or death. Failure to apply the vehicle park-ing brakes when the transmission is in neutralmay allow the vehicle to move unexpectedly, pos-sibly causing property damage or personal injury.
Press the N button to select neutral. The digital dis-play will show N when neutral is selected. It is notnecessary to press neutral before starting the ve-hicle. The electronic control unit (ECU) or TCM auto-matically places the transmission in neutral at start-up.
When neutral is selected, the vehicle service brakes,parking brake, or emergency brake must be applied.Selecting neutral does not apply vehicle brakes un-less an auxiliary system to apply the parking brake isinstalled.
WARNINGDo not coast in neutral. Coasting in neutral cancause an accident, possibly resulting in severepersonal injury or death.
Do not let the vehicle coast in neutral. If the vehicleis allowed to coast in neutral, the engine brake willnot work and the driver could lose control of the ve-hicle.
Always select neutral before turning off the engine.
D (Drive)When the D button is pushed, the highest forwardrange will appear in the display. The transmission willnormally go into first range when drive is selected(except for those units programmed to start in sec-ond range). As vehicle speed increases, the trans-mission will upshift automatically through each range.As the vehicle slows, the transmission will downshiftautomatically.
NOTICEDo not idle in drive for more than 5 minutes. Ex-tended idling in drive may cause transmissionoverheating and damage. Always select neutral iftime at idle is longer than 5 minutes.
NOTE: The shift into drive may not succeed if arange inhibitor is active. When drive is selectedalways be sure that D is not flashing.
5, 4, 3, and 2 (Fifth, Fourth, Third, andSecond Ranges)Occasionally, road conditions, load, or traffic condi-tions will make it desirable to restrict automatic shift-ing to a lower range. Lower ranges provide greaterbraking for going down grades. The lower the range,the greater the braking effect.
Push the up or down arrows on the push-button shiftselector to select individual forward ranges. The digi-tal display will show the selected range. When alower range is selected, the transmission may notdownshift until the vehicle speed or engine RPM (en-gine governed speed) is reduced.
WARNINGWhen going downhill, use a combination ofdownshifting, braking, and other retarding de-vices to control vehicle speed and the engine’srated governed speed. Failure to do so could re-duce vehicle braking, possibly causing loss ofvehicle control and resulting in personal injury orproperty damage.
When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, if theengine governed speed is exceeded in the lower
Transmission
10.4
range, the transmission may upshift to the nexthigher range.
1 (First Range)Use the first range when pulling through mud ordeep snow, when maneuvering in tight spaces, orwhen driving up or down steep grades. First rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect. Push the downarrow until the first range appears on the display.
Up and Down ArrowsWhen a lower range is desired, after D has beenpressed, press the down arrow until the desiredrange is shown on the display. Pressing the downarrow continuously causes the range position to con-tinue to go down until the button is released or thelowest range is attained.
When the transmission is in drive and the downarrow has the transmission in a lower range position,press the up arrow to shift to a higher selector posi-tion. Continuously pressing the up arrow causes therange position to continue to rise until the button isreleased or the highest available position is attained.
Continuously pressing the up or down arrows doesnot override the transmission automatic shifting op-eration. If a higher or lower position is selected, thetransmission continues shifting through the rangesaccording to the vehicle operating characteristicsuntil the highest or lowest selection position isreached.
Mode ButtonThe MODE button starts a specialized input or outputfunction that has been previously programmed intothe ECU or TCM. Pressing the MODE buttonchanges transmission operation for a specific func-tion.
Mode Indicator LEDWhen the MODE button is pressed, the mode indica-tor LED illuminates. A mode identification label, lo-cated above the MODE button, identifies the functionassociated with a mode change.
Digital DisplayThe dual digital display shows both the selectedrange (SELECT) and actual range attained (MONI-TOR). The single digital display shows the selectedrange.
Oil Level SensorAllison 3000 and B300 Series transmissions have anelectronic oil level sensor to read fluid level informa-tion. The fluid level diagnostic will display whetherthe oil level is OK, too low, or too high. It will alsodisplay a default code and indicate if the precondi-tions (of receiving the fluid level information) are notmet.
IMPORTANT: Maintain the proper fluid level atall times. If the fluid level is too low, the con-verter and clutch do not receive an adequatesupply of fluid. If the level is too high, the trans-mission may shift erratically or overheat.
To access the oil level display mode, park the vehicleon a level surface, shift to N (neutral), apply theparking brake, and idle the engine. Then simultane-ously press both the up and down arrows once. Theoil level will display at the end of a two-minute count-down.
Diagnostic CodesDiagnostic codes are numerical indications relating toa malfunction in transmission operation. These codesare logged in the TCM/ECU memory. The most se-vere or most recent code is listed first. A maximum offive codes (numbered d1-d5) may be listed inmemory at one time. If the mode indicator LED isilluminated, the displayed code is active. If it is notilluminated, the displayed code is not active.
NOTE: During normal operation, an illuminatedmode indicator LED signifies the specializedmode operation is in use.
To enter diagnostics mode, first park the vehicle andapply the parking brake. Then simultaneously pressboth the up and down arrows twice.
Eaton® Fuller® Straight-ShiftTransmissionsRefer to the Eaton website for additional information,www.roadranger.com.
General Information, Straight-ShiftEaton Fuller 5-speed FS models are fully synchro-nized. They have five forward speeds and one re-verse. See Fig. 10.3 for the shift pattern.
Transmission
10.5
Eaton Fuller 6-speed FS and FSO models are fullysynchronized. They have six forward speeds and onereverse. See Fig. 10.4 for the shift pattern.
These transmissions are designed for use with on-highway, fuel economy engines where a minimum ofshifting is desired and less gear reduction is accept-able.
Operation, Straight-Shift1. Always use first gear when starting to move the
vehicle forward.
NOTICEDo not rest your foot on the clutch pedal whiledriving. This causes partial clutch disengagementwhich could cause premature clutch wear.
2. On synchronized models, press the clutch pedalto the floor when shifting gears. Double-clutchingis unnecessary.
On unsynchronized models, press the clutchpedal to the floor to contact the clutch brake onlywhen engaging the first or reverse gears.
NOTE: If the vehicle is moving when shifting,depress the pedal just far enough to disengagethe clutch. Pressing it to the floor will engagethe clutch brake, if so equipped, causing prema-ture clutch brake wear.
3. To upshift, do the following steps:
3.1 Accelerate to engine governed speed.
3.2 On synchronized models, depress theclutch pedal and move the shift lever tosecond gear.
On unsynchronized models, depress theclutch pedal and move the shift lever toneutral. Release the clutch pedal again.With the shift lever in neutral, depress theclutch pedal and move the shift lever tosecond gear.
3.3 Release the clutch pedal and note thedrop in engine rpm before accelerating upto engine governed speed again.
3.4 Continue upshifting using the same se-quence described in the previous step.Follow the pattern on the shift lever.
4. To downshift, do the following steps:
4.1 Wait until the engine speed drops to therpm noted immediately after the upshift.
4.2 On synchronized models, depress theclutch pedal and move the shift lever tothe next lower gear.
On unsynchronized models, depress theclutch pedal and move the shift lever toneutral. Release the clutch pedal again.With the shift lever in neutral, depress theclutch pedal and move the shift lever tothe next lower gear.
4.3 Release the clutch pedal smoothly.
4.4 Use the sequence described above toshift progressively down through eachsuccessive lower gear, as driving condi-tions require.
ClutchesClutch OperationApplying the Clutch BrakeThe purpose of the clutch brake is to stop the trans-mission gears from rotating in order to engage the
1
2
3
R 4
5
05/21/2008 f261049
N
Fig. 10.3, Shift Pattern, 5-Speed FS Models
1
2
3 5
4 6
05/21/2008 f261048
N
R
Fig. 10.4, Shift Pattern, 6-Speed FS and FSO Models
Transmission
10.6
transmission gears quickly in making an initial start.To apply the clutch brake, put the transmission inneutral and press the clutch pedal to the floor.
NOTICENever apply the clutch brake while the vehicle ismoving. The clutch pedal should never bepressed down fully before putting the transmis-sion in neutral. Considerable heat will be gener-ated, which will be detrimental to the frictiondiscs, release bearings, and transmission frontbearings.
Applying the clutch brake with the transmission still ingear puts a reverse load on the gear. At the sametime, it will have the effect of trying to stop or decel-erate the vehicle with the clutch brake. Rapid wear offriction discs will take place, necessitating frequentreplacement.
Vehicle Overload, or Overloading theClutch
NOTICEOverloading will not only result in damage to theclutch, but also to the entire powertrain.
Clutches are designed for specific vehicle applica-tions and loads. These limitations should not be ex-ceeded.
Riding the Clutch PedalRiding the clutch pedal is destructive to the clutch.Partial clutch engagement permits slippage, and gen-erates excessive heat. Riding the clutch pedal willalso put a constant thrust load on the release bear-ing, which can thin out the lubricant. Release bearingfailures can be attributed to this type of misuse.
Holding the Vehicle on an Incline With aSlipping ClutchA slipping clutch accumulates heat faster than it canbe dissipated, resulting in early clutch failures. Neveruse the clutch to hold a vehicle on a hill.
Coasting With the Clutch Released(pedal down) and the Transmission inGear
WARNINGDo not allow the vehicle to coast with the clutchreleased (pedal down) and the transmission ingear. If the clutch facing is thrown off the disc,flying debris could cause injury to persons in thevehicle.
If the transmission remains in a low gear and the ve-hicle gains speed, as may occur on a downgrade,the input shaft and clutch driven disc will turn atspeeds that are higher than normal. This occurs be-cause the rear wheels and the driveline become theinput for the transmission, and a higher-than-normalspeed for a given transmission gear translates to ahigher rpm value for the clutch driven disc.
Clutch driven discs are designed to allow for someamount of excess rotational speed, but the facinghas a limited burst strength. If the clutch driven discrpm increases too much, the clutch facing can bethrown off the disc(s).
Engaging the Clutch While CoastingEngaging the clutch while coasting can result in tre-mendous shock loads and possible damage to theclutch as well as to the entire drivetrain.
Report Erratic Clutch Operation PromptlyReporting erratic clutch operation as soon as pos-sible will give maintenance personnel a chance toinspect the clutch components.
CAUTIONOperating the vehicle with incorrect clutch pedalfree-travel could result in clutch damage. SeeGroup 25 of the S2 Chassis Workshop Manual forfree-pedal adjustment procedures and specifica-tions.
On mechanical clutch linkages, free-pedal travelshould be included and commented on daily in thedriver’s report, since clutch free-pedal travel is thebest guide to the condition of the clutch and the re-lease mechanism.
Transmission
10.7
Clutch WearThe major reason clutches wear out too soon is ex-cessive heat. Clutches are designed to absorb anddissipate more heat than encountered in typical op-eration. The temperatures developed in typical op-eration will not break down the clutch friction sur-faces. However, if a clutch is slipped excessively orrequired to do the job of a fluid coupling, high tem-peratures develop quickly and destroy the clutch.Temperatures generated between the flywheel,driven discs, and pressure plates can be highenough to cause the metal to flow and the frictionfacing material to char and burn.
NOTICEDo not allow sustained slippage of the clutch;this could severely damage the clutch disc, pres-sure plate, or flywheel. Damage caused by clutchslippage due to improper break-in is not warrant-able.
Slipping and excessive heat are practically nonexis-tent when a clutch is fully engaged. But during themoment of engagement, when the clutch is pickingup the load, it generates considerable heat. An incor-rectly adjusted or slipping clutch will rapidly generatesufficient heat to destroy itself.
The most important items that a driver should beaware of to ensure long service life of the clutch in-clude: starting in the right gear, recognizing clutchmalfunctions, and knowing when to adjust a clutch.
Clutch AdjustmentsSome clutches have an internal adjustment. See theapplicable section in Group 25 of the S2 ChassisWorkshop Manual for clutch adjustment proceduresand specifications.
NOTICEOperating the vehicle with the clutch incorrectlyadjusted could result in clutch or clutch brakefailure.
Clutch LubricationThe release bearing should be lubricated at frequentintervals. See Group 25 of the S2 Chassis Mainte-nance Manual for intervals and procedures.
NOTICEFailure to lubricate the release bearing as recom-mended could result in release bearing damageand damage to the clutch.
Transmission
10.8
11
Drive AxlesDrive Axles, Detroit™ and Meritor™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Drive Axles, Detroit™ andMeritor™
For additional information regarding Meritor axles,visit the Meritor website at www.arvinmeritor.com.
Drive Axles With Differential LockThe optional driver-controlled differential lock shouldonly be used under adverse road conditions wheregreater traction is needed. With the differential lockon, the turning radius is increased and vehicle han-dling is affected. The red differential lock indicatorlight illuminates on the dash message center whenthe differential lock is engaged.
A differential lock provides maximum traction underslippery conditions. When the differential lock is en-gaged, the clutch collar completely locks the differen-tial case, gearing, and axle shafts together, maximiz-ing the traction of both wheels and protecting againstspinout. Do not exceed 25 mph (40 km/h) when thedifferential lock is engaged.
Under normal traction conditions, do not use the dif-ferential lock feature.
Differential Lock Switch
NOTICEThe differential lock should only be engagedwhen the vehicle is stopped or moving slowly atlow throttle. This will prevent internal axle dam-age.
A two-position guarded rocker switch controls thedifferential lock. See Fig. 11.1. To lock the wheelstogether, momentarily press the upper half of theswitch. To unlock the wheels, press the upper half ofthe switch again.
IMPORTANT: The differential lock rocker switchis guarded to prevent unintentional switch acti-vation. If the light emitting diode (LED) in theswitch begins to blink during normal operation,when the switch has not been activated, anerror condition exists. Bring the vehicle to anauthorized Freightliner service facility as soonas possible.
When the differential lock switch is pressed, threeresponses are possible: a normal response, a slowresponse, and an abnormal response.
Normal Response: The LED in the switch blinks untilthe axle has responded to the request to lock thewheels. At this point, the LED remains illuminatedconstantly. In normal operation, the wheels may lockso quickly that the blinking of the switch is barelynoticeable.
If operation of the switch is not possible for any rea-son (ignition is turned off, vehicle is moving fasterthan 25 mph, etc.), the LED will stop blinking andturn off.
Slow Response: If operation of the switch is slowedfor any reason (vehicle moving too fast, low air pres-sure, etc.), the switch will continue to blink until thewheels are able to lock. As in the normal response,the LED remains illuminated when the differentiallock is engaged.
NOTE: If the vehicle is moving too fast, let upslightly on the accelerator. As the vehicle slows,the wheels will lock.
Abnormal Response: If the LED blinks for more than30 seconds, the lock mechanism may not be fullyengaged/disengaged. Bring the vehicle to an autho-rized Freightliner service facility for testing.
Differential Lock Operation
WARNINGLocking the wheels when the vehicle is travelingdown steep grades or when the wheels are slip-ping could damage the differential and/or lead toloss of vehicle control, causing personal injuryand property damage.
NOTICEThe differential lock should be engaged when thevehicle is stopped or moving at a low, constantspeed and the wheels are not spinning, slipping,
10/26/2001 f610596
Fig. 11.1, Differential Lock Switch, Optional
Drive Axles
11.1
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.
Lock the wheels only when the vehicle is standingstill or moving at very low speed, less than 5 mph (8km/h). Never lock the wheels when the vehicle istraveling down steep grades or when the wheels areslipping.
NOTE: On some vehicles, the differential locksystem is connected through the low speedrange of the transmission. If this system is used,the transmission must be in the low speedrange for the wheels to fully lock.
WARNINGA vehicle with locked wheels can still slip side-ways, causing possible loss of vehicle control,personal injury, and property damage.
Be especially careful when driving under slipperyconditions with the wheels locked. Though forwardtraction is improved, the vehicle can still slip side-ways.
If the vehicle is moving, maintain a constant vehiclespeed when the differential lock is turned on. Brieflylet up on the accelerator to relieve torque on thegearing, allowing the wheels to lock completely.When the wheels are fully locked, the turning radiuswill increase because the vehicle understeers. SeeFig. 11.2. Drive cautiously and do not exceed 25mph (40 km/h).
To disengage the differential lock after leaving poorroad conditions, press the upper half of the switch,while maintaining vehicle speed. Let up momentarilyon the accelerator to allow the wheels to fully unlock,then resume driving at normal speed.
NOTE: If the differential lock system is con-nected with the transmission in its low speedrange, shifting out of the low speed range willalso disengage the differential lock function. Theswitch will blink until the wheels unlock, andthen go out.
f350079a02/03/2017
A
B
A. Turning Radius When the Differential Lock isEngaged (understeer condition).
B. Turning Radius When the Differential Lock isDisengaged.
Fig. 11.2, Turning Radii
Drive Axles
11.2
12
Steering SystemSteering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Steering Controls
WARNINGMake sure that the steering column is locked be-fore driving the vehicle. Never tilt or telescopethe steering wheel while driving the vehicle.Doing so could cause loss of vehicle control,personal injury, and property damage.
When there is no load on the vehicle and the fronttires are pointed straight ahead, the steering wheelspokes should be at the 9 o’clock and 3 o’clock posi-tions, or within 10 degrees to either side as shown inFig. 12.1. See Group 46 of the S2 Chassis Work-shop Manual for steering adjustment procedures.
On some vehicles, the steering column may be tiltedforward or aft to provide the most comfortable anglefor steering the vehicle. The steering column canalso be telescoped (raised or lowered) to provide themost comfortable height above the floor.
To tilt the steering column, press down on the footpedal located below the steering wheel to release thesteering column lock. Adjust the column to the de-sired position. Release the foot pedal to lock thesteering column in place. See Fig. 12.2.
To telescope the steering column, press down on thefoot pedal to release the steering column lock. Pullthe steering wheel upwards or push the steeringwheel downwards until it is at the desired height. Re-lease the foot pedal to lock the steering column inplace.
NOTE: For safety, the steering column is lockedat all times unless the foot pedal is presseddown.f461923 11/14/2001
1 2
10°
10° 10°
10°
1. 9 o’Clock 2. 3 o’Clock
Fig. 12.1, Steering Wheel Centered
11/14/2001 f461922
1
2
3
Push the foot pedal down to adjust the steering column.
1. Steering Wheel2. Steering Column
3. Foot Pedal
Fig. 12.2, Adjustable Steering Column
Steering System
12.1
13
Hydraulic and Air BrakeSystems
Dual Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Air Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Bosch Hydraulic Pin Slide Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3Meritor Cam-Master® Q Plus Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3Meritor WABCO Pneumatic Antilock Braking System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6Brake Burnishing (new vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
Dual Air Brake SystemA dual air brake system consists of two independentair brake systems that use a single set of brake con-trols. Each system has its own reservoir, plumbing,and brake chambers. The primary air system oper-ates the service brakes on the rear axle; the second-ary air system operates the service brakes on thefront axle.
Primary Air Brake SystemLoss of air pressure in the primary air system causesthe rear service brakes to become inoperative. Thefront brakes will continue to be operated by the sec-ondary air system.
Secondary Air Brake SystemLoss of air pressure in the secondary air systemcauses the front axle brakes to become inoperative.The rear service brakes will continue to be operatedby the primary air system.
Emergency Braking SystemWhen air pressure is lost in one air system, the aircompressor will operate, but the air supply in theleaking system will not be replenished. There will beenough air in the working system to stop the vehiclesafely. The dual air brake system thus providesemergency braking capability. When the low air pres-sure warning light and emergency buzzer first comeon, stop the vehicle immediately. Do not drive thevehicle until the cause of the problem is corrected.
Parking BrakesPulling out the yellow diamond-shaped knob (parkingbrake control valve) on the auxiliary dash panel ap-plies the parking brakes (spring brakes). SeeFig. 13.1.
Air Brake Operation
WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol, resulting in property damage or personalinjury.
Before driving the vehicle, secure all loose items inthe vehicle so that they will not fly forward during afull brake application.
Parking Brake Interlock, Optional
NOTICEDo not continually press down on the parkingbrake control valve (yellow knob) without press-ing down on the service brake pedal. This willdamage the safety interlock.
The service brakes and parking brakes have a safetyinterlock that prevents the unintentional release ofthe parking brake. These instructions need to be fol-lowed for the appropriately equipped vehicle to re-lease the parking brake interlock.
Parking Brake Interlock Release1. Depress the brake pedal.
2. Push the parking brake control valve in.
Parking Brake and Ignition Key Release1. Turn the ignition key to the ON position.
2. Depress the brake pedal.
3. Push the parking brake control valve in.
Parking Brake, Ignition Key, Wheel ChairLift Interlock Release1. Turn the ignition key to the ON position.
2. Check to see that the wheel chair lift is in thestowed position.
3. Confirm that the wheel chair lift switch is in theOFF position.
4. Depress the brake pedal.
5. Push the parking brake control valve in.
f430360a11/21/2006
Fig. 13.1, Parking Brake Control Valve
Hydraulic and Air Brake Systems
13.1
Transmission Shifter Interlock Release1. If the vehicle is equipped with a wheel chair lift,
make sure the lift is in the stowed position, andthat the wheel chair lift switch is in the OFF posi-tion.
2. Depress the service brake pedal to move thevehicle shifter out of the park position.
Operating the BrakesTo ensure safe operation and minimum brake wear,follow the steps below when operating the brakes.
1. When the ignition switch is turned on, the low airpressure warning light (pressure circle icon) illu-minates and the emergency buzzer sounds.
1.1 Monitor the air pressure system by ob-serving the low air pressure warning light,the emergency buzzer, and both the pri-mary and secondary air pressure gauges.
1.2 The warning light and buzzer shut offwhen air pressure in both systemsreaches 65 to 75 psi (448 to 517 kPa).
2. Before driving the vehicle, continue to monitorthe air pressure system until the air compressorhas built up a minimum pressure of 95 psi (655kPa) in both the primary and secondary air sys-tems.
3. While driving, the low air pressure warning lightand buzzer come on if air pressure drops below65 to 75 psi (448 to 517 kPa) in either system.
3.1 If this happens, check the air system pres-sure gauges to determine which systemhas low air pressure.
3.2 Although vehicle speed can be reducedusing the service brake, either the front orrear service brakes will not be operating,causing a longer stopping distance.
3.3 Bring the vehicle to a safe stop and havethe air system repaired before continuing.
4. During normal brake stops, depress the servicebrake until braking action slows down the ve-hicle. Increase or decrease the pressure on thepedal so that the vehicle comes to a smooth,safe stop.
IMPORTANT: In the event of a total loss of ser-vice brakes, use the parking brake control valveto bring the vehicle to a complete stop in thesafest location possible.
5. When the forward speed of the vehicle has de-creased almost to the idling speed of the engine,press in the clutch pedal (on manual transmis-sions) and shift the transmission to neutral. Applythe parking brakes, if the vehicle is to be parked.
NOTICEDo not use the spring parking brakes if the ser-vice brakes are hot, such as after descending asteep grade. Also, do not use the spring parkingbrakes during freezing temperatures if the ser-vice brakes are wet. To do so could damage thebrakes if hot, or cause them to freeze during coldweather.
If the brakes are wet, drive the vehicle in lowgear and lightly apply the brakes to heat and drythem. Allow hot brakes to cool before using thespring parking brakes. Always chock the tires.
Caging the Parking Brakes
WARNINGDo not drive the vehicle with the parking brakescaged. If the vehicle is driven with the parkingbrakes caged, there would be no means of stop-ping the vehicle if a complete loss of air pressureoccurred. This could result in serious personalinjury or vehicle damage.
To move a vehicle with insufficient system air pres-sure, it is necessary to release the parking brakesprings.
There are two ways to do this:
• Apply an external air source at the gladhands;
• Cage (manually release) the parking brakes.
IMPORTANT: Before caging the parking brakes,make the connection to a towing vehicle orchock the tires.
After correcting the brake system problem, uncagethe parking brakes before resuming normal vehicleoperation.
Hydraulic and Air Brake Systems
13.2
Bosch Hydraulic Pin SlideBrakesGeneral InformationThe Bosch hydraulic pin slide disc brake is a two-piston sliding caliper brake and is used at both thefront and rear wheel locations. Each pin slide caliperdisc brake wheel installation is made up of a caliperassembly, anchor plate assembly, and disc brakepads.
Caliper AssemblyThe caliper assembly has two hydraulic piston bores.The piston bores contain pistons, piston seals, andpiston boots. The caliper assembly attaches andslides on sealed pins located in the anchor plate.The caliper housing is the main component of thecaliper assembly. The material of the caliper housingis ductile iron and has a protective coating to provideadditional environmental protection. The disc brakecaliper housing straddles the rotor, the inner pad,and the outer pad.
Anchor Plate AssemblyThe anchor plate assembly includes lubricated float-ing guide pins sealed by rubber boots. The anchorplate abutments are protected by stainless steel slip-pers.
Disc Brake PadsThere are two pads per caliper assembly, and theyare the inner and outer pads. The inner pad is lo-cated between the caliper piston and rotor. The outerpad is located between the rotor and caliper housinglegs. The pads are made of friction material and astamped steel backing plate. The pads are referredto as the shoe and lining assembly. These brakepads can be removed without removing the caliper.
OperationBefore driving the vehicle, secure all loose items inthe vehicle so that they will not fly forward during afull brake application. Check that the brake systemwarning light is off after releasing the hand brake. Ifthe warning light does not go off, correct the problembefore continuing operation of the vehicle.
During normal braking 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, safe
stop. Apply the hand parking brake if the vehicle is tobe parked.
IMPORTANT: Make sure that the fluid level inthe master cylinder reservoirs is at the bottom ofthe fill-neck. See Fig. 13.2. Use only DOT 3brake fluid in the Bosch hydraulic pin slidebrake system.
Meritor Cam-Master® Q PlusBrakesCam-Master brakes are air-actuated, cam-operated,foundation brakes. The Q Plus increases service lifeand mileage between relines by providing more liningthickness. A specially designed S-cam and heavy-duty shoe return spring allow additional shoe travelrequired to fully wear the thicker lining blocks. Animproved camshaft bushing contributes to longer ser-vice life.
Cam-Master Q Plus OperationWhen the brake pedal is depressed, compressed airenters the brake chamber, causing the diaphragm tomove a pushrod assembly.
07/31/2015 f460513b
A
B
A. Open caps and check fluid level.B. Fill to this level.
Fig. 13.2, Master Cylinder Reservoir
Hydraulic and Air Brake Systems
13.3
The pushrod turns the slack adjuster and brake cam-shaft. As the camshaft turns, the S-type cam headforces the brake shoes against the brake drum andbraking occurs.
When the brakes are released and air is exhaustedfrom the brake chamber, the actuator return spring(within the brake chamber) and the brake shoe returnspring return the camshaft, brake shoes, slack ad-juster, and pushrod to their released positions.
Meritor WABCO PneumaticAntilock Braking System (ABS)Pneumatic ABS is an electronic wheel speed moni-toring and control system that works with the airbrake system. It passively monitors vehicle wheelspeed at all times, but controls wheel speed duringan emergency or reduced-traction stop. In normalbraking applications, the standard air brake system isin effect.
Pneumatic ABS OperationThe Meritor WABCO ABS is a four-sensor system. Itcombines one front-axle control channel with onerear-axle control channel to form one control circuit.
Example: The sensor and solenoid control valve atthe left front wheel form a control circuit with the sen-sor and solenoid valve at the right rear axle.
ABS includes signal-generating tone wheels and sen-sors located in the wheel hubs of each sensed axle.The sensors transmit vehicle wheel speed informa-tion to an electronic control unit.
IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit. Installing differentsized tires could result in a reduced brakingforce, leading to longer stopping distances.
During emergency or reduced traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop. Do not pump the brake pedal. With thebrake pedal fully depressed, the ABS system willcontrol all wheels to provide steering control and areduced braking distance.
Although the ABS system improves vehicle controlduring emergency braking situations, the driver stillhas the responsibility to change driving styles de-pending on the existing traffic and road conditions.For example, the ABS system cannot prevent an ac-
cident if the driver is speeding or following tooclosely on slippery road surfaces.
Even if the ABS system is partially or completely in-operative, normal braking ability is usually main-tained.
IMPORTANT: If a solenoid control valve (orcombination solenoid control valve) is damagedand inoperative, normal braking may be im-paired.
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.
During reduced-traction situations, the ATC solenoidvalve controls air pressure to the modulator valvesand they in turn increase, hold, or reduce pressure tothe appropriate brake chambers to provide bettertraction whenever 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 may include a deep snow and mud option toincrease available traction on extra soft surfaces likesnow, mud, or gravel. If so equipped, a momentarycontact rocker switch labeled ATC will be located onthe dash. Pressing the switch will temporarily allowmore wheel spin. The activation of the deep snowand mud option is indicated by a flashing WHEELSPIN lamp. Pressing the switch again will cycle thesystem 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 ABS indica-tor light and the WHEEL SPIN indicator light illumi-nate for about three seconds. After three seconds,the warning lights go out if all of the ABS compo-nents are working.
During vehicle operation, solid illumination of theABS light indicates a problem with the vehicle ABS.
Hydraulic and Air Brake Systems
13.4
Repair the ABS immediately to ensure full brakingcapability.
If equipped with ATC, an amber WHEEL SPIN indica-tor light illuminates if one of the drive wheels spinsduring acceleration. When the light illuminates, par-tially release the throttle pedal to stop the spinningwheel. The light goes out when the wheel stops spin-ning.
If slippery road conditions continue, turn on the differ-ential lock switch. See Chapter 11 for axle switch in-structions.
NOTICEDo not turn the differential lock switch on whilethe WHEEL SPIN indicator light is on. To do socould damage the rear axle.
Automatic Slack Adjusters
NOTICEManually adjusting an automatic slack adjuster tobring the pushrod stroke within legal limits islikely masking a mechanical problem. Adjustmentis not repairing. In fact, continual adjustment ofautomatic slack adjusters may result in prema-ture wear of the adjuster itself. Further, the im-proper adjustment of some automatic slack ad-justers may cause internal damage to theadjuster, thereby preventing it from properlyfunctioning.
Automatic 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.
Exhaust BrakeGeneral InformationAn exhaust brake is an optional auxiliary braking sys-tem that assists, but does not replace, the servicebrake system. The driver can use the exhaust brake,
in combination with the accelerator and clutch pedal(if so equipped), to make maximum use of the ex-haust brake in off-highway and mountain driving aswell as in traffic or high-speed highway driving.
The exhaust brake is controlled by a dash-mountedrocker switch, shown in Fig. 13.3, to help slow thevehicle when the accelerator is released.
To turn the exhaust brake on, press on the upperpart of the rocker switch. When the exhaust brakeswitch is on, an amber light emitting diode (LED) illu-minates inside the switch. When the panel lights areon, the EXHST BRK legend is backlit in green.
The exhaust brake is only active when engine speedis between 1100 and 2700 rpm. Depressing the ac-celerator or clutch pedal deactivates the exhaustbrake. The ABS system, when active, also deacti-vates the exhaust brake.
The exhaust brake is a butterfly valve mounted in theexhaust pipe. When the driver’s foot is not on theaccelerator pedal and the upper half of the exhaustbrake switch is pressed in, with the amber light onthe switch illuminated, an air cylinder shuts the but-terfly valve, which restricts the flow of exhaust gasesand retards the engine. This retarding action is car-ried through the engine and drivetrain, slowing thevehicle and reducing the need for frequent servicebrake applications.
Exhaust brakes are not intended for use as the pri-mary braking system during vehicle operation.
Starting the EngineBefore starting the engine, make sure that the lowerhalf of the exhaust brake switch is pressed in andthe amber light is not illuminated. Do not turn the ex-haust brake on until the engine has reached normaloperating temperatures.
f61058911/28/2001
Fig. 13.3, Exhaust Brake Switch
Hydraulic and Air Brake Systems
13.5
Operating Characteristics
WARNINGDo not use the exhaust brake when driving onslippery or low-traction road surfaces. Failure tofollow this precaution could result in a loss ofvehicle control and possible personal injury orproperty damage.
When you remove your feet from both the accelera-tor and clutch pedal (if so equipped), and the upperhalf of the exhaust brake switch is pressed in withthe amber LED illuminated, the exhaust brake is ap-plied. The following conditions should exist if thebrake is operating properly:
• A slight change in the sound of the engine maybe noticed when the exhaust brake is applied.
• Exhaust smoke should appear as normal.
• Engine temperature should remain in the nor-mal operating range.
• Road speed usually decreases when the ex-haust brake is applied during a descent. Whenthe vehicle is carrying a heavy load or thegrade is extremely steep, the driver may needto apply the service brakes occasionally.
• Do not expect a retarding effect similar to sud-den hard application of the service brakes. Theexhaust brake retards the vehicle with asmooth braking effect.
• During a descent, the tachometer usuallyshows a drop in rpm depending on the gradeand the vehicle load.
• Depending on the grade and vehicle load, youmay or may not feel the retarding force actingagainst your body when the brake is applied.The retarding force of the brake may not al-ways be noticed, but it is actually preventingthe vehicle from going much faster.
Driving DownhillWhile approaching a steep grade, make sure that theupper half of the exhaust brake switch is pressed in,with the amber LED illuminated. The exhaust brakecomes on as soon as you remove your foot from theaccelerator pedal. While going down the grade, usea low enough gear to safely descend with a minimumapplication of the service brakes. As a general guide-line, use the same gear as you would to ascend thehill.
NOTICEDo not allow the engine to exceed its governedspeed, or serious engine damage could result.
Apply the service brakes to reduce the engine rpm ormake a slower descent by using a lower gear.
Shutting Down the EngineMake sure the exhaust brake switch is turned off be-fore shutting down the engine.
Engine BrakeEngine Brake SwitchThe engine brake switch controls the degree of en-gine braking. Normally there are two paddleswitches, a two-position On/Off Switch to activate theengine brake, and a two-position Hi-Lo Switch tocontrol the amount of engine braking.
To turn the two-position On/Off Switch on, raise thepaddle. When the two-position switch is on, anamber light-emitting diode (LED) illuminates insidethe switch.
To turn the two-position Hi-Lo Switch on high, raisethe paddle. To turn the two-position Hi-Lo Switch onlow, lower the paddle. See Fig. 13.4.
A three-position switch is used on MBE900 enginesequipped with both the regular engine brake and theconstant-throttle (decompression) brake. It works thesame as the two-position Hi-Lo switch, except thatthere is a third (off) position when the switch is left atits normal position.
10/17/2001 f610588
1 2
1. On/Off Switch 2. Hi-Lo Switch
Fig. 13.4, Engine Brake Switches
Hydraulic and Air Brake Systems
13.6
When the panel lights are on, the Hi-Lo icon is back-lit in amber on the three-position switch. On both thethree-position switch and the two-position switch, theENG BRK legend is backlit in green when the panellights are on.
Constant-Throttle ValvesTo increase braking performance, Mercedes-Benzengines are equipped with optional constant-throttlevalves in each combustion chamber. Small valvesbuilt into the cylinder head allow a small amount ofcompressed air to escape through the exhaust portduring the combustion stroke. The constant-throttlevalves are open during the entire time that the en-gine brake is activated. Although some braking abilityis lost because the valves are constantly open,constant-throttle braking is quieter in operation thanother types of engine brakes.
When both the exhaust brake and the constantthrottles are installed, a three-position switch on thedash controls the amount of engine braking deliv-ered. Like the exhaust brake, the constant throttlesare deactivated when the accelerator or clutch pedalis depressed. The ABS system, when active, alsodeactivates constant-throttle braking.
The engine brake will deactivate if the engine speedfalls below a preset level. This level is program-mable, but is set at the factory at 1100 rpm.
Brake Burnishing (newvehicle)IMPORTANT: Check the brake system and en-sure that it is in proper operating condition be-fore attempting the brake burnishing procedure.
1. In a safe area, make 10 sharp brake applicationsor "snubs," slowing the vehicle from 40 to 20mph (64 to 32 km/h) using light (approximately10 to 20 psi [69 to 138 kPa]) brake pressure.
2. Make 10 stops from 20 mph (32 km/h) usingmoderate (20 to 30 psi [138 to 207 kPa]) brakepressure.
3. Make 2 stops from 20 mph (32 km/h) using hard(full application of air pressure) brake applica-tions.
NOTE: After the hard brake applications, it isnormal to notice a hot brake odor.
4. Drive the vehicle 5 to 7 miles (8 to 11 km) allow-ing the brakes to cool, and then come to a stop.
NOTE: After performing the burnishing proce-dure, there should be no brake noise and thebrakes should have good stopping ability.
5. If the brakes pull the vehicle to one side or grabafter the burnishing procedure, contact a Freight-liner dealer for assistance.
Hydraulic and Air Brake Systems
13.7
14
Pre- and Post-TripChecklists
Pretrip and Post-Trip General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Daily Pretrip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Weekly Post-Trip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3Monthly Post-Trip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
Pretrip and Post-Trip GeneralInformationRegulations in both Canada and the United Statesclearly indicate that it is the driver’s responsibility toperform an inspection and ensure the complete road-worthiness of a vehicle before placing it into servicefor the day. Commercial vehicles may be subject toinspection by authorized inspectors, and an unsafevehicle can be put "out of service" until the driver orowner repairs it.
IMPORTANT: The pre- and post-trip checklists,and inspections and maintenance proceduresdetailed in this chapter, are not all-inclusive.Also refer to other component and body manu-facturers’ instructions for specific inspection andmaintenance instructions.
Use the pretrip inspection checklist to ensure thatvehicle components are in good working conditionbefore each trip. Use the weekly and monthly post-trip inspection checklists to note any items that re-quire attention before the next trip. A driver that isfamiliar with the vehicle, and drives it regularly, canperform the daily inspections, then add the weeklyand monthly post-trip inspections as scheduled. If thedriver does not operate the vehicle on a consistentbasis, all three of the inspection procedures shouldbe performed before the trip.
Pre- and post-trip inspections cannot be donequickly. However, careful inspections save time byeliminating stops later to adjust items overlooked orforgotten.
Numbers in parentheses within each of the checklistsreference the corresponding detailed instructionsfound under "Daily (D), Weekly (W), or Monthly (M)Procedures" in Chapter 15.
If any system or component does not pass this in-spection, it must be corrected before operating thevehicle. Whenever equipment requires adjustment,replacement, repair, addition of lubricants, or achange of lubricants, see the S2 Chassis WorkshopManual for procedures and specifications, or take thevehicle to an authorized Freightliner dealer.
Daily Pretrip Inspection andMaintenance ChecklistIMPORTANT: Before performing any of thesechecks, apply the parking brake and chock thetires.
For the daily pretrip inspection and maintenancechecklist see Table 14.1.
Pre- and Post-Trip Checklists
14.1
Procedure Performed(check off)
Daily Pretrip Inspections/ChecksProcedureReference
_______ Drain manually drained air reservoirs (that are not equipped with automatic drainvalves) D1
Check _______ windshield washer reservoir fluid D2Inspect _______ wheel seal and hub cap (for leakage) —Check _______ surge tank coolant level D3Inspect _______ radiator and charge air cooler D4Check _______ engine for fuel, oil, or coolant leaks —Inspect _______ engine and chassis wiring D5Inspect _______ air intake system D6Check _______ intake-air restriction indicator mounted on air intake D6Check _______ engine oil level D7Check _______ power steering fluid level —Inspect _______ fuel tank(s), fuel lines, and connections D8Check _______ fuel level D9Check _______ fuel/water separator D10Inspect _______ front and rear suspension components D11Inspect _______ headlights, mirrors, and window glass, and windshield wipers D12Check _______ doors (open without difficulty and close securely) —
_______ Adjust driver’s seat, then align rearview and downview mirrors —Check _______ dash-mounted intake-air restriction indicator D6Check _______ oil- and air-pressure warning systems D13Check _______ ICU fault codes D14Check _______ horn, windshield wipers, and windshield washer D15Check _______ heater, defroster, and optional mirror heat controls D16Check _______ backup alarm —Check _______ panel lights and interior lights D17Check _______ exterior lights and reflectors D18Check _______ tire pressure D19Inspect _______ tire condition D20Inspect _______ rims and wheels D21Check _______ automatic transmission fluid level —Inspect _______ air brake chambers and pushrods D22Inspect _______ air brake lines D23Inspect _______ slack adjusters D24Check _______ air brake system operation D25Check _______ Bendix® Hydro-Max Power Booster D26Inspect _______ frame rails (missing bolts), crossmembers (bent or loose) —
Check _______ mud flaps (aren’t damaged, at least 10 inches above the ground, and bracketsare secure) —
Check _______ exhaust system (mounted securely, connected tightly, no signs of leaks such assoot trails) —
_______ Remove chocks and test service brakes D27
Inspector___________________________________________________ Date ________________
Table 14.1, Daily Pretrip Inspection and Maintenance Checklist
Pre- and Post-Trip Checklists
14.2
Weekly Post-Trip Inspectionand Maintenance ChecklistIMPORTANT: Before performing any of thesechecks, apply the parking brake and chock thetires.
For the weekly post-trip inspection and maintenancechecklist see Table 14.2.
Procedure Performed(check off)
Weekly Post-Trip Inspections/ChecksProcedureReference
_______ Manually drain air reservoirs that are equipped with automatic drain valves —Inspect _______ batteries and battery cables W1Check _______ wheel bearing lubricant level W2Inspect _______ steering components W3Check _______ serpentine drive belt condition W4Check _______ drive belt tension W5Inspect _______ seat belts and tether belts W6
Inspector___________________________________________________ Date ________________
Table 14.2, Weekly Post-Trip Inspection and Maintenance Checklist
Monthly Post-Trip Inspectionand Maintenance ChecklistIMPORTANT: Before performing any of thesechecks, apply the parking brake and chock thetires.
For the monthly post-trip inspection and maintenancechecklist see Table 14.3.
Procedure Performed(check off)
Monthly Post-Trip Inspections/ChecksProcedureReference
_______ Clean the battery terminals M1Inspect _______ radiator hoses and heater hoses M2
Check _______ fluid level in the hydraulic clutch reservoir (if applicable, and if necessary, fill withDOT 4 brake fluid) —
Check _______ fluid level in the hydraulic brake reservoir (if applicable, and if necessary, fill withDOT 3 brake fluid) M3
Check _______ steering wheel play M4Check _______ outer surfaces of the hood and body (for visible surface breaks and damage) —Check _______ hood tilt damper (attached at both ends) —Inspect _______ brake lining wear M5Inspect _______ driveshaft —
Inspector___________________________________________________ Date ________________
Table 14.3, Monthly Post-Trip Inspection and Maintenance Checklist
Pre- and Post-Trip Checklists
14.3
15
Pre- and Post-TripInspections and
MaintenanceSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Daily Pretrip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Weekly Post-Trip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11Monthly Post-Trip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
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 andMaintenance ProceduresWhenever equipment requires adjustment, replace-ment, and/or repair, see the S2 Chassis WorkshopManual for procedures and specifications. Specificreferences to the manual will be found where appro-priate.
1. Drain the brake system air reservoirs (reservoirswithout automatic drain valves only).
Water and oil normally enter the air reservoir inthe form of vapor because of the heat generatedduring compression. After the water and oil con-dense, drain the resulting emulsion as follows:
1.1 Open the wet tank valve. The drain cockor pull chain drain is located on the for-ward end of the supply air reservoir, whichis connected directly to the air compres-sor. Block the valve open.
WARNINGWhen draining the air reservoir, do not look intothe air jets or direct them toward anyone. Dirt orsludge particles may be in the airstream andcould cause injury.
1.2 Exhaust the remaining air and moisturefrom the system by opening the draincocks on the bottoms of the remaining airreservoirs. Block the valves open.
1.3 Water and oil emulsion often form pocketsthat will not drain while compressed air isin the reservoirs. Because of these pock-ets, leave the valves blocked open duringthe first part of the pretrip inspection.
1.4 If the drained water is cloudy or oily, itmay indicate a problem with the compres-sor. If oil is allowed to contaminate the air
dryer, it will not remove the water from theair brake system, which could adverselyaffect braking.
2. Check the fluid level in the windshield washerreservoir.
Add washer fluid as needed. Unscrew the cap toadd fluid.
WARNINGWasher fluids may be flammable and poisonous.Do not expose washer fluid to an open flame orany burning material, such as a cigarette. Alwayscomply with the washer fluid manufacturer’s rec-ommended safety precautions.
3. Check the coolant level in the surge tank.
See Fig. 15.1. If the coolant is low, add a 50/50mixture of water and antifreeze. Refer to the en-gine manufacturer’s service literature for ap-proved coolants. Fill the surge tank with coolantto the FULL line when the tank is cool. If thesurge tank was empty, start the engine after re-filling and check the level again when the engineis at operating temperature.
NOTICECoolant must be filled to the full line of the surgetank. Low coolant could result in engine over-heating, which could cause engine damage.
4. Inspect the radiator and charge air cooler.
11/02/2001 f820382
Add coolant here (arrow).
Fig. 15.1, Coolant Level Checking
Pre- and Post-Trip Inspections and Maintenance
15.1
4.1 Inspect the radiator and charge air coolerfor clogged fins. Use compressed air orwater directed from the fan side of thecore to backflush any material restrictingairflow.
4.2 Inspect the radiator and charge air coolerfor damage and accumulated debris.Straighten bent or damaged fins to permitairflow across all areas of the cores.
NOTE: When traveling through areas of highinsect concentration, it may be necessary toclean the exterior of the radiator or thecharge air cooler core as often as every 200miles (320 km).
4.3 Also inspect and clean the condenser. Ifclogged, the condenser can restrict airflowthrough the radiator.
4.4 Check the radiator for leaks. If leaks arefound, have the radiator repaired or re-placed. See Group 20 of the S2 ChassisWorkshop Manual for instructions, or takethe vehicle to an authorized Freightlinerdealer.
5. Inspect the engine and chassis wiring.
Check for loose wiring, chafed insulation, anddamaged or loose hold-down clamps. Tightenloose wires or hold-down clamps; replace dam-aged wiring or clamps.
6. Inspect the air intake system for leaks or dam-age.
NOTICEFailure to maintain a sealed air intake systemcould allow entry of dirt and contaminants intothe engine. This could adversely affect engineperformance and result in engine damage.
6.1 Check the intake-air restriction indicator.
6.2 Replace the primary filter element in theair cleaner if the yellow signal stayslocked at 20 inH2O for Mercedes-Benzengines and 25 inH2O for Cummins ISBengines. See Group 09 of the S2 ChassisWorkshop Manual for filter element re-placement instructions, or take the vehicleto an authorized Freightliner dealer. SeeFig. 15.2.
NOTE: After replacing the filter element,reset the restriction indicator by pressing therubber reset button.
6.3 Inspect the secondary or safety filter ele-ment in the air cleaner when replacing theprimary element, and replace it whenclogged or dirty. This element should bereplaced with every third primary elementreplacement.
6.4 Check the engine air intake piping fromthe air cleaner to the engine intake. In-spect the piping for loose connections,cracks, torn or collapsed hoses, punc-tures, and other damage. Tighten looseconnections, and have damaged compo-nents replaced. Make sure the piping sys-tem is airtight so that all intake air passesthrough the air cleaner.
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.
09/12/2001 f090363
2
1
1. Primary Filter Element2. Secondary or Safety Filter Element
Fig. 15.2, Air Cleaner Filter Elements
Pre- and Post-Trip Inspections and Maintenance
15.2
IMPORTANT: On engines that comply withEPA07 or newer regulations, use CJ-4 engineoil with less than 1% sulfated ash. Failure touse CJ-4 oil may void the warranty on emissionaftertreatment components.
7. 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.
7.1 Park the vehicle on a level surface. Allowseveral minutes for the oil to drain backinto the oil pan to ensure an accuratereading.
NOTE: For diesel engines, follow the enginemanufacturer’s guidelines for engine shut-down time requirements prior to checkingthe oil level.
7.2 Pull out the dipstick and clean it with apaper towel or cloth, then push the dip-stick back in all the way. Remove it again,keeping the tip down, and check the oillevel.
7.3 If the oil is below the cross-hatched area,or the add mark, at the tip of the dipstick,add at least one quart (liter) of the recom-mended oil. See Fig. 15.3 and Fig. 15.4for diesel engines, and Fig. 15.5 for pro-pane engines.
For diesel engines that comply withEPA07 or newer regulations, use CJ-4engine oil with less than 1% sulfated ash.
For liquid propane gas (LPG) engines, useSAE 5W–30 oil that meets GM standardGM6094M and has the American Petro-leum Institute (API) symbol. Do not useSAE 10W–40 or 20W–50.
NOTICEFailure to use the recommended oil can result inengine or aftertreatment component damage andwill void the warranty.
8. Inspect the fuel tanks, fuel lines, and connectionsfor leaks.
8.1 Check that the fuel tanks are secured totheir mounting brackets and that themounting brackets are secured to theframe.
8.2 Replace leaking fuel tanks.
8.3 If lines or connections are leaking, havethem repaired or replaced.
For repair and/or replacement procedures,see Group 47 of the S2 Chassis Work-shop Manual, or take the vehicle to anauthorized Freightliner dealer.
8.4 If equipped with fuel tank shutoff valves,be sure the valves are fully open.
WARNINGNever operate the engine with the fuel tank shut-off valves partly closed. This could damage thefuel pump, causing sudden loss of engine power,possibly resulting in serious personal injury dueto reduced vehicle control.
9. Check the fuel level in the fuel tank(s).
10/26/2012 f012203
FULL ADD 2 QT
Fig. 15.3, Oil Dipstick (Cummins engine)
01/13/99 f011525
1 2
1. Maximum Fill Level 2. Minimum Fill Level
Fig. 15.4, Oil Dipstick (Mercedes-Benz engine)
08/05/2010 f012186
Oil should be within the cross-hatched area of thedipstick.
Fig. 15.5, Oil Dipstick (LPG engine)
Pre- and Post-Trip Inspections and Maintenance
15.3
To keep condensation to a minimum, fuel tanksshould be filled at the end of each day. Federalregulations prohibit filling a fuel tank to morethan 95 percent of its liquid capacity. Select theproper grade of fuel as specified by the enginemanufacturer.
WARNINGDo not mix gasoline or alcohol with diesel fuel.This mixture could cause an explosion, possiblyresulting in serious personal injury or death. Donot fill the fuel tanks in the presence of sparks,open flames, or intense heat. These could ignitethe fuel, possibly causing severe burns.
IMPORTANT: Use ultralow-sulfur diesel(ULSD) fuel with 15 ppm sulfur content orless, based on ASTM D2622 test procedure.Failure to use ultralow-sulfur diesel fuelsmay void the warranty on emission compo-nents.
9.1 Fuel should always be strained or filteredbefore being put into the tanks. This willlengthen the life of the engine fuel filterand reduce the chances of dirt getting intothe engine.
9.2 Before installing the fuel cap, clean thearea with a rag, or if necessary, clean thecap with solvent.
9.3 If needed, prime the fuel system. Forpriming procedures, see the applicableengine manufacturer’s manual.
10. If equipped with a fuel/water separator, check forwater.
Drain any water found. Check the fuel/waterseparator for leaks and contaminants.
For an Alliance Model, see Fig. 15.6. Place asuitable container under the fuel/water separator.Check the water level in the sight bowl, if soequipped. To drain the water, loosen the valve atthe bottom and allow the water to run out. Closeand tighten the valve finger-tight.
IMPORTANT: When draining fluid from a fuel/water separator, drain the fluid into an appropri-ate container and dispose of it properly. Manystates now issue fines for draining fuel/waterseparators onto the ground. On all types ofseparators, stop draining fluid when you seefuel come out of the separator drain valve.
11. Inspect the front and rear suspension compo-nents, including springs, spring hangers, shocks,and suspension brackets.
11.1 Check for broken spring leaves, looseU-bolts, cracks in the suspensionbrackets, and loose fasteners in the springhangers and shackles.
11.2 Inspect the shock absorbers for loose fas-teners and leaks.
11.3 Tighten all loose fasteners and have anycomponents replaced that are worn,cracked, or otherwise damaged.
11.4 On vehicles with air suspensions, checkfor leaks. Check air suspension compo-nents for cuts and bulges.
12. Clean the headlights, mirrors, windshield, side,and rear windows with a long-handled or tele-scoping window cleaning device and standardcleaning solutions. Stand only on the ground, ona stepladder, or an elevated walkway. The ve-hicle entry/exit steps and handholds are not de-signed for this purpose. The tires, fenders, en-gine, and other under-hood components do nothave adequate gripping surfaces and handholds.
Check the condition of the windshield wiper armsand blades.
Be sure the windshield wiper blades are ten-sioned against the windshield.
11/30/95 f470167
Fig. 15.6, Alliance Fuel/Water Separator
Pre- and Post-Trip Inspections and Maintenance
15.4
Inspect the wiper blades for damage and deterio-rated rubber.
Replace the wiper arms if the wiper blades arenot tensioned against the windshield.
Replace damaged or deteriorated wiper blades.
WARNINGWhen cleaning windshields and windows, alwaysstand on the ground or on a secure ladder orplatform. Use a long-handled window cleaner. Donot use the cab steps, tires, fenders, fuel tanks,engine, or under-hood components to access thewindshield or windows. Doing so could cause afall and result in an injury.
Replace wiper arms and blades when necessaryto maintain good visibility. Poor visibility couldinterfere with the driver’s ability to control thevehicle, possibly resulting in serious personalinjury or death.
13. Check the oil- and air-pressure warning systems.
When the engine is started, oil- and air-pressurewarnings will come on until the oil and air pres-sure rise above a preset minimum. After startingthe engine, make sure the oil- and air-pressurewarning systems are operating and that thebuzzer stops sounding when the preset minimumis reached.
13.1 If the warning systems do not come onwhen the ignition is turned on, have thesystems repaired.
13.2 If the air pressure in both systems isabove the preset minimum when the en-gine is started, test the low air pressurewarning system by lowering the pressureto below this range, or until the warningsystem comes on.
NOTE: The air pressure in both the primaryand secondary air reservoir systems mustbe above 65 psi (448 kPa) on most vehicles.For vehicles with an optional Bendix dryerreservoir module (DRM), the cut-out pres-sure is 130 psi (896 kPa).
14. Check the instrumentation control unit (ICU) forfault codes.
During the ignition sequence, if an active fault isdetected in any device that is connected to thedatalink, the message display screen will showthe active fault codes, one after the other, until
the parking brake is released or the ignitionswitch is turned off. See Chapter 3 for detailedoperating instructions for the ICU.
15. Make sure that the horn, windshield wipers, andwindshield washers are operating properly.These devices must be in good working order forsafe vehicle operation.
15.1 Make sure that the horn works. If a horn isnot working, have it repaired before tripdeparture.
15.2 Check the wiper and washer control onthe multifunction turn signal switch. If thewipers and/or washers are not working,have them repaired before trip departure.
16. During cold weather, make sure the heater, de-froster, and optional mirror heat controls are op-erating properly. If so equipped, turn on the mir-ror heat switch and make sure the system isworking.
17. Check the operation of all the panel lights andinterior lights.
Turn on the headlights, dash lights, and four-wayflashers and leave them on. If any of the gaugebulbs, the dome light bulbs, or the right- and left-turn indicator bulbs are not working, replacethem. See Chapter 19 of this manual for re-placement bulb identification.
18. Make sure all the exterior lights are workingproperly.
Check that all the lights and reflectors are clean.See Fig. 15.7.
18.1 Check that the brake lights, taillights,headlights, parking lights, turn signals,road lights (if so equipped), and frontclearance lights are working properly andare clean.
18.2 Test the high and low beams of the head-lights.
18.3 Replace light bulbs or sealed beam unitsthat are not working.
18.4 Be sure all reflectors and lenses are ingood condition and are clean. Replaceany broken reflectors or lenses.
19. Check tire inflation pressures using an accuratetire pressure gauge.
Pre- and Post-Trip Inspections and Maintenance
15.5
Tires should be checked when cool. For inflationpressures and maximum loads (per tire) see thetire manufacturer’s guidelines.
19.1 Be sure valve stem caps are on every tireand that they are screwed on finger-tight.
19.2 Inflate the tires to the applicable pressuresif needed.
19.3 If a tire has been run flat or underinflated,check for possible wheel or tire damagebefore adding air.
Moisture inside a tire can result in bodyply separation or a sidewall rupture. Dur-ing tire inflation, compressed air reservoirsand lines must be kept dry. Use well-maintained inline moisture traps and ser-vice them regularly.
WARNINGDo not operate the vehicle with underinflated oroverinflated tires. Incorrect inflation can stressthe tires and make the tires and wheels suscep-tible to damage, possibly leading to wheel or tirefailure and loss of vehicle control, resulting inserious personal injury or death.
IMPORTANT: The load and cold inflation pres-sure must not exceed the wheel manufacturer’srecommendations, even though the tire may beapproved for a higher load inflation. Somewheels are stamped with a maximum load andmaximum cold inflation rating. If they are notstamped, consult the wheel manufacturer for thecorrect tire inflation pressure for the vehicleload. If the load exceeds the maximum wheelcapacity, the load must be adjusted or reduced.
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 andfuel 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.
20. Inspect each tire for wear, bulges, cracks, cuts,penetrations, and oil contamination. A weeklypressure loss of 4 psi (28 kPa) or more in a tiremay indicate damage. The tire should be in-spected and if necessary, repaired or replaced.
20.1 Check the tire tread depth. If tread is lessthan 4/32 inch (3 mm) on any front tire, orless than 2/32 inch (1.5 mm) on any reartire, replace the tire.
20.2 Inspect each tire for bulges, cracks, cuts,and penetrations.
20.3 Inspect each tire for oil contamination.Fuel oil, gasoline, and other petroleumderivatives, if allowed to contact the tires,will soften the rubber and destroy the tire.
21. Check the wheel nuts for indications of loose-ness. Examine each wheel component.
21.1 Remove all dirt and foreign material fromthe assembly. Dirt or rust streaks from thestud holes, metal buildup around studholes, or out-of-round or worn stud holesmay be caused by loose wheel nuts. SeeFig. 15.8 and Fig. 15.9.
21.2 Examine the wheel components (includingstuds, and nuts) for cracks, or other dam-age.
08/15/2006 f544882
12
3
4
4
1. Headlight High Beam2. Headlight Low Beam
3. Side-View Mirror4. Marker Light
Fig. 15.7, Exterior Lights
Pre- and Post-Trip Inspections and Maintenance
15.6
See Group 33 or Group 35 of the S2Chassis Workshop Manual for service pro-cedures on the studs and hubs, and seeGroup 40 in the same manual for wheeland tire servicing, or take the vehicle to anauthorized Freightliner dealer.
WARNINGHave any worn or damaged wheel componentsreplaced by a qualified person using the wheelmanufacturer’s instructions and the wheel indus-try’s standard safety precautions and equipment.Otherwise a vehicle or workshop accident couldoccur, possibly resulting in serious personal in-jury or death.
21.3 Make sure all wheel nuts are tightened450 to 500 lbf·ft (610 to 678 N·m) for Ac-curide wheels with unlubricated threads.Use the tightening pattern in Fig. 15.10 for10-hole wheels and the tightening patternin Fig. 15.11 for 8-hole wheels. SeeGroup 40 of the S2 Chassis WorkshopManual for more information.
NOTICEInsufficient wheel nut torque can cause wheelshimmy, resulting in wheel damage, stud break-age, and extreme tire tread wear. Excessivewheel nut torque can break studs, damagethreads, and crack discs in the stud hole area.
Use the recommended torque values and followthe proper tightening sequence.
02/09/95 f400058
Fig. 15.8, Dirt and Rust Streaks from the Stud Holes
02/09/95 f400001
Fig. 15.9, Worn Stud Holes
1
2
3
45
6
7
8
9
10
f400081a08/23/93
Fig. 15.10, Tightening Pattern, 10-Hole Wheels
Pre- and Post-Trip Inspections and Maintenance
15.7
NOTE: Vehicles operating under severe or ad-verse conditions should be checked more fre-quently.
22. Inspect the air brake chamber and the air brakechamber pushrods. See Fig. 15.12.
DANGERDo not loosen or remove the parking brake clampring for any purpose. See Fig. 15.11. The parking/emergency brake section of the brake chamber isnot intended to be serviced. Serious injury or
death may result from sudden release of thepower spring.
Before doing any repairs or adjustments on aservice/parking brake chamber, read the appli-cable warnings and instructions in Group 42 ofthe S2 Chassis Workshop Manual.
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.
22.1 Check that the air brake chamber ismounted securely on its mounting bracket,and that there are no loose or missingbolts.
22.2 Look for worn clevis pins on brake cham-ber pushrods, and missing or damagedcotter pins on brake chamber pushrodclevis pins. Replace worn clevis pins andinstall new cotter pins if necessary.
22.3 See if the chamber piston rod is in linewith the slack adjuster. Misalignment cancause the piston rod to rub on the non-pressure chamber and cause a draggingbrake. See Group 42 of the S2 ChassisWorkshop Manual.
22.4 Inspect the exterior surfaces of the cham-ber for damage. Make sure that breatherholes in the non-pressure section(s) areopen and free of debris. See Group 42 ofthe S2 Chassis Workshop Manual to re-place any damaged parts.
22.5 On all parking brake installations, makesure the end cover cap or dust plug is se-curely snapped into place.
NOTE: On most MGM parking brake cham-bers equipped with an integral release bolt,an end cover cap is installed over the re-lease bolt.
22.6 Check for rusted connections, missingsnap rings, and damaged camshaftgrease seals. Have damaged or missingparts repaired or replaced.
23. Inspect the air brake lines.
f400052a
1 2
3
4
5 6
7
803/08/2012
Fig. 15.11, Tightening Pattern, 8-Hole Wheels
f42135202/22/2017
1
A
A. Do not remove this clamp ring.1. MGM TR–T (TR Series) Brake Chamber Shown
Fig. 15.12, Parking Brake Chamber Clamp
Pre- and Post-Trip Inspections and Maintenance
15.8
23.1 Check the clearance between the hosesand the exhaust manifold or other hotspots. Excessive heat will cause materialin the hoses to deteriorate rapidly or be-come brittle. Provide at least 6 inches(150 mm) of clearance. More clearance isrecommended if the hose is located abovethe heat source.
23.2 Check for kinks, dents, or swelling of thehoses. If damaged, have the hose re-placed with the same size and type.
NOTE: Do not route the hose on top of any-thing likely to be stepped on.
23.3 Check for damage to hoses located nearmoving parts, such as drivelines, kingpins,suspensions, and axles. If moving partsare catching or pinching the lines, correctas needed.
23.4 Check for hose damage caused by abra-sion. If abraded, have the hose replaced.Check for the cause of abrasion, such asloose or damaged hose clamps. Have theclamps repaired or replaced as needed.
23.5 Observe the hose cover condition, espe-cially hoses exposed to water splash andice. If dried out or ragged (the wire or lineris showing through the cover), have thehose(s) replaced.
23.6 Inspect the air tubing, especially tubingmade of nylon. In cold weather, nylon tub-ing is sensitive to damage, such as nicksor cuts. Have nicked or cut tubing re-placed, even if it is not leaking.
NOTE: The front brake lines flex continu-ously in vehicle operation, so they requirespecial examination. Give particular attentionto the areas near where they connect to thefront air brake chambers.
23.7 This inspection requires two people, onein the driver seat, and another to inspectthe brake line connections at the wheels.
Both wheel air lines must be inspectedwith the emergency brake set, engineidling, air pressure at 80 to 90 psi (550 to620 kPa), and the brake pedal held down.
23.8 Turn the wheels to full lock in one direc-tion and inspect both air lines where theyconnect to the air chambers, then turn the
wheels to full lock in the other directionand inspect both lines. If a hose is leak-ing, have it replaced.
IMPORTANT: ABS-equipped vehicles operat-ing in regions where especially corrosive iceremoval chemicals are used may experiencehigher than normal rotor corrosion. Tonerings should be routinely inspected for corro-sion. Severe corrosion of the integral ABStone ring may cause the ABS warning lampin the dash to illuminate due to false wheelspeed readings. If the ABS warning lampilluminates at any time other than at vehiclestart-up, have the problem repaired immedi-ately.
24. Inspect the slack adjusters.
24.1 Meritor Slack Adjusters: Check the bootfor cuts, tears, or other damage. Have itreplaced if necessary.
24.2 Gunite Slack Adjusters: Inspect the slackadjuster for any signs of damage. If dam-aged, have the slack adjuster replaced.
Inspect the slack adjuster boot for cuts ortears. If the boot is damaged, have it re-placed. See Fig. 15.13.
24.3 Haldex Slack Adjusters: Inspect eachslack adjuster and anchor strap for dam-age. Have any damaged components re-placed.
25. Check the air brake system for proper operation.
25.1 Check the air governor cut-in and cut-outpressures as follows:
Run the engine at fast idle. The air gover-nor should cut out the air compressor atapproximately 120 psi (827 kPa). With theengine idling, apply the brake pedal sev-eral times. The air governor should cut inthe air compressor at approximately 100psi (689 kPa). If the air governor does notcut in and out as described above, it mustbe adjusted to these specifications. If theair governor cannot be adjusted or re-paired, replace it before operating the ve-hicle.
25.2 Check the air pressure buildup time asfollows:
Pre- and Post-Trip Inspections and Maintenance
15.9
With the air system fully charged to 120psi (827 kPa), make one full brake appli-cation and note the air pressure readingon the gauge. Continue to reduce the airpressure by moderate brake applicationsto a maximum of 90 psi (620 kPa), thenrun the engine at governed rpm. If thetime required to raise the air pressure to120 psi (827 kPa) (from the pressurenoted after one brake application) is morethan 30 seconds, eliminate any leaks orreplace the air compressor before operat-ing the vehicle.
25.3 Check the air pressure reserve as follows:
With the air system fully charged to 120psi (827 kPa), stop the engine and notethe air pressure. Then make one full brakeapplication and observe the pressuredrop. If it drops more than 25 psi (172kPa), all areas of leakage must be elimi-nated before operating the vehicle.
25.4 Check the air leakage in the system asfollows:
With the parking brake (spring brake) ap-plied, the transmission out of gear, andthe tires chocked, charge the air systemuntil cut-out pressure of 120 psi (827 kPa)is reached.
With the service brakes released, shutdown the engine, wait 1 minute and notethe air pressure gauge reading. Observethe air pressure drop in psi (kPa) per min-ute.
Charge the air system until cut-out pres-sure of 120 psi (827 kPa) is reached. Withthe parking brakes released and the ser-vice brake applied, shut down the engine,wait 1 minute and note the air pressuregauge reading. Observe the air pressuredrop in psi (kPa) per minute.
If leakage exceeds the limits shown inTable 15.1, repair all areas of leakage be-fore driving the vehicle.
Maximum Allowable Service Brake LeakageMaximum Air Leakage Per Minute
Brakes Released Brakes Applied2 psi (14 kPa) 3 psi (21 kPa)
Table 15.1, Maximum Allowable Service BrakeLeakage
26. Check the operation of the Bendix® Hydro-Maxbrake booster, as follows.
26.1 With the ignition off, depress the brakepedal and listen for the back-up motor toengage. The operator should also feel thepedal force relieve and the pedal shoulddepress easily.
26.2 With the engine running, and the parkingbrake released, ensure that the BRAKEwarning indicator light is not on. This is adual indicator, and indicates that the park-ing brake is set, and warns if there is aHydro-Max failure condition other thanloss of back-up motor power.
27. Test the service brakes.
When starting to move the vehicle and beforepicking up speed, test the brakes with the footpedal and parking brake control valve (yellowknob) to be sure they will bring the vehicle to asafe stop.
f42139802/03/2017
1
2
3
45
6
7
8
10
9
1. 7/16-inch Adjusting Nut2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston Rod6. Clevis7. ½-inch Clevis Pin8. 1/4-inch Clevis Pin9. Grease Relief Opening10. Slack Adjuster Spline
Fig. 15.13, Gunite Automatic Slack Adjuster
Pre- and Post-Trip Inspections and Maintenance
15.10
Weekly Post-Trip Inspectionand Maintenance Procedures1. Inspect the batteries and battery cables.
WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.
1.1 Access the batteries. Be sure the batteryhold-down is secure. If it is loose, tightenthe hold-down bolts; if it is broken, replaceit.
1.2 If the battery is equipped with a built-inhydrometer, examine the hydrometer. If agreen dot shows in the sight glass, thebattery is sufficiently charged.
If the sight glass is dark, the charge is lowand the battery must be recharged.
If the sight glass is clear, the battery has alow level of electrolyte and must be re-placed.
2. Check the level of the wheel bearing lubricant inthe hub cap at each end of the front axle.
If needed, fill the hubs to the level indicated onthe hub cap. See Chapter 19, for recommendedlubricants.
IMPORTANT: Before removing the fill plug, al-ways clean the hub cap and plug.
3. Examine the steering components.
See Fig. 15.14. If repairs are needed, seeGroup 46 of the S2 Chassis Workshop Manualfor instructions, or take the vehicle to an autho-rized Freightliner dealer.
3.1 Check the mounting bolts and pitman armnut, for tightness.
3.2 Check the drag link nuts for missing cotterpins.
3.3 Inspect the steering drive shaft and steer-ing linkage for excessive looseness, orother damage.
3.4 Tighten loose nuts and have damagedparts replaced as needed.
4. Check the condition of the serpentine drive belt.
Look for signs of glazing, wear (frayed edges),damage (breaks or cracks), or oil contamination.If a belt is glazed, worn, damaged, or oil soaked,have the belt replaced, following the instructionsin Group 01 of the S2 Chassis WorkshopManual.
5. Check the drive belt for proper tension.
Use your index finger to apply force at the centerof the belt free-span. See Fig. 15.15. There is no
f46191605/16/2017
1
1
1
2
3
3
1. Steering Gear Mounting Bolt2. Pitman Arm Pinch Bolt Nut3. Drag Link Nut
Fig. 15.14, Steering Gear Fasteners
10/31/94 f200036a
A
B
A. Deflection B. Belt Free-Span
Fig. 15.15, Checking Belt Tension
Pre- and Post-Trip Inspections and Maintenance
15.11
adjustment for belt tension on engines with auto-matic belt tensioners. If there is not proper ten-sion, have the belt tensioner replaced. SeeGroup 01 of the S2 Chassis Workshop Manualfor instructions, or take the vehicle to an autho-rized Freightliner dealer.
6. Inspect the seat belts and tether belts.
WARNINGInspect and maintain seat belts as instructedbelow. Worn or damaged seat belts could failduring a sudden stop or crash, possibly resultingin serious injury or death.
IMPORTANT: Seat belts have a finite lifewhich may be much shorter than the life ofthe vehicle. Regular inspections and re-placement as needed are the only assur-ance of adequate seat belt security over thelife of the vehicle.
NOTE: When any part of a seat belt needsreplacement, the entire seat belt must bereplaced, both retractor and buckle side.
6.1 Check the web for fraying, cuts, or ex-treme wear, especially near the bucklelatch plate and in the D-loop guide area.
6.2 Check the web for extreme dirt or dustand for severe fading from exposure tosunlight.
6.3 Check the buckle and latch for operationand for wear or damage.
6.4 Check the Komfort Latch for function andcracks or other damage.
6.5 Check the web retractor for function anddamage.
6.6 Check the mounting bolts for tightnessand tighten any that are loose.
Monthly Post-Trip Inspectionand Maintenance Procedures
WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-
sonal injury, always wash your hands after han-dling battery parts and related accessories.
1. Clean the batteries.
1.1 Remove any corrosion from the hold-downand the top of the battery.
NOTICETake care to keep the vent plugs tight so that theneutralizing solution does not enter any of thebattery cells and damage the battery.
1.2 Use a soda solution to neutralize the acidpresent, then rinse off the soda solutionwith clean water.
1.3 If the battery posts or cable terminals arecorroded, disconnect the terminals fromthe posts. Clean them with a soda solutionand a wire brush. After cleaning, connectthe terminals to the battery posts, thenapply a thin coat of petroleum jelly to theposts and terminals to help retard corro-sion.
2. Inspect the radiator and heater hoses, includingthe clamps and support brackets.
2.1 Make sure the radiator inlet and outlethoses are pliable and are not cracking orballooning. Replace hoses that show signsof cracking, weakening, or ballooning.
2.2 Make sure the heater hoses are pliableand are not cracking or ballooning. Re-place hoses that show signs of cracking,weakening, or ballooning.
2.3 Tighten hose clamps as necessary, but donot overtighten, as hose life can be ad-versely affected.
2.4 Be sure the hose support brackets aresecurely fastened. Make sure the hosesare not located near sources of wear,abrasion, or high heat.
IMPORTANT: Replace all hoses, includingheater hoses, at the same time. Service-typeknitted or braided yarn-reinforced neoprenehose is acceptable. Silicone hoses having anextended service life can be substituted for thereinforced neoprene type. See the FreightlinerService Parts Catalog or contact your Freight-liner dealer.
Pre- and Post-Trip Inspections and Maintenance
15.12
3. Check the fluid level in the hydraulic brake fluidreservoir, if so equipped.
If needed, fill the reservoir to the bottom of thefill-neck with DOT 3 heavy-duty brake fluid. SeeFig. 15.16.
4. Check the steering wheel for excessive play. SeeFig. 15.17.
4.1 With the front tires straight ahead, turn thesteering wheel until motion is observed atthe front wheels.
4.2 Align a reference mark on a ruler, thenslowly turn the steering wheel in the oppo-site direction until motion is again detectedat the wheels.
4.3 Measure the lash (free play) at the rim ofthe steering wheel. Excessive lash existsif steering wheel movement exceeds 2-1/4inches (57 mm) with an 18-inch (450-mm)steering wheel.
See local/federal regulations for accept-able ranges of lash.
5. Check the brake lining wear on all vehicles, in-cluding those with automatic slack adjusters.Proper brake operation is dependent on periodicmaintenance and inspection of the brake linings.
5.1 Check that brake linings are free of oil andgrease.
5.2 Inspect the thickness of the brake linings.If the axle assembly is equipped with adust shield or backing plate, remove theinspection plugs. If any brake linings areworn to less than approximately 1/4 inch(6.4 mm) at the thinnest point, have thelinings replaced on all brake assemblieson that axle. See Group 42 of the S2Chassis Workshop Manual for lining re-placement instructions and camshaft end-play inspection.
5.3 Check the brake drums for wear andcracks.
5.4 Check that the inspection plugs in the dustshields or backing plates, if so equipped,are installed.
07/31/2015 f460513b
A
B
A. Open caps and check fluid level.B. Fill to this level.
Fig. 15.16, Hydraulic Brake Reservoir
10/10/95 f461057
A
A. Lash Area
Fig. 15.17, Measuring Lash at the Steering Wheel
Pre- and Post-Trip Inspections and Maintenance
15.13
16
Cleaning and CareWashing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Dashboard and Instrument Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
Washing and Polishing
NOTICEWhen pressure washing the vehicle or leavingthe hood open when parked outdoors and sub-ject to rain, cover the air cleaner inlet with a plas-tic bag to prevent water from entering the air in-take system and possibly damaging the engine.
To protect the new vehicle’s finish, follow theseguidelines carefully:
• During the first 30 days, rinse the 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 the vehicle. Brushes, chemicals,and cleaners may scratch the finish.
• During the first 120 days, do not wax thevehicle.
To extend the life of the vehicle’s finish, follow theseguidelines:
• Avoid washing the vehicle in the hot sun. Al-ways use water. After the vehicle is completelywashed, dry it with a towel or chamois.
• Do not dust painted surfaces with a dry cloth,as this will scratch the paint.
• Do not remove ice or snow from a painted sur-face with a scraper of any sort.
• To prevent damage to the finish, wax it regu-larly. If the finish has become dull, before wax-ing, remove oxidized paint using a cleaner spe-cifically designed for this purpose. Remove allroad tar and tree sap before waxing. Freight-liner recommends the use of a high qualitybrand of cleaner or cleaner-polish and polish-ing wax.
• Do not let diesel fuel or antifreeze stand on apainted surface. If either should occur, rinsethe surface off with water.
• To prevent corrosion, have any nicks or otherdamage on the finish touched up as soon aspossible.
• Park the vehicle in a sheltered area wheneverpossible.
Care of Fiberglass PartsWash unpainted fiberglass air fairings and shieldsmonthly with a mild detergent, such as dishwashingliquid. Avoid strong alkaline cleansers.
Apply a wax specifically designed for fiberglass.
Care of Chrome PartsTo prevent rust, keep chrome parts clean and pro-tected at all times. This is especially important duringwinter driving and in coastal areas where there isexposure to salt air.
When cleaning chrome parts, use clean water and asoft cloth or sponge. A mild detergent may also beused.
Sponge gently, then rinse. If necessary, use a non-abrasive chrome cleaner to remove stubborn rust orother material. Do not use steel wool.
To help protect the chrome after cleaning, apply acoat of polishing wax to the surface. Never use waxon parts that are exposed to high heat, such as ex-haust pipes.
Care of Exterior LightsClean the headlight lenses by hand only, using aflannel cloth with mild, non-caustic soap or detergent,and water.
NOTICEDo 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 and InstrumentPanel 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 can
Cleaning and Care
16.1
also 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 CreosoteTars, asphalts, and creosote stain vinyl after pro-longed contact. They should be wiped off immedi-ately and the area carefully cleaned, using a clothdampened with naphtha.
Paint and Shoe Heel MarksPaint should be removed immediately. Do not usepaint remover or liquid-type brush cleaner on vinyl.An unprinted cloth, dampened with naphtha or tur-pentine may be used. Use care to prevent contactwith parts of the upholstery that are not vinyl.
Sulfide StainsSulfide compounds, such as those found in eggs andsome canned goods, can stain after prolonged con-tact with vinyl. These stains can be removed by plac-ing a clean, unprinted piece of cloth over the spottedarea and pouring a liberal amount of 6 percent hy-drogen peroxide onto the cloth. Allow the saturatedcloth to remain on the spot for 30 to 60 minutes. Forstubborn spots, allow the hydrogen-peroxide satu-rated cloth to remain on the area overnight. Use cau-tion to prevent the solution from seeping into theseams or it will weaken the cotton thread.
Nail Polish and Nail Polish RemoverProlonged contact with these substances causes per-manent damage to vinyl. Careful blotting immediatelyafter contact minimizes damage. Do not spread theliquid during removal.
Shoe PolishMost shoe polishes contain dyes which penetratevinyl and stain it permanently. Shoe polish should bewiped off as quickly as possible using naphtha orlighter fluid. If staining occurs, try the procedure usedfor sulfide stains.
Ball Point InkBall point ink can sometimes be removed if rubbedimmediately with a cloth damp with water or rubbingalcohol. If this does not work, try the procedure usedfor 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.
Cleaning and Care
16.2
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.
Cleaning and Care
16.3
17
In an EmergencyHazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3Running Out of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4Changing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6Flare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
Hazard Warning LightsThe hazard warning light switch is part of the multi-function turn signal switch. It is a red rocker switchlocated on the top of the multifunction switch module.See Fig. 17.1.
To activate the hazard warning lights, press down onthe upper part of the rocker switch (towards thedash). To cancel the hazard warning lights, pressdown on the lower part of the rocker switch (towardsthe steering wheel).
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 heatin 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.
NOTICEMake sure that both starting systems are thesame voltage. Electronic devices on both ve-hicles can be damaged when connected to a ve-hicle with a different operating voltage.
1. Apply the parking brakes and turn off all lightsand other electrical devices.
IMPORTANT: Do not attempt to jump start adamaged battery.
2. Open the battery door to access the batteries.Pull both pull-pin spring latches and slide thebattery tray out. See Fig. 17.2.
NOTICEAlways connect the batteries and jumper cablescorrectly (positive-to-positive and negative-to-negative). Connecting a charging device back-wards (positive-to-negative) can severely damagethe vehicle electrical content and cause non-warrantable failures.
3. Connect the positive (+) jumper cable to thepositive terminal on the discharged battery. SeeFig. 17.3.
4. Connect the other end of the positive jumpercable to the positive terminal on the booster bat-tery providing the charge.
f820386
12
3
4
5
11/16/2001
Press down on the upper part of the rocker to activatethe hazard warning lights.1. Washer Button2. Wiper Control Dial3. Turn Signal Lever4. Hazard Warning Light Switch (red)5. Multifunction Switch Module
Fig. 17.1, Multifunction Turn Signal Switch
12/05/2003 f544365
1
2 23
4
1. Battery Access Door2. Pull-Pin Spring Latch
3. Battery Tray4. Battery
Fig. 17.2, Battery Access
In an Emergency
17.1
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.
5. Connect the negative (-) jumper cable to thenegative terminal on the booster battery.
6. Connect the other end of the negative jumpercable to the negative ground stud on the vehiclerequiring the jump start.
7. Start the engine of the vehicle providing the jumpstart and let the engine run for a few minutes tocharge the batteries of the other vehicle.
01/07/2011 f545725
1
2
3
4
A
C
EB
D
−−
−
−
+
+
+
+
+
+
−
−
Disconnect jumper cables in the REVERSE order that they were connected.
A. Discharged BatteryB. Negative Ground Stud
C. Positive Jumper CableD. Negative Jumper Cable
E. Booster Battery
1. 1st Connection: Positive Jumper Cable to Discharged Battery2. 2nd Connection: Positive Jumper Cable to Booster Battery3. 3rd Connection: Negative Jumper Cable to Booster Battery4. 4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)
Fig. 17.3, Jumper Connections (three battery system shown for clarity)
In an Emergency
17.2
NOTICEDo not crank the engine for more than 30 sec-onds at a time during any of the following proce-dures. Wait two minutes after each try to allowthe starter to cool. Failure to do so could causestarter damage.
8. Attempt to start the engine of the vehicle with thebatteries receiving the charge.
9. When the engine starts, let it idle for a few min-utes.
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.
10. Disconnect the negative jumper cable from thenegative cable stud on the jump started vehicle.
11. Disconnect the negative jumper cable from thebooster battery.
12. Disconnect the positive cable from the boosterbattery.
13. Disconnect the other end of the positive jumpercable from the jump started vehicle.
14. Pull both pull-pin spring latches and slide thebattery tray back into position. Release the pull-pin spring latches to lock the battery tray, thenclose the battery door.
Towing
WARNINGDo not tow an unbraked vehicle if the combinedweight of both vehicles is more than the sum ofthe gross axle weight ratings (GAWR) of the tow-ing vehicle. Otherwise brake capacity will be in-adequate, which could result in personal injury ordeath.
IMPORTANT: When it is necessary to tow thevehicle, make sure the instructions below areclosely followed to prevent damage to the ve-hicle.
NOTE: Towing rules and regulations vary fromfederal, state, local, and transit authority. Theselaws must be followed when towing the vehicle.
Front Towing Hookup
NOTICEThe vehicle should never be towed from the rear.The gross axle weight rating (GAWR) of the frontaxle may not be sufficient to support the in-creased load when towing from the rear. Thiscould damage the front axle.
1. Disconnect the battery ground cables.
NOTICEFailure to remove the axle shafts when towingthe vehicle with the rear wheels on the groundcould result in damage to the transmission andother parts.
2. Remove the drive axle shaft.
IMPORTANT: Cover the ends of the hubs withmetal plates or plywood cut to fit the axle open-ing, and drilled to fit the axle shaft studs. Thisprevents lubricant from leaking out and will keepcontaminants from getting into and damagingthe wheel bearings and axle lubricant.
NOTICEFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.
3. Remove the bumper.
4. Attach the towing device. Due to the many vari-ables that exist in towing, positioning the liftingand towing device is the sole responsibility of thetowing-vehicle operator.
5. Lift the vehicle and secure the safety chains. Ifextra towing clearance is needed, remove thefront wheels.
6. Connect the clearance lights, taillights, and sig-nal lights. Connect any special towing lights re-quired by local regulations.
In an Emergency
17.3
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.
NOTICEBefore attempting to tow a vehicle with an airsuspension (and during the towing operation),ensure that the air suspension is properlycharged. Charge the suspension through theSchrader valve on the air dryer. Attempting totow a vehicle with an improperly charged air sus-pension may result in damage to the chassis andbody.
7. 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 brake and remove the chocks.
8. On vehicles equipped with hydraulic disc brakesbe sure the parking brake is released beforestarting the towing process.
Running Out of Fuel
WARNINGDo not mix gasoline or alcohol with diesel fuel.This mixture could cause an explosion. When fill-ing fuel tanks, do not smoke or use an openflame near the fuel tanks. Combustion of dieselfuel oil or fuel vapors could result, possibly caus-ing personal injury or property damage.
1. If possible, stop the vehicle on a level surface,away from traffic.
2. Apply the parking brake.
IMPORTANT: Any time the vehicle runs out offuel, the fuel system should be primed. This willpurge any trapped air in the system and allowsfuel to fill the fuel filter.
3. See the engine manufacturer’s manual for in-structions to prime the fuel system.
4. If further assistance is needed, call the Freight-liner Customer Assistance Center at 1-800-385-4357 or 1-800-FTL-HELP.
NOTICEDo not crank the engine for more than 30 sec-onds at a time during the following procedure.Wait two minutes after each try to allow thestarter to cool. Failure to do so could causestarter damage.
5. Add fuel to the fuel tank.
6. After adding fuel to the fuel tank, start the en-gine. Once the vehicle is running, let the engineidle until it operates smoothly before driving thevehicle.
Changing a Flat Tire
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.
WARNINGWheel lug nut torque is very high and thewheel/tire assemblies are very heavy. Changing atire could result in back injury. If possible, call aqualified service facility to change a flat tire.
IMPORTANT: If a flat tire occurs while driving,gradually decrease vehicle speed. Holding thesteering wheel firmly, move to a safe place onthe side of the road.
1. Stop the vehicle on a level surface, away fromtraffic.
2. Apply the parking brake, place the transmissionin neutral (N), and shut down the engine.
3. Turn on the hazard warning lights.
4. Block the wheel diagonally opposite the wheelbeing changed.
5. Remove the spare wheel, jack, jack handle, andlug wrench from storage.
In an Emergency
17.4
WARNINGThis vehicle is very heavy. Jacking this vehicleshould be done with extreme caution. The vehiclecould slip, causing personal injury or death.
IMPORTANT: The jacking point for the frontwheels is on the front axle beam and other loca-tions shown in Fig. 17.4. The jacking point forrear wheels is on the rear axle and at the loca-tions on the rear suspension H-frame, shown inFig. 17.4.
Only use the front bumper locations if the ve-hicle is equipped with a jackable bumper. Whenjacking the front bumper, the jacking point(s)must be centered and within the bottom surfaceof the bumper support as shown in Fig. 17.4.Do not position the jack under the droppedframe rails in the center section of the vehicle.
6. Place the jack on a solid surface. Insert the jackhandle and pump the handle slightly. Do notraise the wheel off of the ground yet. Loosen thewheel lug nuts, but do not remove them.
IMPORTANT: The dual rear wheels are attachedusing two-element lug nuts. The larger nut re-tains the outer dual. The inner square stud re-tains the inner dual. Remove and install thesenuts separately. The rear dual outer lug nutmust be loosened to check and retighten theinner nut.
7. Raise the vehicle until the wheel is off of theground. Remove the lug nuts and the wheel.
8. Install the spare wheel and lug nuts. Make surethat the beveled sides of the nuts face inward,or, on hub-piloted wheels, make sure that thehub-pilot pad is centered at the top.
IMPORTANT: When a tire is changed, the ve-hicle should be taken to a mechanic as soon aspossible, to have the lug nuts tightened properlywith an impact air gun.
9. In a star pattern, tighten the nuts evenly untilsnug. See Group 40 of the S2 WorkshopManual for wheel tightening patterns and torquespecifications. Lower the vehicle until the wheeltouches the ground. Tighten the nuts.
10. Finish lowering the vehicle to the ground, thenremove the jack.
11. Remove the block, then stow the jack, jackhandle, and lug wrench.
12. After operating the vehicle for 50 to 100 miles(80 to 161 km), retighten the wheel nuts to the
specified torque values.
Fire ExtinguisherAn optional fire extinguisher is located in the front ofthe cab, between the driver and passenger seats.
12/13/2010 f311093
1 2
3
1. Jack Locations—Front Axle 2. Jack Locations—Rear Axle 3. Jack Locations—Front Bumper
Fig. 17.4, Jack Placement
In an Emergency
17.5
First Aid KitAn optional first aid kit is mounted to the back of thecab, between the driver and passenger seats.
Flare KitAn optional flare kit is located in the center of thecab, between the driver and passenger seats.
In an Emergency
17.6
18
Headlight AimingPreliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Preliminary ChecksBefore checking or adjusting the headlight aim, dothe following:
• Check that the hood is closed and latched.
• Check the suspension for proper functioning ofthe leveling mechanism. On vehicles with airsuspensions, make sure that the height isproperly adjusted.
• Remove any large amounts of mud or ice fromthe underside of the fenders.
• Check the springs for sagging or brokenleaves.
• Check for damage to the hood and hinge as-sembly. Repair as necessary.
• Clean the headlight lenses. Use a soft clothwith mild, non-caustic soap or detergent, andwater.
• With the vehicle unloaded, check that the tiresare inflated to the recommended air pressure.
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. 18.1. Measure the distance from the groundto the height adjusting dot on each headlight.Note those distances. See Fig. 18.2, Ref. A.
3. Mark the vertical distances found in step 2 onthe screen or wall, directly in front of the head-lights. These marks represent the desired loca-tions of each headlight bulb center in the follow-ing steps. See Fig. 18.2, Items 2 and 3.
4. Turn on the low-beam headlights.
5. Identify the center of each beam projection bymarking the area of brightest intensity on thewall. The area of brightest intensity should fall onor very near the marks made during step 3. SeeFig. 18.3.
6. Use Table 18.1 to determine the maximum verti-cal distance allowable between the marks madein step 3 and the marks made in step 5. If thevertical distance between the marks made insteps 3 and 5 is greater than the maximum dis-tance given in Table 18.1, adjust the vertical po-sitioning of that headlight.
Adjusting Headlight AimNOTE: Because of the various headlight assem-bly options offered, the location of adjustmentscrews on the vehicle’s headlight assembly mayvary from what is shown here.
1. Lift the flap over the rear end of the headlightbucket to expose the two plastic adjusting knobson each headlight. See Fig. 18.4.
2. If necessary, adjust the horizontal positioning ofthe headlights so that each projection points di-rectly forward.
3. Turn the vertical adjustment knob to adjust theheadlight beam to meet the desired height. SeeTable 18.1. Turn the knob clockwise to raise thebeam; turn the knob counterclockwise to lower it.
4. Adjust the other headlight.
11/06/2002 f544236
Measure beam height from the ground to the small dotroughly in the center of the headlight lens.
Fig. 18.1, Headlight Beam Height Adjusting Dot
Headlight Aiming
18.1
f545850g10/15/2012
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. 18.2, Headlight Aiming Screen/Wall
10/15/2012 f545851g
A
12
3
1. Low-Beam Angle Upper Limit2. Ideal Low-Beam Projection
3. Low-Beam Angle Lower Limit
Fig. 18.3, Vertical Low-Beam Headlight Variation Limits
Headlight Aiming
18.2
Vertical Low-Beam Headlight Variation LimitsDistance Between Ground
and Headlight: in (mm)Desired Variation ( Fig. 18.3,
Item 2): in (mm)Upper Limit ( Fig. 18.3, Item
1): in (mm) upLower Limit ( Fig. 18.3, 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 18.1, Vertical Low-Beam Headlight Variation Limits
11/05/2002 f544235
1
2
NOTE: The right-hand side headlight bucket is shown.The left-hand side is opposite.1. Horizontal (inboard) Adjusting Knob2. Vertical (outboard) Adjusting Knob
Fig. 18.4, Headlight Adjusting Knobs
Headlight Aiming
18.3
19
Propane Fuel SystemGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3Propane Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4Warning and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9Grade Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10Ametek Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10
General Information
CAUTIONThe propane fuel system requires special tools tomake repairs. Service and repair of the propanefuel system should only be performed by trainedpropane service technicians. To prevent personalinjury or damage to the fuel system, do not at-tempt repairs yourself.
DANGERNever cut or weld on the propane storage tank.Severe bodily injury or fire could result.
Propane is highly flammable. Keep sparks andopen flames away from propane. Do not smokewhen refueling the vehicle. Failure to observethese safety precautions could cause seriousbodily injury or death.
The information provided in this chapter is specific tothe propane engine, however, other chapters in thismanual pertain to the propane operated vehicle.These include, but are not limited to, the controls andpretrip inspection and daily maintenance chapters.
IMPORTANT: For assistance with propane en-gine related questions, contact Freightliner Cus-tom Chassis Corporation at 1-800-385-4357,option 1.
NOTE: Oil consumption is normal during opera-tion of the propane engine. The rate of con-sumption is highly dependent on vehicle loadingand duty cycles. New engines may experiencehigher oil consumption during the enginebreak-in period. For further information, refer tothe engine manufacturer’s manual.
NOTICEIf the ignition switch is in the RUN position formore than 15 seconds and the fuel tank is empty,the fuel pump must be unplugged. Failure to fol-low this procedure will result in damage to thefuel pump. Refer to the propane engine manualfor instructions on how to unplug the fuel pump.
HD5 grade propane is recommended for propaneengines. HD5 is a heavy duty engine grade propanewith a minimum of 90% propane and a maximum of5% propylene. This grade of propane is 100 plus oc-
tane and provides proper performance and emissionscontrol, which the fuel system is designed to deliver.
The engine is designed to operate properly on awide variety of liquid propane gas (LPG) blendswhich can fall in the category of HD5, and is not af-fected by "heavy ends" or other waxy hydrocarbonsthat have traditionally affected other systems.
NOTICELPG should be free of contaminants including,but not limited to, rust, dirt, sand, water, salt, andbrine. These contaminants can cause enginedamage that is not covered by the engine war-ranty.
WARNINGThe propane fuel system operates at pressuresup to 312 psi (2151 kPa). A sudden release ofpropane can cause serious injuries if it contactsthe skin or eyes. Always wear protective glovesand eye protection when handling propane.
LPG has no color. A distinctive odorant, similar tosulfur or rotten eggs, is added to LPG to alert any-one nearby in the event of a leak.
Ignition Switch and KeyThe ignition switch can be turned to four positions:ACCESSORY, OFF, RUN, and START. SeeFig. 19.1.
The key can be inserted and removed only in theOFF position. The headlights (low beams), taillights,brake lights, road lights, clearance lights, turn sig-nals, hazard warning lights, horn, CB radio, clock,
08/27/2013 f610509a
Fig. 19.1, Ignition Switch Positions
Propane Fuel System
19.1
and electric oil pan heater operate with the ignition inthe OFF position, regardless of whether the key isinserted.
In the ACCESSORY position, the key is turned coun-terclockwise. All of the components that are operablein the OFF position are operable in the ACCESSORYposition, as well as the radio (if so equipped), mirrorheat, air dryer, and backup lights.
IMPORTANT: The propane engine is equippedwith an amber wait to start indicator. The indica-tor illuminates when the ignition is in the RUNposition prior to engine start-up. Do not crankthe engine until the wait to start indicator goesout. See the "Ametek Panel" information in thischapter for the location of the wait to start indi-cator.
Turn the key fully clockwise to the START position tostart the engine. When the engine starts, release thekey.
All electrical systems are operable in the RUN posi-tion. The warning lights and the buzzer for low airpressure and low oil pressure operate until minimumpressures are built up.
Engine OperationGeneral InformationNOTE: Before starting the engine, read the"Ametek Panel" information in this chapter andChapter 4 for detailed information on how toread the instruments and operate the controls.
Before operating the vehicle, perform the pretrip in-spection and daily maintenance checks in Chap-ter 14 and Chapter 15 of this manual.
NOTICEIf a vehicle does not start on the first attempt,make sure that the engine has completelystopped rotating before reapplying the starterswitch. Failure to do so can cause the pinion torelease and re-engage, which could cause ringgear and starter pinion damage.
Moving a vehicle with the starter and/or using thestarter to bump the engine for maintenance pro-cedures is strictly prohibited. Use of these meth-ods to bump the engine over or move the vehiclecan cause the pinion to release and re-engage,
which could cause ring gear and starter piniondamage.
Engine Starting1. Set the parking brake.
2. Turn the ignition switch to the RUN position.
The amber wait to start indicator light illuminateswhen the ignition is in the RUN position prior toengine start-up. Do not crank the engine until thewait to start indicator light goes out.
3. Make sure that the transmission shift control is inNeutral (N), or if so equipped, the Park (P) posi-tion.
WARNINGNever start the engine unless the parking brakeis applied. Accidental movement of the vehiclecould result in property damage, personal injury,or death.
IMPORTANT: Do not depress the throttle pedalwhile starting the engine.
4. Turn the ignition switch to the START position.After the engine starts, release the key.
NOTICEDo not crank the engine for more than 30 sec-onds at a time. Wait two minutes after each try toallow the starter to cool. Failure to do so couldcause starter damage.
5. Bring the engine up to operating speed graduallyas it warms up and develops stable oil pressure.
IMPORTANT: When the engine is started, ittakes a short time to build up a lubricating oilfilm between the shafts and bearings, and be-tween the pistons and cylinder walls. The oilpressure gauge indicates any drop in lubricatingoil pressure within 15 seconds of engine startup.
Engine ShutdownShut down the engine immediately if:
• the oil pressure gauge needle swings back andforth or falls sharply;
• engine power and rpm fall, even though theaccelerator pedal remains steady;
Propane Fuel System
19.2
• the exhaust pipe gives off heavy smoke;
• the coolant and/or oil temperature climb abnor-mally;
• abnormal sounds suddenly occur in the engine.
1. With the vehicle stopped, place the transmissionin Neutral (N), or if so equipped, the Park (P)position.
2. Set the parking brake.
3. Idle the engine for two to three minutes beforeshutting it down. This allows the lubricating oiland the coolant to carry heat away from thecombustion chambers, bearings, shafts, etc.
NOTE: Long periods of idling are not needed orrecommended.
4. Shut down the engine by turning the ignitionswitch to the OFF position.
TransmissionT-Handle Shift SelectorThe S2 propane chassis is equipped with an Allison2300 or 2350 Series transmission. A T-handle shiftselector is used by the driver to select the transmis-sion ranges. See Fig. 19.2. Refer to www.allison-transmission.com for additional information.
P (Park)Use park, if so equipped, when turning the engine onor off, to check vehicle accessories, or to operate theengine in idle for longer than 5 minutes. This positionplaces the transmission in neutral and engages thepark pawl of the transmission.
NOTE: This does not apply the parking brake.
The park pawl is standard on the 2350 seriestransmission. The park pawl effectively groundsthe transmission output shaft, thereby prevent-ing rotation of the driveline. Provided the vehicleis stationary, selecting P (park) on the shift se-lector, if so equipped, places the transmission inneutral and engages the park pawl.
PB (Auto-Apply Parking Brake, optionalon 2300 Series)The auto-apply parking brake places the transmis-sion in neutral and applies the parking brake.
R (Reverse)Reverse is used to back the vehicle. When the selec-tor is in reverse, the reverse warning signal willsound. Always bring the vehicle to a complete stopbefore shifting from a forward range to reverse, orfrom reverse to a forward range.
Do not idle in reverse for more than 5 minutes. Whentime at idle exceeds 5 minutes, select N (neutral), orif so equipped, P (park) or PB (auto-apply parkingbrake).
NOTE: The shift into reverse may not succeed ifa range inhibitor is active. Check the driver dis-play screen in the instrument panel for aRANGE INHIBIT message.
N (Neutral)The neutral position places the transmission in neu-tral. When neutral is selected, the vehicle servicebrakes, parking brake, or emergency brake must beapplied. Selecting neutral does not apply vehiclebrakes unless an auxiliary system to apply the park-ing brake is installed.
This position is used when starting the engine andfor stationary operation. It is also used to shut downthe vehicle when P (park) or PB (auto-apply parkingbrake) are not available on the shifter. In this case,the parking brake must be applied.
03/25/2014 f270166
Fig. 19.2, T-Handle Shift Selector
Propane Fuel System
19.3
Do not let the vehicle coast in neutral. If the vehicleis allowed to coast in neutral, the engine brake willnot work and the driver could lose control of the ve-hicle.
D (Drive)In the drive position, the transmission will initially gointo first range when drive is selected. As vehiclespeed increases, the transmission will upshift auto-matically through each available range up to fifth orsixth range. As the vehicle slows, the transmissionwill downshift automatically.
When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, thetransmission may upshift to the next higher range, ifthe engine is exceeding its governed speed in thelower range.
NOTE: The shift into drive may not succeed if arange inhibitor is active. Check the driver dis-play screen in the instrument panel for aRANGE INHIBIT message.
4 and 3 (Fourth and Third Ranges)Use the fourth or third range for heavy city traffic andfor braking on steep downgrades.
L (Low Range)Use low range when pulling through mud or deepsnow, when maneuvering in tight spaces, or whendriving up or down very steep grades. Low rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect.
NOTE: To have the transmission select theseranges automatically, leave the selector lever inD (drive).
Transmission Mode SwitchSome vehicles are equipped with a transmissionmode switch, shown in Fig. 19.3. The transmissionmode switch is a fuel conservation option that allowsthe driver to choose either performance or economyshifting. When the switch is in the on position (thetop of the rocker switch is pushed down), the trans-mission shift pattern changes from primary (perfor-mance) shift mode to secondary (economy) shiftmode. When the transmission mode switch is in theoff position (the bottom of the rocker switch is
pushed down), the transmission reverts back to theprimary shift mode.
NOTE: Primary and secondary shift mode cali-bration varies by vehicle.
Propane RefuelingAgility Fuel Systems recommends that the LiquidPropane Injection® (LPI) vehicle be refilled with fuelat stations that are specifically designed for vehiclerefueling. For assistance locating LPG fuel stations,contact Agility Fuel Systems at www.agilityfuelsys-tems.com or at 1-949-267-7745.
The propane fuel system utilizes a closed system,with fuel supply and return lines. This requires moreadvanced refueling equipment due to variances inpressure. When refueling the vehicle at a station notspecifically designed for dispensing propane (alsoreferred to as autogas), the refueling process may bevery slow or the tank may not fill at all. The vehiclepropane tank is subjected to heat from the pavementand chassis components, which cause a normal in-crease in tank pressure. The station pump may notbe able to produce pressure high enough to over-come that of the tank on the vehicle. It is recom-mended that the filling dispenser have a minimum of90 psi (621 kPa) pump differential boost pressureover the storage tank pressure; most modern sta-tions are designed to 130 psi (896 kPa) differentialpressure. It is recommended to refuel the vehicle ata modern station to prevent any customer inconve-nience.
LPI fuel tanks are equipped with both an 80% fixedliquid level gauge, and an automatic overfill protec-tion device (OPD). The LPI system is designed to be
01/21/2016 f611330
Fig. 19.3, Transmission Mode Switch
Propane Fuel System
19.4
filled reliably and safely using only the OPD. There-fore, it is not recommended to use the 80% fixed liq-uid level gauge unless required by the filling stationattendant, or for annual OPD verification. For instruc-tions on how to perform the annual OPD verificationtest, go to www.agilityfuelsystems.com.
Propane is a liquid under pressure and is stored in apressure vessel unlike a gasoline or diesel tank. Apropane tank must never be filled to more than 80%of its actual capacity, to allow room for expansion.80% is considered "full" for all propane tanks. Whenthe tank is filled to the correct 80% level, the fuelgauge should read full.
The following steps describe a typical refueling pro-cedure. See Fig. 19.4 for an example of the dualpropane tank system.
1. Park the vehicle on level ground to ensure thatthe tank is properly filled.
2. Turn the vehicle ignition to OFF and set the park-ing brake. Chock the tires if required.
3. Ensure that there are no open flames or ignitionsources in the area.
4. Turn the fuel tank cap counterclockwise and re-move it.
5. Inspect the fill valve O-ring, making certain theO-ring is seated in the groove and is not dam-aged or missing.
CAUTIONNever connect the propane fill nozzle to the tankfill valve if the O-ring is damaged or missing, asthis could result in serious injury. Replace theO-ring before connecting the propane fill nozzle.
6. Connect the propane fill nozzle to the tank fillvalve.
7. Rotate the propane fill valve nozzle clockwise
until it is firmly attached to the tank fill valve.
8. Close the fill nozzle vent valve if so equipped.
9. Open the 80% bleeder valve only if required.Agility Fuel Systems does not recommend usingthe bleeder valve. Use of the valve in a lowemission fuel station is prohibited.
10. Open the valve on the refueling nozzle.
10/30/2013 f470606
1 23
4
5
A
B67
A. Front Side B. Back Side1. Bleeder Valve2. Fuel Level Gauge3. Return Valve
4. Fill Valve5. Service Valve
6. Pressure Relief Valve7. Access Cover and Collar
Fig. 19.4, Propane Tank System
Propane Fuel System
19.5
11. Turn the propane dispenser on to begin refuel-ing.
12. When the OPD stops the flow of fuel into thetank, close the filling valve.
If use of the 80% bleeder valve is required, stopfilling when liquid from the bleeder appears in theform of a white cloudy vapor.
13. Turn the propane dispenser off.
CAUTIONNever overfill the propane fuel tank. Overfillingthe fuel tank can cause a dangerous condition,resulting in serious injury and damage to the ve-hicle.
After refueling, if a strong smell of propane per-sists or if a hissing sound is heard, notify thefuel station operator. Do not start the vehicle.
14. Disconnect the filling nozzle from the tank fillvalve.
14.1 If necessary, first open the vent valve onthe nozzle, if so equipped, and release thepressure from the valve for safety.
14.2 Rotate the filling nozzle connector coun-terclockwise and remove it. Then return itto the dispenser.
15. Install the fuel cap.
16. Check for leaks on the fill valve and connectingpiping, and around the 80% bleeder valve.
17. Ensure that all of the fuel tank valves are in thefully-closed position.
Warning and Indicator LampsThere are 19 warning and indicator lamps (telltales)installed in the dash message center. See Fig. 19.5.
The instrument cluster has an emergency buzzer thatsounds when serious conditions that require immedi-ate attention occur.
A description of the standard warning and indicatorlamps are listed below.
Maintenance Warning LampWhen amber maintenance warning lamp illuminates,the message display center alerts the driver as fol-lows:
• Oil Change Required—alerts the driver that theengine has reached the recommended oilchange interval.
• Air Filter Reminder—the air filter requireschecking or replacement.
• Transmission Prognostics Warning—if thetransmission has prognostics enabled.
Left-Turn IndicatorThe left-turn indicator flashes on and off when theleft-turn signal lights are flashing.
Both turn signal indicators flash when the hazardwarning flasher is turned on.
Check Engine WarningThe check engine warning indicator illuminates whencertain faults are detected. If a critical engine condi-tion exists (for example, low oil pressure or highcoolant temperature), the check engine indicator willilluminate to alert the driver to correct the conditionas soon as possible. If the condition gets worse, thestop engine indicator will illuminate.
NOTE: If the check engine indicator illuminatesduring vehicle operation, take the vehicle di-rectly to an authorized Freightliner service facil-ity.
Stop Engine Warning
WARNINGWhen the red STOP engine lamp illuminates, 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.
The stop engine warning indicator illuminates whenthe protection system available for the engine hasbeen activated. The engine ECU will derate the en-gine, allowing it to run, but at lower rpm and slowervehicle speed. The vehicle may be driven to a safelocation.
NOTICEBecause operating the engine when the stop en-gine indicator is illuminated can lead to severe
Propane Fuel System
19.6
engine damage, the driver must move the vehicleto a safe location as quickly as possible.
If the engine is shut down while the vehicle is in ser-vice, a single restart attempt may be performed. De-pending on the nature of the fault condition, a cool-down period may be required before restarting. If,upon restarting, the fault condition still exists the indi-cator will come on and the engine should be shutdown. At this point, the vehicle is unsafe to drive andshould be transported to an authorized Freightlinerservice facility.
IMPORTANT: Do not attempt to restart the en-gine while the vehicle is moving. Bring the ve-hicle to a safe stop and restart the engine withthe vehicle stopped.
Malfunction Indicator Lamp (MIL)The malfunction indicator lamp (MIL) indicates anengine emissions-related fault. See the engine op-eration manual for details.
Low Air Pressure WarningThe low air pressure warning indicator (BRAKE icon)and emergency buzzer activate when the engine isturned on if air pressure in the primary or secondaryair reservoir is below 65 to 75 psi (448 to 517 kPa),and remain on until air pressure rises above thatlevel in both reservoirs.
Headlight High-Beam IndicatorThe high-beam indicator (sideways beam icon) illumi-nates when the headlight high beams are on.
Wait to Start IndicatorThe wait-to-start indicator illuminates when the intakeheater is active. Wait until the indicator goes off tostart the engine.
Hydraulic Brake System WarningThe brake system warning lamp illuminates if there isa hydraulic brake system failure, or if the vehicle ispowered and the engine is not running.
10/30/2012 f611201
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18
19
1. Maintenance Warning Lamp2. Left-Turn Indicator3. Check Engine Warning4. Stop Engine Warning5. Malfunction Indicator Lamp (MIL)6. Low Air Pressure Warning7. Engine Brake Light (not used)
8. Headlight High-Beam Indicator9. Wait to Start Indicator10. Hydraulic Brake System Warning11. ABS Warning12. Traction Control Indicator13. Shift Inhibit Indicator
14. Check Transmission Indicator15. Stop Transmission Indicator16. Right-Turn Indicator17. Fasten Seat Belt Warning18. Parking Brake On Warning19. Cruise Control Indicator
Fig. 19.5, LPG Engine Warning and Indicator Lamps
Propane Fuel System
19.7
ABS WarningThe ABS indicator illuminates when there is a mal-function in the vehicle antilock brake system (ABS).
NOTE: For more information about this indicatorand the ABS system, see Chapter 13.
Traction Control IndicatorThe traction control indicator illuminates when thewheels lose traction.
Shift Inhibit IndicatorThe shift inhibit indicator illuminates when the trans-mission ECU prohibits shifting.
Check Transmission IndicatorThe LPG check transmission indicator has a differenticon (exclamation point), and illuminates when thetransmission fluid temperature goes above a presetlevel set by the transmission manufacturer.
For more information, see the transmission manufac-turer’s manual provided with the vehicle.
Stop Transmission IndicatorThe stop transmission indicator illuminates when thetransmission control unit senses a malfunction.
Right-Turn IndicatorThe right-turn indicator flashes on and off when theright-turn signal lights are flashing.
Both turn signal indicators flash when the hazardwarning flasher is turned on.
Fasten Seat Belt WarningThe fasten seat belt warning indicator (seat belt icon)illuminates for 3 seconds after the ignition switch isturned on.
When the engine is operating, if the driver’s seat beltis unfastened and the park brake is not set, the seatbelt warning indicator illuminates and a warningchime activates. The warning chime will remain ac-tive for 15 seconds. The warning indicator remainsilluminated until the driver’s seat belt is fastened.
Parking Brake On WarningThe parking brake on indicator activates when theparking brake is engaged.
If the vehicle is moving at a speed of 2 mph (3 km/h)or more, the emergency buzzer will sound until theparking brake is released.
Cruise Control IndicatorThe cruise control indicator illuminates when thecruise control is activated.
Emergency BuzzerThe emergency buzzer sounds during the ignitionsequence and whenever one of the following condi-tions exists:
• The engine oil pressure falls below the presetlevel which is 6 psi (41 kPa) at 700 rpm, or 18psi (124 kPa) at 4400 rpm.
• The air pressure falls below the preset level,which is 65 psi (448 kPa).
• The parking brake is set with the vehicle mov-ing at a speed greater than 2 mph (3 km/h).
• The coolant temperature rises above 253°F(123°C) and the check engine and stop enginelamps illuminate. When the coolant tempera-ture falls below 244° (118°C) the emergencybuzzer and stop engine lamp turn off.
NOTE: The check engine lamp will remain onuntil the vehicle is inspected at an authorizedFreightliner service facility.
Speedometer and TachometerSpeedometerThree kinds of speedometer faces are available. TheU.S. version of the speedometer registers speed inboth miles per hour (mph) and kilometers per hour(km/h), with mph in larger numbers. See Fig. 19.6.
The NAFTA version (not shown) of the speedometerface reverses this arrangement, with km/h in largernumbers. The metric-only version (not shown) showskm/h exclusively.
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. See Fig. 19.6.
Propane Fuel System
19.8
Standard InstrumentsFuel Level GaugeThe fuel level gauge indicates the level of fuel in thefuel tank. See Fig. 19.7. A low-level warning lampilluminates when the diesel fuel level registers 1/8thof capacity.
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 could
cause 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 pressurewith the engine running is 100 to 120 psi (690 to 827kPa) in both systems. See Fig. 19.8.
Air pressure gauges are required on all vehicles withair brakes. A low-air-pressure warning lamp andbuzzer, connected to both the primary and secondarysystems, activate when air pressure in either systemdrops below a minimum pressure of 65 to 75 psi(448 to 517 kPa).
When the engine is started, the warning lamp andbuzzer remain on until air pressure in both systemsexceeds minimum pressure.
Coolant Temperature Gauge
NOTICEA sudden increase in coolant temperature mayindicate engine or cooling system failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.
During normal engine operation, the coolant tem-perature gauge should read 200 to 205°F (93 to96°C). See Fig. 19.9. If the temperature remainsbelow 160°F (71°C) or exceeds 235°F (113°C), in-spect the cooling system to determine the cause.See the vehicle workshop manual for troubleshootingand repair procedures.
If the coolant temperature rises above 253°F(123°C), the check engine and stop engine warningindicators will illuminate, and the buzzer will sound.
3020
10
0 60
5040 30
20
40
10
0 90
80
7060
50
806040
20
0
100120
140
X 100RPM
MPH
09/18/2013 f611217
1 2
1. Tachometer 2. Speedometer
Fig. 19.6, Speedometer and Tachometer (U.S. version)
10/01/2013 f611219
F
E
1/2
1
1. Low-Level Warning Lamp
Fig. 19.7, Fuel Level Gauge
Propane Fuel System
19.9
At this point, the engine will derate and idle speedwill increase, to speed up the cooling fan and waterpump to cool the engine.
Grade BrakeIMPORTANT: The grade brake is an optionalauxiliary brake system that works through thetransmission. It should not be confused with ex-haust brake or engine brake. Furthermore, thegrade brake should not be used in place of theservice brakes to stop the vehicle.
Chassis equipped with a propane engine may havean optional grade brake. The grade brake is de-
signed to downshift the transmission—when goingdownhill for example—without overspeeding the en-gine. Refer to the Allison Operator’s Manual forproper operation of the grade brake. See Fig. 19.10for an example of the grade brake switch. An amberlight activates at the top of the switch when thegrade brake is activated.
Ametek Instrument PanelThe following information describes the Ametek in-strument panel, used with liquid propane gas (LPG)engines. The instrument panel is shown inFig. 19.11.
NOTE: The instrument panel is shown with astandard U.S. speedometer, which shows milesper hour (mph) more prominently than kilome-ters per hour (km/h).
150
0
75
PSI P
150
0
75
PSIS
09/18/2013 f611218
1 4
2 3
1. Primary Air Pressure Gauge2. Low Primary Air Pressure Warning Lamp
3. Low Secondary Air Pressure Warning Lamp4. Secondary Air Pressure Gauge
Fig. 19.8, Air Pressure Gauges
H
C
09/18/2013 f611220
1
1. High Coolant Temperature Warning Light
Fig. 19.9, Coolant Temperature Gauge09/20/2013 f261458
Fig. 19.10, Grade Brake Switch
Propane Fuel System
19.10
Message Display CenterThe message display is a graphical, backlit, liquidcrystal display (LCD) that relays information to thevehicle operator. The messages displayed include:
• Odometer
• Trip Odometer 1/Trip Odometer 2
• Chassis Battery Voltage
• Instantaneous Fuel Rate
• Average Fuel Rate
• Gear Attained Status
• Transmission Temperature
• Hour Meter
• Boost Pressure
• Engine Oil Pressure
• Coolant Temperature
• Fuel Level
• Percent Engine Load
• Engine RPM
During normal operation, the LCD displays the odom-eter value and chassis battery voltage on the topline, and driver selected parameters, such as the tripodometer and fuel rate, on the second and thirdlines.
Priority MessagesPriority messages (including warning messages) aredisplayed in the LCD due to various inputs or datamessages. Unless noted otherwise, the priority mes-sage will take over the whole screen, allowing mul-tiple messages to be displayed in five second inter-vals.
Self-TestWhen the ignition is turned on, a required self-testautomatically begins. Gauge needles will reset tozero during the self-test, and then immediately moveto the position dictated by the data received. Duringthis time, the warning lights, alarm (buzzer), anddriver display screen will also perform a self-test.
NOTE: The driver can activate or deactivate thestart-up self-test by accessing the setup menu.
Menu SystemThe menu system is shown on the driver displayscreen once the self-test is finished. The menu sys-tem responds to input from the driver and remainsactive as long as the ignition is on. In order for thedriver to operate the menu system, the ignition mustbe ON, and the park brake must be set (ON). Themain features of the menu system are describedbelow.
• Setup—this is used to set various parameters,which are saved when the ignition is turned off.Setup has select display units, startup screen,LCD contrast, and reset parameters.
• Maintenance—shows various maintenance in-tervals such as engine oil, air filter, etc.
• Diagnostics—this is used for setting and read-ing inputs and outputs and checking thegauges. It also shows the hardware and soft-ware version of the instrument panel, and hasmenus to retrieve active error codes from theengine, transmission, and ABS controllers.
NOTE: No lines can be highlighted in the menusystem screen. To get to the sections that canbe highlighted, press the right arrow toggle but-ton and hold it for two seconds. The displayscreen will change and the options shown canthen be highlighted. Once a selection has beenchosen and changes are made, press the rightarrow toggle button to go back to the main mes-sage display screen.
Setup MenuSelect Display UnitsThe set units screen allows the driver to choose be-tween English or metric units of measurement for thedisplayed values. To navigate to the set units screen,see Fig. 19.12, screens H, I, and J.
Startup ScreenThe startup screen selection allows the driver to turnthe startup screen on or off.
LCD ContrastSelect contrast from the menu to set the LCD con-trast. Use the down toggle button to set the contrastto the desired level. To navigate to the contrastscreen, see Fig. 19.12, screen M.
Propane Fuel System
19.11
Reset ParametersThe reset parameters screen is included with ve-hicles that have the Allison transmission prognosticsfeature.
Maintenance MenuThe maintenance menu has the following three submenus:
• maintenance intervals
• transmission oil life remaining
• transmission oil filter life monitor
Maintenance IntervalsThe maintenance intervals menu allows the driver toset the change intervals for engine oil and engine airfilter. If the intervals are set to zero, the maintenancewarnings must be disabled.
Transmission Oil Life RemainingIf transmission prognostics are enabled, this menuindicates how much useful oil life remains.
Transmission Oil Filter Life MonitorIf transmission prognostics are enabled, the trans-mission oil filter life monitor tells the driver if thetransmission oil filter is clogged and in need of repair.A message will appear on the display screen asTRANS OIL FILTER FUNCTIONAL or TRANS OILFILTER CLOGGED.
Diagnostic MenuThe diagnostic menu contains the following items:
• engine faults
• transmission faults
• ABS faults
• check outputs
• odometer diagnostics
• check gauges
• check indicators (warning lamps)
• check LCD
• check binary inputs
• check analog inputs
• check datalink
• hardware/software version
All of the items in the diagnostic menu can be ac-cessed by using the toggle buttons and selecting theauxiliary screens. Then navigate to the diagnosticsub-menu. Some of the more frequently used diag-nostic menus are described further below.
Engine FaultsThis screen displays engine fault codes that are re-ceived from the engine electronic control unit (ECU).To navigate to the engine fault screen, seeFig. 19.13, screen AA.
Transmission FaultsThis screen displays transmission fault codes thatare received from the transmission ECU. To navigateto the transmission fault screen, see Fig. 19.13,screen AB.
ABS DiagnosticsThis screen displays Antilock Brake System (ABS)fault codes that are received from the ABS ECU. Tonavigate to the ABS diagnostic screen, seeFig. 19.13, screen AC.
Check GaugesThe check gauges screen allows the driver to seteach gauge as a percentage of scale (either 0, 50, or100%), as shown in the LCD. To navigate to thecheck gauges screen, see Fig. 19.14, AG screens.
Warning LampThe warning lamp screen allows the driver to testeach warning lamp (not the vehicle load) on and thenoff, displaying the lamp name and status in the LCD.To navigate to the warning lamp screen, seeFig. 19.14, screen AH.
Check LCDSelecting the check LCD screen displays the Freight-liner Custom Chassis Corporation (FCCC) logo innormal and reverse video three times and then re-turns to the menu. To navigate to the check LCDscreen, see Fig. 19.14, screen AI.
Check Binary InputsThe check binary inputs screen displays the pin num-ber and status of each binary input. The toggle but-tons allow the driver to select each binary input. Thisinformation is continuously updated to assist introubleshooting. To navigate to the check binary in-puts screen, see Fig. 19.14, screen AJ.
Propane Fuel System
19.12
Check Analog InputsThe check analog inputs screen displays the pinnumber and actual value of each analog input de-fined in the system. The toggle buttons allow thedriver to select each analog input. This information iscontinuously updated to assist in troubleshooting. Tonavigate to the check analog input screen, seeFig. 19.15, screen AK.
Check DatalinkThe check datalink screen allows the driver to viewall devices that communicate on the J1939, J1587,and GMLAN datalinks. To navigate to the check da-talink screen, see Fig. 19.15, screen AL.
Menu NavigationThe menu navigation screens are provided to illus-trate the menu system. The paths to specific screensare shown, along with instructions for using thetoggle buttons to move from one screen to another.See Fig. 19.12, Fig. 19.13, Fig. 19.14, Fig. 19.15,Fig. 19.16, Fig. 19.17, Fig. 19.18, Fig. 19.19,Fig. 19.20, Fig. 19.21, Fig. 19.22, Fig. 19.23, andFig. 19.24.
IMPORTANT: Follow the steps below to changethe three items (also known as favorites) shownin the message display center. The messagedisplay center is referred to as screen C inFig. 19.18.
NOTE: The driver can check the pressure of thepropane in the fuel rail (pressure of the fuel inboth the tank and pump booster), and make thisone of the three items shown in the messagedisplay center. Select the item with the fuelpump and psi reading, then follow the directionsbelow to make it one of the favorites.
1. With the vehicle in park, turn the ignition to RUN,and allow the self test to complete.
2. Press the down toggle button to select an item tochange. The selected item will now be high-lighted.
3. Press the right toggle button once to enter thefavorites display menu, shown in Fig. 19.18, asscreen D.
4. Use the down toggle button to scroll through theavailable items.
5. Highlight the new item, then press the righttoggle button. The selected item will now appear
in the message display center.
Propane Fuel System
19.13
12/05/2012 f611202
4 5
810
9
1 2 3
6 7
1. Tachometer2. Dash Message Center3. Speedometer4. Fuel Level Gauge
5. Primary Air Pressure Gauge6. Secondary Air Pressure Gauge7. Coolant Temperature Gauge
8. Dash Driver Display Screen9. Toggle Button, Down10. Toggle Button, Right
Fig. 19.11, Gauge Layout (typical, U.S.), LPG Engines
Propane Fuel System
19.14
SETUP
Down HoldOr (Right & Exit
highlighted)
Down PressCurrent Units =
Metric
Down PressCurrent Units =
English
Current Units =English
Current Units =Metric
Down PressStartup Screen =
Disabled
Down PressStartup Screen =
Enabled
Startup Screen =Enabled
Startup Screen =Disabled
Down PressNot At Min Contrast /
Decrease Contrast
Down PressAt Min Contrast /
Set Contrast to Max
Right PressStartup Screen
highlighted
Right PressSelect Display
Units highlighted
Right PressDisplay Contrast
highlighted
Right PressOr
Down Hold
Right PressOr
Down Hold
Right PressOr
Down Hold
Right PressOr
Down Hold
Right PressOr
Down Hold
Down PressHighlight next
line of list.At middle,wrap to top
Right HoldReset Parameters
Right PressReset Parameters
highlighted
Right PressOr
Down Hold
Right PressOr
Down Hold
AUXILIARYSCREENS
09/23/2009 f040792
Fig. 19.12, Setup Menu Screens
Propane Fuel System
19.15
Diagnostics
Note 5:Screen Z scrolls to display the following items: ENGINE FAULTS TRANSMISSION FAULTS ABS FAULTS CHECK OUTPUTS CHECK DATA INPUTS ODOMETER DIAGNOSTICS CHECK GAUGES CHECK WARNING LAMPS CHECK LCD CHECK BINARY INPUTS CHECK ANALOG INPUTS CHECK DATA LINK VERSION INFORMATION EXITThe text DIAGNOSTIC MENU remains fixed on the first line.
Down PressDisplay Next Fault
Down PressDisplay Next Fault
Down PressDisplay Next Fault
Right PressOr
Down Hold
Down PressChange to
Next Output
Right PressOr
Down Hold
Right HoldToggle OutputState Between
Off and On
MenuRight Press
Engine FaultsHighlighted
Right PressTrans FaultsHighlighted
Right PressABS FaultsHighlighted
Right PressCheck Outputs
Highlighted
Menu
(Right & Exithighlighted)
Menu
Right PressOr
Down HoldMenu
Right PressOr
Down HoldMenu
Screens AA,AB,AC Format For J1587
Screen AE For J1587
Down PressHighlight next
line of list.At bottom,wrap to top
Right || Hold DownRight Press
Odometer DiagHighlighted
Menu
09/23/2009 f040795
Fig. 19.13, Diagnostic Menu Screens, Screen 1
Propane Fuel System
19.16
Down PressChange to
Next Gauge
Right HoldStep Gauge toNext Position
Right || Hold Down
Down PressChange to
Next Telltale
Right HoldToggle State
BetweenOff and On
Right || Hold Down
Every 1.5 Seconds /Invert Video of
Displayed Image
Right ||9 Seconds Elapsed
|| Hold Down
Down PressChange toNext Input
Right || Hold Down
Right PressCheck Gauges
Highlighted
Right PressWarning Lamps
Highlighted
Right PressCheck LCDHighlighted
Right PressCheck Binary Inputs
Highlighted
Menu
Menu
Menu
Menu
Other Text for Screen AG
09/23/2009 f040796
Fig. 19.14, Diagnostic Menu Screens, Screen 2
Propane Fuel System
19.17
02/06/2012 f040797
AUXILIARYSCREENS
SOFTWARE VER: x.yyCONFIG: cccccccHARDWARE VER: z
Right || Hold DownRight Press
Version InformationHighlighted
Menu
Screen AM
Input NamePin pp of 26xx.x Units
Down PressChange toNext Input
Right || Hold Down
ECUs on Data BusJ1939 SA xxJ1939 SA yy
Down PressScroll ScreenDown 1 Line
Right || Hold Down
Right PressCheck Analog Inputs
Highlighted
Right PressCheck Data Link
Highlighted
Menu
Menu
Screen AK
Screen AL
Fig. 19.15, Diagnostic Menu Screens, Screen 3
Propane Fuel System
19.18
H*
SELF TEST
DISPLAY MESSAGES
WARNING MESSAGES
Active WarningMessages
No Warnings Active orAll Warnings
Acknowledged
Right HoldPark Brake On
IGNITION ON
IGNITIONOFF
IgnitionOff
Ignition On orHeadlamps On or
Marker Lamps On orPark Brake Off
IgnitionOn
Ignition Off &Headlamps Off &
Marker Lamps Off &Park Brake On
Self TestEnabled
AUXILIARYSCREENS
ACTIVE
Ignition Off &( Headlamps On or
Marker Lamps On orPark Brake Off )
Ignition On
USB Drive Present &Park Brake On &
Vehicle Speed = 0 &Not in Self Test
H*
NORMAL MODE
DOWNLOADMODE
09/23/2009 f040788
Fig. 19.16, Ignition On, Normal Mode
Propane Fuel System
19.19
SELF TEST
DISPLAY MESSAGES
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
Screen Displayedfor 1.5 Seconds
Screen Displayedfor 1.5 Seconds
Startup Screen Enabled
The Self Test screens display the FCCClogo in normal video (Screen A) and in
reverse video (Screen B)
Startup Screen Disabled
Screen A
Screen B
02/06/2012 f040789
Fig. 19.17, Self Test
Propane Fuel System
19.20
DISPLAY MESSAGES
Selected Line 1 DataSelected Line 2 DataSelected Line 3 Data
Favorites Display MenuAverage Fuel EconomyGear Attained Status
Right Press Highlight First Item in List
Down PressMove to, and Highlight,
Next Item in List
Right PressPut Data For Highlighted ItemIn Display Line CurrentLine
Down HoldMake No Changes
Down Press Highlight CurrentLine
HighlightTimer = 5 sec.
WARNING MESSAGES
AUXILIARY SCREENS
New WarningMessage Active
Right HoldPark Brake On
HighlightTimer = 0
Right Hold Reset Highlighted Item
(if resettable)
Screen C Screen D
11/23/2011 f040790
Fig. 19.18, Display Messages
Propane Fuel System
19.21
AUXILIARY SCREENS
SETUP MAINTENANCE DIAGNOSTICS
Down PressHighlight next
line of list.At middle,wrap to top
MAINTENANCE
DIAGNOSTICS
Right PressSetup
highlighted
Right PressDiagnosticshighlighted
Right PressMaintenancehighlighted
SETUP
SETUP.
DISPLAYMESSAGES
Down Hold
TRIP DATARight Press
Trip Datahighlighted
Screen G
02/06/2012 f040791
Fig. 19.19, Auxiliary Screens
Propane Fuel System
19.22
MAINTENANCE
(Right & Exithighlighted)
Right PressEngine OilHighlighted
Right PressEngine Air Filter
Highlighted
Down PressHighlight next
line of list.At middle,wrap to top
MaintMenu
Down PressDisplay NextValue of Air
Change Distance
Air Change Baseline +Air Change Distance >=
Odometer
Air ChangeDistance = 0
else
Right PressAir Change Distance =
Current DisplayedValue
Right HoldAir ChangeBaseline =Odometer
Right HoldAir ChangeBaseline =Odometer
Right PressOr
Down Hold
Right PressOr
Down Hold
Down PressDisplay NextValue of Oil
Change Distance
Oil Change Baseline +Oil Change Distance >=
Odometer
else
Right PressOil Change Distance =
Current DisplayedValue
Right HoldOil ChangeBaseline =Odometer
Right HoldOil ChangeBaseline =Odometer
Right PressOr
Down Hold
Right PressOr
Down Hold
Oil ChangeDistance = 0
09/23/2009 f040793
Fig. 19.20, Maintenance Menu Screens, Screen 1
Propane Fuel System
19.23
02/06/2012 f040794
AUXILIARYSCREENS
Right HoldSend SPN 1584 = 39
Right PressTransmission
Oil LifeHighlighted
Right PressTransmission
Oil FilterHighlighted
Right PressOr
Down Hold
Right PressOr
Down Hold
Right PressOr
Down Hold
MaintMenu
Right HoldSend SPN 1584 = 37
Right PressOr
Down Hold
Fig. 19.21, Maintenance Menu Screens, Screen 2
Propane Fuel System
19.24
Trip Data
AUXILIARYSCREENS
Note 6:Screen AO scrolls to display the following items:
Trip TimeIdle TimeMax RPMAvg RPMMax SpeedAvg SpeedAvg Fuel EconomyReset AllExit
Right PressReset AllHighlighted
Correct Passcode /Reset Trip
Data
Right Press
Down PressHighlight next
line of list.At bottom,wrap to top
(Right & Exithighlighted)
Wrong Passcode /Down Press
Right Press
09/23/2009 f040798
Fig. 19.22, Trip Data
Propane Fuel System
19.25
02/06/2012 f040799
WARNING MESSAGES
DISPLAY MESSAGES
H*
WARNING Warning Message
No WarningMessages in List /
Msg Displayed for 5 Sec. /Display Next Entry in
Warning Message List
Any Button Press
/Display 1st Message
in WarningMessage List
Screen AN
Fig. 19.23, Warning Messages
Propane Fuel System
19.26
IGNITION OFF
Park Brake On
Park Brake On
Park Brake Off
IGNITIONON
Headlamps Off &Marker Lamps Off &
Park Brake On
Ignition On
02/06/2012 f040800
Fig. 19.24, Ignition Off (shown when ignition is keyed OFF)
Propane Fuel System
19.27
20
SpecificationsTorque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5
Torque ChartsTorque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads†
ThreadDiameter—
Pitch
Regular Hex FlangedGrade 5
BoltGrade 5 or
B NutGrade 8 or
8.2 BoltGrade 8 or
C NutGrade 5
BoltGrade B
NutGrade 8 or
8.2 BoltGrade G
NutTorque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)
f230002 f230003 f230004 f230005 f230006 f230007 f230008 f230009
1/4–20 7 (9) 8 (11) 6 (8) 10 (14)1/4–28 8 (11) 9 (12) 7 (9) 12 (16)
5/16–18 15 (20) 16 (22) 13 (18) 21 (28)5/16–24 16 (22) 17 (23) 14 (19) 23 (31)3/8–16 26 (35) 28 (38) 23 (31) 37 (50)3/8–24 30 (41) 32 (43) 25 (34) 42 (57)
7/16–14 42 (57) 45 (61) 35 (47) 60 (81)7/16–20 47 (64) 50 (68) 40 (54) 66 (89)1/2–13 64 (87) 68 (92) 55 (75) 91 (123)1/2–20 72 (98) 77 (104) 65 (88) 102 (138)
9/16–12 92 (125) 98 (133) 80 (108) 130 (176)9/16–18 103 (140) 110 (149) 90 (122) 146 (198)
5/8–11 128 (173) 136 (184) 110 (149) 180 (244)5/8–18 145 (197) 154 (209) 130 (176) 204 (277)3/4–10 226 (306) 241 (327) 200 (271) 320 (434)3/4–16 253 (343) 269 (365) 220 (298) 357 (484)7/8–9 365 (495) 388 (526) 320 (434) 515 (698)
7/8–14 402 (545) 427 (579) 350 (475) 568 (770)1–8 — 582 (789) — —
1–12 — 637 (863) — —1–14 — 652 (884) — —
* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.† Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed, Geomet 321XL
coated, or waxed).
Table 20.1, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads
Specifications
20.1
Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads†
ThreadDiameter—
Pitch
Regular Hex Flanged
Grade 5 BoltGrade 5 or B
NutGrade 8 or 8.2
BoltGrade 8 or C
NutGrade 8 or 8.2
BoltGrade G Nut
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)
f230002 f230003 f230004 f230005 f230008 f230009
1/4–20 8 (11) 10 (14) —1/4–28 9 (12) 12 (16) —
5/16–18 15 (20) 22 (30) 22 (30)5/16–24 17 (23) 25 (34) —3/8–16 28 (38) 40 (54) 40 (54)3/8–24 31 (42) 45 (61) —
7/16–14 45 (61) 65 (88) 65 (88)7/16–20 50 (68) 70 (95) —1/2–13 70 (95) 95 (129) 95 (129)1/2–20 75 (102) 110 (149) —
9/16–12 100 (136) 140 (190) 140 (190)9/16–18 110 (149) 155 (210) —
5/8–11 135 (183) 190 (258) 190 (258)5/8–18 155 (210) 215 (292) —3/4–10 240 (325) 340 (461) 340 (461)3/4–16 270 (366) 380 (515) —7/8–9 385 (522) 540 (732) —
7/8–14 425 (576) 600 (813) —1–8 580 (786) 820 (1112) —
1–12 635 (861) 900 (1220) —1–14 650 (881) 915 (1241) —
* Threads may have residual oil, but will be dry to the touch.† Male and female threads (bolt and nut) must both be unlubricated and unplated. If either is plated or lubricated, use Table 20.3. Freightliner recommends
that all plated and unplated fasteners be coated with oil before installation.
Table 20.2, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads
Specifications
20.2
Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads†
ThreadDiameter—
Pitch
Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)
f230010
8.8
f230011
8
f230012
10.9
f230013
10
M6 5 (7) 7 (9)M8 12 (16) 17 (23)M8 x 1 13 (18) 18 (24)M10 24 (33) 34 (46)M10 x 1.25 27 (37) 38 (52)M12 42 (57) 60 (81)M12 x 1.5 43 (58) 62 (84)M14 66 (89) 95 (129)M14 x 1.5 72 (98) 103 (140)M16 103 (140) 148 (201)M16 x 1.5 110 (149) 157 (213)M18 147 (199) 203 (275)M18 x 1.5 165 (224) 229 (310)M20 208 (282) 288 (390)M20 x 1.5 213 (313) 320 (434)M22 283 (384) 392 (531)M22 x 1.5 315 (427) 431 (584)M24 360 (488) 498 (675)M24 x 2 392 (531) 542 (735)M27 527 (715) 729 (988)M27 x 2 569 (771) 788 (1068)M30 715 (969) 990 (1342)M30 x 2 792 (1074) 1096 (1486)* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.† Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated,
cadmium-plated, or waxed, Geomet 321XL coated, or waxed).
Table 20.3, Torque Values for Metric Thread Fasteners With Lubricated or PlatedThreads
Specifications
20.3
Conversion ChartsWhen You Know U.S.
CustomaryMultiply
ByTo Get Metric
When YouKnow Metric
MultiplyBy
To Get U.S. Customary
Lengthinches (in) 25.4 millimeters (mm) 0.03937 inches (in)inches (in) 2.54 centimeters (cm) 0.3937 inches (in)feet (ft) 0.3048 meters (m) 3.281 feet (ft)yards (yd) 0.9144 meters (m) 1.094 yards (yd)miles (mi) 1.609 kilometers (km) 0.6215 miles (mi)Areasquare inches (in2) 645.16 square millimeters (mm2) 0.00155 square inches (in2)square inches (in2) 6.452 square centimeters (cm2) 0.155 square inches (in2)square feet (ft2) 0.0929 square meters (m2) 10.764 square feet (ft2)Volumecubic inches (in3) 16387.0 cubic millimeter (mm3) 0.000061 cubic inches (in3)cubic inches (in3) 16.387 cubic centimeters (cm3) 0.06102 cubic inches (in3)cubic inches (in3) 0.01639 liters (L) 61.024 cubic inches (in3)fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz)pints (pt) 0.47318 liters (L) 2.1134 pints (pt)quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt)gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal)cubic feet (ft3) 28.317 liters (L) 0.03531 cubic feet (ft3)cubic feet (ft3) 0.02832 cubic meters (m3) 35.315 cubic feet (ft3)Weight/Forceounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz)pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb)U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t)U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t)Torque/Work Forceinch–pounds (lbf·in) 11.298 Newton–centimeters (N·cm) 0.08851 inch–pounds (lbf·in)foot–pounds (lbf·ft) 1.3558 Newton–meters (N·m) 0.7376 foot–pounds (lbf·ft)Pressure/Vacuuminches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg)pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi)
Table 20.4, Metric/U.S. Customary Conversion
When You Know SubtractThen
Divide ByTo Get
When YouKnow
MultiplyBy
ThenAdd
To Get
degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F)
Table 20.5, Temperature Conversion
Specifications
20.4
Fluids and LubricantsSee Table 20.6 for fluid and lubricant specifications.
Fluid and Lubricant SpecificationsComponent Recommended Fluid or Lubricant
Front Axle Spindle Pins, Tie Rods, Drag Link,Intermediate Steering Shaft, Front Brake andPedal Shafts, Slip Spline and Universal Joints
Multipurpose Grease Lithium 12- Hydroxy Stearate NLGI No. 2; fortemperatures below 0°F (–18°C), use MIL-G-10924B
Hydraulic Brake Master Cylinder Heavy-Duty DOT 3 Brake FluidBrake and Pedal Pivots Starplex 2 (lithium soap-based grease)Engine See Manufacturer’s RecommendationsTransmission Mobil Delvac Synthetic ATFFuel Ultralow-Sulfur Diesel Fuel
HD5 Grade PropaneDisc Brake Caliper Rails FCCC No. 4JD623 Brake Caliper Slide GreaseRear Axle Differential See Manufacturer’s RecommendationsHydraulic System Reservoir ATF must meet Dexron® III or TES-389 specificationsEngine Coolant Refer to the engine manufacturer’s service literature for approved
coolant.
Table 20.6, Fluid and Lubricant Specifications
Fuse InformationSee Table 20.7 for descriptions of a typical set offuses. Fuse identification varies with options.
Main PDM Fuse IdentificationCAV Description FuseF1 Engine VCU (spare) 10AF2 Blower Motor 30AF3 Engine ECU 20AF4 Spare —F5 Ignition Switch 5A
F6 Hydro-Max RLY (if equipped withhydraulic brakes) 30A
F7 Bulkhead Module 30AF8 ICU3 10AF9 Transmission ECU 10A
F10 Spare —F11 Spare —F12 Radio/Diagnostic 20AF13 Chassis Module 30AF14 Spare —F15 Bulkhead Module 30AF16 ABS ECU 25AF17 Chassis Module 30AF18 Bulkhead Module 30AF19 Chassis Module 30A
Main PDM Fuse IdentificationCAV Description FuseF20 Bulkhead Module 30AF21 Spare —F22 Bulkhead Module 30AF23 Spare —
F24 Hydraulic Pump and RLY (if equippedwith hydraulic brakes) 25A
F25 Spare —F26 Spare —
Table 20.7, Main PDM Fuse Identification
Bulb ReplacementSee Table 20.8 for bulb replacement information.
Replacement Bulb Part NumbersDescription Part Number
Headlight, Low Beam WEE 9006Headlight, High Beam WEE 9005Front Turn Signal Light WEE 3157Front Fender Marker Light WEE 194
Table 20.8, Replacement Bulb Part Numbers
Specifications
20.5
Subject Page
AAdjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 18.1Aftertreatment System (ATS)
Regen Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4Aftertreatment System, EPA10
and Newer Engines . . . . . . . . . . . . . . . . . . . . . . 9.1ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 9.2DPF Maintenance . . . . . . . . . . . . . . . . . . . . . . 9.5Parked Regen . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Principles of Operation . . . . . . . . . . . . . . . . . . . 9.1Shorting Plug . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Air Brake Operation . . . . . . . . . . . . . . . . . . . . . . 13.1Caging the Parking Brakes . . . . . . . . . . . . . . . 13.2Operating the Brakes . . . . . . . . . . . . . . . . . . . 13.2Parking Brake Interlock,
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Allison On-Highway
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Operating Instructions, 2000
and B200 SeriesTransmissions . . . . . . . . . . . . . . . . . . . . . . . 10.2
Operating Instructions, 3000and B300 Series . . . . . . . . . . . . . . . . . . . . . 10.3
Range Inhibit Indicator, 2000and B200 Series . . . . . . . . . . . . . . . . . . . . . 10.2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . 10.1Ametek Instrument Panel . . . . . . . . . . . . . . . . . . 19.10
Menu Navigation . . . . . . . . . . . . . . . . . . . . . 19.13Menu System . . . . . . . . . . . . . . . . . . . . . . . . 19.11Message Display Center . . . . . . . . . . . . . . . . 19.11Priority Messages . . . . . . . . . . . . . . . . . . . . . 19.11Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.11
BBattery Access . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Battery Compartment . . . . . . . . . . . . . . . . . . . . 2.1Battery Disconnect Switch,
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Bosch Hydraulic Pin Slide
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3General Information . . . . . . . . . . . . . . . . . . . . 13.3Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Brake Burnishing (new vehicle) . . . . . . . . . . . . . . . 13.7Braking Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Exhaust Brake Switch . . . . . . . . . . . . . . . . . . . . 4.8Meritor™ WABCO® Antilock
Braking System (ABS) . . . . . . . . . . . . . . . . . . 4.8Parking Brake Control Knob . . . . . . . . . . . . . . . 4.8
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . 20.5
Subject Page
CCab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Cab Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 16.1Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 16.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 16.1Changing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . 17.4Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 18.1Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . 7.1
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . 7.3Air Selection Switch . . . . . . . . . . . . . . . . . . . . . 7.1Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Fresh Air Mode . . . . . . . . . . . . . . . . . . . . . . . . 7.3Recirculation Mode . . . . . . . . . . . . . . . . . . . . . 7.3Temperature Control Switch . . . . . . . . . . . . . . . . 7.3
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6Clutch Adjustments . . . . . . . . . . . . . . . . . . . . . 10.8Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . 10.8Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 10.6Clutch Wear . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Component Information Label . . . . . . . . . . . . . . . . 1.1Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . 20.4Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Cruise Control Switch . . . . . . . . . . . . . . . . . . . . 4.4Fast Idle System . . . . . . . . . . . . . . . . . . . . . . . 4.5
DDaily Pretrip Inspection and
Maintenance Checklist . . . . . . . . . . . . . . . . . . . 14.1Daily Pretrip Inspection and
Maintenance Procedures . . . . . . . . . . . . . . . . . . 15.1Dashboard and Instrument
Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Diesel Exhaust Fluid and Tank,
EPA10 and Newer Engines . . . . . . . . . . . . . . . . . 9.5DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5DEF Warnings and Engine
Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 9.5Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . . 9.5
Drive Axles, Detroit™ andMeritor™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Drive Axles With Differential
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Driving Precautions . . . . . . . . . . . . . . . . . . . . . . 10.1Dual Air Brake System . . . . . . . . . . . . . . . . . . . . 13.1
Emergency Braking System . . . . . . . . . . . . . . . 13.1Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . 13.1Primary Air Brake System . . . . . . . . . . . . . . . . 13.1
Index
I-1
Subject Page
Secondary Air Brake System . . . . . . . . . . . . . . 13.1
EEaton® Fuller® Straight-Shift
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 10.5General Information,
Straight-Shift . . . . . . . . . . . . . . . . . . . . . . . . 10.5Operation, Straight-Shift . . . . . . . . . . . . . . . . . 10.6
Electrical System GeneralInformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Emergency Starting WithJumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Aftertreatment System
Indicators Label . . . . . . . . . . . . . . . . . . . . . . 1.1Vehicle Emission Control
Information Label . . . . . . . . . . . . . . . . . . . . . 1.2Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Constant-Throttle Valves . . . . . . . . . . . . . . . . . 13.7Engine Brake Switch . . . . . . . . . . . . . . . . . . . 13.6
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 19.2Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . 19.2Engine Starting . . . . . . . . . . . . . . . . . . . . . . . 19.2General Information . . . . . . . . . . . . . . . . . . . . 19.2High Idle Options . . . . . . . . . . . . . . . . . . . . . . . 8.3
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 8.4Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
General Information . . . . . . . . . . . . . . . . . . . . . 8.1Starting After Extended
Shutdown or Oil Change . . . . . . . . . . . . . . . . . 8.1EPA07 Aftertreatment System
(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7High-Soot-Load Idle
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . 13.6General Information . . . . . . . . . . . . . . . . . . . . 13.5Operating Characteristics . . . . . . . . . . . . . . . . 13.6Shutting Down the Engine . . . . . . . . . . . . . . . . 13.6Starting the Engine . . . . . . . . . . . . . . . . . . . . . 13.5
FFire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 17.5First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6Flare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . 20.5Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . 20.5
GGeneral Information . . . . . . . . . . . . . . . . . . . . . . 19.1
Subject PageGrade Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10
HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . 17.1Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.1
Closing the Hood . . . . . . . . . . . . . . . . . . . . . . . 2.2Tilting the Hood . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
IIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . 4.1Instrumentation Control Unit . . . . . . . . . . . . . . . . . . 3.1
Dash Message Center . . . . . . . . . . . . . . . . . . . 3.1Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 3.1Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . . 3.3Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
LLighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Headlight/Parking LightSwitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Marker Lamp InterruptSwitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Panel Light Increase/Decrease Switch . . . . . . . . . . . . . . . . . . . . . . 4.1
MMeritor Cam-Master® Q Plus
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3Cam-Master Q Plus
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3Meritor WABCO Pneumatic
Antilock Braking System(ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4Automatic Slack Adjusters . . . . . . . . . . . . . . . . 13.5Automatic Traction Control . . . . . . . . . . . . . . . . 13.4Pneumatic ABS Operation . . . . . . . . . . . . . . . . 13.4
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Down View Mirror, Optional . . . . . . . . . . . . . . . . 5.1Mirror Heat Switch, Optional . . . . . . . . . . . . . . . 5.1Power Mirrors, Optional . . . . . . . . . . . . . . . . . . 5.1
Monthly Post-Trip Inspectionand Maintenance Checklist . . . . . . . . . . . . . . . . 14.3
Monthly Post-Trip Inspectionand Maintenance Procedures . . . . . . . . . . . . . . 15.12
Multifunction Turn Signal Lever . . . . . . . . . . . . . . . 4.2Hazard Warning Lights . . . . . . . . . . . . . . . . . . . 4.3
Index
I-2
Subject Page
High-Beam Headlights . . . . . . . . . . . . . . . . . . . 4.3Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . 4.2Windshield Wiper/Washer
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
OOptional Instruments . . . . . . . . . . . . . . . . . . . . . . 3.9
Air Intake Restriction Gauge . . . . . . . . . . . . . . . 3.9Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Axle Oil Temperature Gauge,
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Engine Oil Temperature
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11Transmission Fluid
Temperature Gauge . . . . . . . . . . . . . . . . . . . 3.11Turbocharger Boost
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 3.12
PPower Distribution Modules . . . . . . . . . . . . . . . . . . 6.1Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 4.6
Automatic Transmissions . . . . . . . . . . . . . . . . . . 4.6Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . . 4.7Manual Dump Valve . . . . . . . . . . . . . . . . . . . . . 4.7
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 18.1Pretrip and Post-Trip General
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Propane Refueling . . . . . . . . . . . . . . . . . . . . . . . 19.4
RRunning Out of Fuel . . . . . . . . . . . . . . . . . . . . . . 17.4
SSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . 15.1Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 5.6
General Information . . . . . . . . . . . . . . . . . . . . . 5.6Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 5.6Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 5.7
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . 5.3General Information . . . . . . . . . . . . . . . . . . . . . 5.2National 2000 Series Seat . . . . . . . . . . . . . . . . . 5.4Sears Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Speedometer and Tachometer . . . . . . . . . . . . . . . . 3.7Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 3.7Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Standard Instruments . . . . . . . . . . . . . . . . . . . . . . 3.7Coolant Temperature Gauge . . . . . . . . . . . . . . . 3.7
Subject Page
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . 3.7Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . 19.9Fuel/Diesel Exhaust Fluid
(DEF) Gauge . . . . . . . . . . . . . . . . . . . . . . . . 3.8Primary and Secondary Air
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 3.8Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . 12.1
TTorque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
Front Towing Hookup . . . . . . . . . . . . . . . . . . . 17.3Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3
T-Handle Shift Selector . . . . . . . . . . . . . . . . . . 19.3Transmission Mode Switch . . . . . . . . . . . . . . . 19.4
VVehicle Identification Number . . . . . . . . . . . . . . . . . 1.1Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 16.3
Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 16.3Grease and Oil-Based Stains . . . . . . . . . . . . . . 16.3Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3Sugar and Water-Based
Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 16.2
Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 16.2Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 16.2Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 16.2Nail Polish and Nail Polish
Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 16.2Paint and Shoe Heel Marks . . . . . . . . . . . . . . . 16.2Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 16.2Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 16.2Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 16.2
WWarning and Indicator Lamps . . . . . . . . . . . . . . . . . 3.3
ABS Warning . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Check Engine Warning . . . . . . . . . . . . . . . . . . . 3.3Check Transmission
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8Cruise Control Indicator . . . . . . . . . . . . . . . . . . 3.6Diesel Particulate Filter
(DPF) Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 3.5Emergency Buzzer . . . . . . . . . . . . . . . . . . . . . . 3.6Fasten Seat Belt Warning . . . . . . . . . . . . . . . . . 3.5Headlight High-Beam
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Index
I-3
Subject Page
High Coolant TemperatureWarning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
High Exhaust SystemTemperature (HEST) Lamp . . . . . . . . . . . . . . . 3.5
Hydraulic Brake SystemWarning . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7
Left-Turn Indicator . . . . . . . . . . . . . . . . . . . . . . 3.5Low Air Pressure Warning . . . . . . . . . . . . . . . . . 3.6Low Battery Voltage Warning . . . . . . . . . . . . . . . 3.5Low Oil Pressure Warning . . . . . . . . . . . . . . . . . 3.5Maintenance Warning Lamp . . . . . . . . . . . . . . . 19.6Malfunction Indicator Lamp
(MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Optional Warning and
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . 3.6Parking Brake On Warning . . . . . . . . . . . . . . . . 3.5Right-Turn Indicator . . . . . . . . . . . . . . . . . . . . . 3.6Shift Inhibit Indicator . . . . . . . . . . . . . . . . . . . . 19.8Stop Engine Warning . . . . . . . . . . . . . . . . . . . . 3.3Stop Transmission Indicator . . . . . . . . . . . . . . . 19.8Traction Control Indicator . . . . . . . . . . . . . . . . . 19.8Transmission Overheat
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5Wait to Start Indicator . . . . . . . . . . . . . . . . . . . 19.7Water In Fuel Indicator . . . . . . . . . . . . . . . . . . . 3.6
Washing and Polishing . . . . . . . . . . . . . . . . . . . . 16.1Weekly Post-Trip Inspection
and Maintenance Checklist . . . . . . . . . . . . . . . . 14.3Weekly Post-Trip Inspection
and Maintenance Procedures . . . . . . . . . . . . . . 15.11Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Index
I-4
