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Cargo Driver`s Manual

1. da Description Pe Rating 12 Stop Lamps 25A 13 Backup Lamps 10A 14 Washer Pump 10A 15 Fuel Shutoff 15A 16 Two Speed Axle 25A 17 Wheel Wheel and Diff Lock 10A 18 Exhaust Brake 10A 19 Customer Use Start Run 20 Air Dryer 10A 21 Windshield Wipers i 22 Blower Motor 10A 23 Radio 15A 24 Not Used 25 I P Illumination Lamps 5A 26 Trailer Tail License Lamps 10A 27 Park and S M Lamps 10A 28 Cab Roof Marker 10A 29 Not Used 30 Not Used A Fuel Shutoff Relay B Exterior Lighting Relay Vehicle Access and Features Fuse Relay Circuit Breaker Identification Fuse Relay Circuit Breaker Identification Customer Use Terminals 31 Accessory Run Non Fused 32 Trailer Park and Marker Lamps 33 Accessory Run Fused 34 39 Not Used 40 Accessory Marker Lamps 41 45 Not Used 46 Trailer Lamps 47 Accessory Run Non Fused Pos ar Pos ar Part No Description No Description Number Rating C Brake Low Air Warning 48 Battery Prove out Special Cycling Circuit Breakers Replace with authorized service parts D Cab Latch Warning Prove out or equivalent E Windshield Wiper Timer Table 2 1 Fuse Relay Circuit Breaker Identification F Not Used G Marker Lamps las H Headlamp Dimmer Radio Cab Tilting Two Speed Axle y Trans T
2. Place your right foot on the top step Ref B Bring your left foot up to the cab floor Ref C 5 Place your right foot into the cab and seat yourself Ref D 6 To exit the cab on the driver s side grasp the upper grab handle with your left hand and the lower grab handle with your right hand IMPORTANT Do not attempt to exit the cab while carrying any items in your hand 2 4 Vehicle Access and Features Place your right foot on the top step Bring your left foot to the bottom step Bring your right foot down to the ground then bring your left foot down to the ground Seats IMPORTANT When adjusting the seats unless otherwise noted make all adjustments while seated and before the engine is started Keep hands tools and other objects away from the scissor points under the seats Failure to do so could cause personal injury National Cush N Aire ll Seat Back Cushion Tilt To tilt the back cushion turn the knob and lean forward or backward See Fig 2 5 Height Adjustment To raise the seat push the rocker switch on the side of the seat up until the seat reaches the desired height To 2 5 lower the seat push the rocker switch down until the seat reaches the desired height Fore and Aft Seat Adjustment Move the lever to the left and slide the seat forward or backward to the desired position Bottom Cushion Front Height To adjust the height of the front of the bottom cushion lift
3. 08 27 97 hi dl 1601435 1 All Lights On except headlights 2 All Lights On including headlights Fig 3 5 Headlight Switch ary position makes the dome light turn on whenever the doors are opened Windshield Wipers To operate the wipers at low speed move the control lever up one position See Fig 3 7 To operate the wipers at high speed move the control lever up two 3 4 Driver Controls and Instruments positions To operate the wipers in delay mode move the control lever down one position 1 Steering Column 1541756 2 Control Lever Fig 3 6 High Low Beam Control Windshield Washer Depress the button on the wiper washer control lever to activate the windshield washer See Fig 3 7 Interrupt Switch A spring loaded interrupt rocker switch operates the marker lights See Fig 3 8 With the vehicle lights on depress and release the interrupt rocker switch to briefly turn off the marker lights Cummins Electronic Engine The Cummins electronic engine has a fuel control sys tem controlled by a microprocessor based computer 3 5 2 5 3 4 f820210 1 High Speed 4 Delay Mode 2 Low Speed 5 Washer Button 3 Off Fig 3 7 Windshield Wiper and Washer Control This computer controls specific engine and vehicle speed modes of operation to maximize vehicle fuel economy and performance A yellow engine check light and a red engine stop light are located on the
4. 09 08 97 1601449 Fig 3 10 Cigar Lighter and Ashtray Turn Signal Switch The turn signal lever is mounted on the steering col umn See Fig 3 11 Pushing the lever counterclockwise Driver Controls and Instruments turns on the left turn signal lights pushing it clockwise turns on the right turn signal lights When one of the signal lights is on an indicator light flashes on the warning and indicator light panel When the turn is com pleted the signal will cancel and the lever will return to the neutral position z NX he F 1 gt 1541755 1 Turn Signal Lever 2 Horn Fig 3 11 Turn Signal Lever Electric Horn To sound the electric horn push the button on the turn signal lever See Fig 3 11 Air Horn Optional To sound the air operated horn pull the cable located above the driver s door Hazard Warning Light Switch The hazard warning light switch Fig 3 12 is located in the left switch bank on the instrument panel Hazard warning lights are operated by pushing the top of the switch When the hazard warning light switch is on all of the turn signal lights and both of the indicator lights on the control panel will flash To cancel the warning lights push the bottom of the switch Allison Automatic Transmission Controls Allison automatic transmission MD series models are controlled by an electronic control unit ECU The ECU processes information from sensors pressure switc
5. 5 Connect the clearance lights taillights and signal lights Also connect any special towing lights re quired by local regulations Emergency Starting With Jumper Cables When using jumper cables follow the instructions below Ah WARNING Batteries release explosive gas Do not smoke when working around batteries Put out all flames and re move all sources of sparks or intense heat in the vicinity of the battery Do not allow the vehicles to touch each other Do not lean over the batteries when making connections and keep all other per sons away from the batteries Failure to follow these precautions could lead to severe personal in jury as a result of an explosion or acid burns A CAUTION Make sure both starting systems have the same voltage outputs and avoid making sparks Other wise the vehicle charging systems could be se verely damaged Also do not attempt to charge iso 10 3 lated deep cycle batteries with jumper cables Follow the manufacturer s instructions when charg ing deep cycle batteries NOTE On vehicles equipped with an optional jump start post attach the positive cable clamp to that post instead of to the battery 1 Apply the parking brakes and turn off the lights and all other electrical loads 2 Connect an end of one jumper cable to the positive terminal of the booster battery or jump start post if equipped and connect the other end of the cable to the positive terminal of the d
6. 8 2 Door Windows 2 1 E Emergency Starting With Jumper Gables a ce as ts 10 3 Engine Braking System Optional 4 9 PacBrake Exhaust Brake 4 9 Engine Break In 4 4 Cummins Engines 4 4 Engine Operation 4 5 Subject Page Cummins Engines 4 5 Engine Shutdown 4 8 Cummins Engines 4 8 Engine Starting 4 1 Cummins 2 46660 068480404 4 1 EPA Vehicle Noise Emission Control Label 1 3 E Federal Motor Vehicle Safety Standard FMVSS Labels Tel Fire in the Cab 10 4 In Case of a Cab Fire 10 5 Fontaine Fifth Wheels 11 6 Fifth Wheel Lock Mechanism for Trailer Kingpin 11 6 Fifth Wheel Locking Operation 11 7 General Information 11 6 Front Access Panel 2 15 Fuller Straight Shift Models 5 1 General Information 5 1 Operation cu caw ee epee be 5 1 Fuse Relay Circuit Breaker Identification 2 11 H Hazard Warning Lights 10 1 Subject Page Heater and Ventilation System 3 17 High Altitude Operation 4 9 CUMMINS 2 4 ab eee ee es 4 9 Holland Fifth Wheels 11 1 Fifth Wheel Locking Operation 11 1 General Information 11 1 l Instrument and Control Panel 3 1 INSTUMENTS op iraa mor 3 12 Engine Oil Pressure Gauge 3 14 Fuel Gauge 3 15 Intake Air Restriction
7. 862 kPa from the pressure noted after one brake application is more than 30 seconds eliminate any leaks or replace the air com pressor before operating the vehicle Check the air pressure reserve With the air system fully charged to 125 psi 862 kPa stop the engine and note the air pressure Then make one full brake application and observe the pressure drop If it drops more than 25 psi 172 kPa all areas of leakage must be eliminated before operating the ve hicle Check the air leakage in the system With the parking brakes applied the trans mission out of gear and the tires chocked charge the air system until cutoff pressure of 125 psi 862 kPa is reached Pretrip Inspection and Daily Maintenance With the service brakes released shut down the engine wait one minute and note the air pressure gauge reading Observe the air pressure drop in psi kPa per minute Charge the air system until cutoff pressure of 125 psi 862 kPa is reached With the parking brakes released and the service brake applied shut down the engine wait one minute and note the air pressure gauge reading Observe the air pressure drop in psi kPa per minute If leakage exceeds the limits shown in Table 9 1 repair all areas of leakage before driving the vehicle Before operating the vehicle be sure the spring parking brakes on the vehicle pass the above tests Otherwise an unexpected parking brake application could occur causin
8. adjusting procedures IMPORTANT Brake checking and adjusting is nec essary for all vehicles including trucks equipped with automatic slack adjusters Do not operate the vehicle with underinflated or overinflated tires Incorrect inflation can stress the tires and make the tires and rims more susceptible to damage possibly leading to rim or tire failure and loss of vehicle control resulting in serious per sonal injury or death 37 Check the tire inflation pressures and inspect each tire for bulges cracks cuts and penetrations IMPORTANT The load and cold inflation pres sure must not exceed the rim or wheel manu facturer s recommendations even though the tire may be approved for a higher load or infla tion Some rims and wheels are stamped with a maximum load and maximum cold inflation rating If they are not stamped consult the rim or wheel manufacturer for the correct tire infla tion pressure for the vehicle load If the load exceeds the maximum rim or wheel capacity the load must be adjusted or reduced 37 1 Check the inflation pressures of the tires be fore each trip using an accurate tire pres sure gauge Fig 9 5 Tires should be checked when cool Be sure the valve stem 9 18 Pretrip Inspection and Daily Maintenance 37 2 37 3 37 4 caps are on every tire and that they are screwed on finger tight Inflate the tires to the applicable pressures if needed Overinflation gives the treaded sur
9. www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov 1998 2006 Freightliner LLC All rights reserved Canadian customers who wish to report a safety related defect to Transport Canada Defect Investigations and Recalls may telephone the toll free hotline 1 800 333 0510 or contact Transport Canada by mail at Transport Canada ASFAD Place de Ville Tower C 330 Sparks Street Ottawa Ontario Canada K1A ON5 For additional road safety information please visit the Road Safety website at http www tc gc ca roadsafety menu htm No part of this publication in whole or part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written per mission of Freightliner LLC For additional information please contact Freightliner LLC Service Systems and Docu mentation P O Box 3849 Portland OR 97208 3849 U S A or refer to http www Freightliner com http www FreightlinerTrucks com or http www SterlingTrucks com Chapter mo A OOANODUBRWN Contents Page Introduction Environmental Concerns and Recommendations Event Data Recorder Customer Assistance Center Reporting Safety Defects Foreword Vehicle IdentificatOn ni aa
10. 1 Foot Level Vent 2 Open Close Actuator Lever Fig 3 25 Foot Level Vent 3 19 ENCINO Sano J Ancien ena era Gok CAE a E ae ate 4 1 Gold Start Manifold Heater ocicocierc risas pararse e a a a a wad es 4 3 Gold Weather OPetratlON sana tans anand died nee et a diate dean sete aad A 4 3 Enno Break 0 cortar dey eels deg Pe ee Ede doh wh PE ey A Biel ete oe ed Be ee 4 4 ENGine Operation sa ea eddies Hee wae a eee Rae eee a aa dee 4 5 Engine SHULGOWMN 2 5 54 d2 aah saa peed Sh die ade ee a li nd tiie a eed a ge wk gels G 4 8 High Almude Operation cs sas tae anes sad bu Se eee ba dae boca eas a da 4 9 Engine Braking System Optional Engines Engine Starting Cummins NOTE Before starting the engine read Chapter 3 in this manual for detailed information on how to read the instruments and operate the controls 4h CAUTION When starting a vehicle equipped with a manual transmission and clutch lock out switch the clutch pedal must be fully depressed during the entire start sequence Failure to do so can cause the pin ion to release and re engage which could cause ring gear and starter pinion damage If a vehicle does not start on the first attempt make sure that the engine has completely stopped rotat ing before reapplying the starter switch Failure to do so can cause the pinion to release and re engage which could cause ring gear and starter pinion damage Moving a vehicle with the starter and or using th
11. 4 Canadian National Safety Mark Fig 1 3 Incomplete Vehicle Certification Label U S Canadian Motor Vehicle Safety Standard CMVSS Labels In Canada tractors with fifth wheels are certified by means of a Statement of Compliance label and the Canadian National Safety Mark Fig 1 4 which are attached to the left rear door post In addition tire and rim labels Fig 1 5 are also attached to the left rear door post If purchased for service in Canada trucks built without a cargo body and tractors built without a fifth wheel are certified by a Statement of Compliance label similar to 12 3 02 12 98 1080079 1 Date of manufacture by month and year 2 Gross vehicle weight rating developed by taking the sum of all the vehicle s gross axle ratings 3 Gross axle weight ratings developed by considering each component in an axle system including suspension axle wheels and tires The lowest component capacity is the value used for the system Fig 1 5 Tire and Rim Label 1 2 Vehicle Identification Fig 1 2 This label must be attached by the final stage manufacturer after completion of the vehicle The label is located on the left rear door post and certifies that the vehicle conforms to all applicable CMVSS regula tions in effect on the date of completion Tire and Rim Labels Tire and rim labels certify suitable tire and rim combina tions that can be installed on the vehicle for t
12. 4 0 6 44 ded ace eae eee ga daba Bleed egw adi Mae Ae a 1 1 Vehicle Access and Features 0 0 ee ee eens 2 1 Driver Controls and IMStrUMeNtS sesu soa a des a wale Bie Pe Sa a a ee we a a 3 1 ENQINGS care nade gears ee aE ee Wale aed Se wa aaa aap ea a ad aha ea dated 4 1 RAMSMMSSIOMS sents ie aca a nce i ae lana a aa rond E so ht al wast IS ted Bee 5 1 Clutches Rear Axles and Steering o o o ooocoooocnrr eee teens 6 1 PAC teres eo arcs a eaten O O has neta a oo 7 1 Cab Appearance i ine eek bes dew dd aie wale debe atin add ali yal a a 8 1 Pretrip Inspection and Daily Maintenance 0 0 0 ee ee 9 1 IMANVEMENGONCyY lt 22 nd ene kee coed Ma Oe ede are ed be A EA a edd ea dee Gee 10 1 Tits Wheels tesise ro aedeagal adhe a is gw fe Mune phe wg ag dhe ae ee cE heehee ad Be 11 1 A E svete abe San tenet O 1 1 Vehicle Identification Vehicle Specification Decal etau A rr ida ara a cow and ei a a 1 1 Federal Motor Vehicle Safety Standard FMVSS Labels 00 000 cece eee eae 1 1 Canadian Motor Vehicle Safety Standard CMVSS Labels 0 00000 eee ee 1 2 me ANON FUME AGN 22 x cated a Sete caste bee yaw ys ean mane Gand ce da Vans Ae dis 1 3 EPA Vehicle Noise Emission Control Label Vehicle Identification Vehicle Specification Decal The vehicle specification decal Fig 1 1 identifies the vehicle model I D number and major component mod els lt also lists the major assemblies and install
13. See Fig 11 3 Ad just the trailer landing gear to give enough align ment height so that the fifth wheel picks up the trailer on the fifth wheel ramps 4 With the fifth wheel lock opening aligned with the trailer kingpin back the tractor slowly toward the trailer making sure that the kingpin correctly enters the throat of the locking mechanism When the trailer is picked up by the fifth wheel stop the trac tor then resume a slow backward motion until posi tive lockup occurs Apply the tractor parking brakes Make a visual check for proper kingpin lockup Re lease the tractor parking brakes Test for kingpin lockup by pulling on the trailer against the chocks Check for correct maximum clearance between the lock halves If more than 1 8 inch 3 2 mm clearance exists between the lock halves the lock must be adjusted Refer to Group 31 of the Cargo Workshop Manual for ad justment procedures A WARNING Adjust the locks correctly to a maximum clearance of 1 8 inch 3 mm Incorrect adjustment of the lock 11 3 could cause the trailer to disconnect possibly re sulting in serious personal injury or death 7 10 11 After lockup is completed connect the tractor to trailer air system lines and electrical cable to the trailer Take care to prevent dirt or foreign material from entering the air lines Charge the air brake system with air Make sure that the air connections do not leak Retract the trailer la
14. also has a safety circuit that constantly monitors the wheel sensors solenoid control valves and the electrical circuitry The ABS warning light comes on after turning on the ignition switch The warning light goes out if all ABS components are work ing properly If during vehicle operation the safety circuit senses a failure in any part of the ABS system a sensor sole noid control valve wiring connection short circuit etc the ABS warning light comes on and the control circuit where the failure occurred is switched to normal braking action The remaining control circuit will retain the ABS effect Even if the ABS system is partially or completely inoperative normal braking ability is maintained An ex ception would be if a solenoid control valve or combi nation solenoid control valve is damaged and inopera tive As these components are an integral part of the air brake system normal braking may be impaired or inop erative Brakes IMPORTANT If any of the ABS warning lights do not work as described above or come on while driving repair the ABS system immediately to en sure full antilock braking capability During emergency or reduced traction stops fully de press the brake pedal until the vehicle comes to a safe stop do not pumpthe brake pedal With the brake pedal fully depressed the ABS system will control all wheels to provide steering control and a reduced braking dis tance Although the ABS system i
15. fins and the charge air cooler as equipped If the coolant is low check the amount of antifreeze protection If the protection is adequate add a 50 50 mixture of water and antifreeze If additional protection is needed add antifreeze only Fill to the line on the surge tank Good airflow through the radiator core and air to air aftercooler core is essential for proper engine cool ing The cores allow air passage but form a particle barrier which tends to collect insects and airborne debris Inspect for clogged fins Use compressed air or wa ter directed from the fan side of the core to back flush any material restricting airflow On vehicles equipped with a charge air cooler also inspect and clean this component If clogged the airflow through the radiator could be restricted Bent or damaged fins should also be straightened to permit airflow across all areas of the cores Repair or replace the radiator if it is leaking See Group 20 of the Cargo Workshop Manual for in structions NOTE When traveling through areas of high in sect concentrations it may be necessary to clean Pretrip Inspection and Daily Maintenance the exterior of the radiator or aftercooler core as often as every 200 miles 320 km 7 Check the condition of the coolant hoses and heater hoses Make sure the radiator inlet and outlet coolant hoses and heater hoses are pliable and are not cracking or ballooning Replace hoses that show sig
16. includes a manual steering mechanism a hy draulic control valve and a hydraulic power cylinder hydraulic hoses power steering pump reservoir and other components The power steering pump driven by the engine provides the power assist for the steering system If the engine is not running there is no power assist If the power assist feature does not work due to hydrau lic fluid loss steering pump damage or some other cause bring the vehicle to a safe stop Do not drive the vehicle until the cause of the problem has been cor rected Clutches Rear Axles and Steering LIC L Es 10 05 24 94 f460307a 1 8 0 Clock 2 4o0 Clock Fig 6 4 Steering Wheel Centered Driving the vehicle without the power assist feature of the steering system requires much greater effort especially in sharp turns or at low speeds which could result in an accident and possible injury Drivers should use the power available with a power steering system carefully If the front tires become lodged in a deep chuckhole or rut drive the vehicle out instead of using the steering system to lift the tires from the hole Also avoid turning the tires when they are against a curb as this places a heavy load on steering components and could damage them 6 6 Brakes Alt Brake Systemi iia A a da A ew oe ete eee ee a 7 1 Brakes Air Brake System General Information A dual air brake system consists of two independent a
17. is forced into the jaws and the lock control handle moves to the locked position The fifth wheel top plate is bracket mounted to the trac tor frame in a position that best distributes the trailer load over the tractor axles Fifth Wheel Lock Mechanism for Trailer Kingpin The Fontaine fifth wheel lock mechanism for the trailer kingpin consists of a spring loaded jaw and a sliding wedge See Fig 11 5 The jaw and wedge each have a pin permanently attached The pin on the jaw and the pin on the wedge fit into elongated notches in the lock control handle The notches in the handle control the limit of movement for both the jaw and wedge The notches are arranged so that the wedge is actuated first during release of the kingpin During lockup the jaw is moved first with the spring loaded wedge being allowed to slip into place against 11 6 Fifth Wheels the jaw A timing bracket ensures that the wedge and jaw are moved at the correct time Placing the lock control handle in the unlocked position moves the wedge away from the jaw This action un locks the jaw so that it can be moved by the trailer king pin When the tractor is moved out from under the trailer the kingpin moves the jaw until the kingpin is out of the mechanism With the jaw in the unlocked posi tion the lock control handle will remain in the unlocked position until manually moved by the operator During coupling Fig 11 5 the motion of the kingpin ente
18. needed Do not overfill 4 2 Engines Cold Start Manifold Heater Do not use starting fluid on an engine equipped with a manifold heater Using starting fluid could cause an explosion possibly resulting in severe personal injury and engine damage Turn the ignition switch to the ON position If the tem perature is below 32 F 0 C the wait to start indicator will come on while the manifold heater warms up After the indicator light goes out start the engine Run the engine slightly above idle until oil pressure shows on the gauge If oil pressure doesn t show on the gauge within 30 seconds of starting turn the key to the OFF position and wait 1 minute then repeat the starting pro cedure Cold Weather Operation Cummins Engines Satisfactory performance of a diesel engine operating in low ambient temperatures requires modification of the engine surrounding equipment operating practices and maintenance procedures The lower the tempera tures the greater the amount of modification required and yet with the modifications applied the engines 4 3 must still be capable of operation in warmer climates without extensive changes The following information is provided to engine owners Operators and maintenance personnel on how the modifications can be applied to get satisfactory perfor mance from their diesel engines There are three basic objectives 1 Reasonable starting characteristics followed by practica
19. opening the drain cocks on the bottoms of the remaining air reservoirs Block the valves open Water and oil emulsion often form pockets which will not drain while compressed air is in the reservoirs Because of these pockets leave the valves blocked open during the first part of the pretrip inspection 2 Inspect the batteries and battery cables as follows Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm To prevent possible per sonal injury always wash your hands after handling battery parts and related accessories 2 1 Be sure the battery holddown is secure If it is loose tighten the hold down bolts If it is broken replace it CAUTION Take care to keep the vent plugs tight so that the neutralizing solution does not enter any of the bat tery cells and damage the battery 2 2 Remove any corrosion from the hold down and the top of the battery Use diluted am monia or a soda solution to neutralize the acid present then rinse off the ammonia or soda solution with clean water If the battery posts or cable terminals are corroded disconnect the terminals from the posts Clean them with a soda solution and a wire brush After cleaning connect the ter minals to the battery posts then apply a thin coat of petroleum jelly or dielectric grease to the posts and terminals to help retard corro s
20. or more devices that record specific vehicle data The type and amount of data recorded varies depending on how the vehicle is equipped such as the brand of engine if an air bag is installed or if the vehicle features a collision avoidance system etc Customer Assistance Center Having trouble finding service Call the Freightliner Customer Assistance Center at 1 800 385 4357 or 1 800 FTL HELP or the Sterling Customer Assistance Center at 1 800 785 4357 or 1 800 STL HELP Call night or day weekdays or weekends for dealer referral vehicle information breakdown coordination or Fleet pack assistance Our people are knowledgeable pro fessional and committed to following through to help you keep your truck moving 4 06P Printed in U S A Foreword Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Freightliner LLC If the NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or the vehicle manufacturer To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http
21. recom mends that a quality brand of cleaner or cleaner polish and polishing wax be used Do not let diesel fuel or antifreeze stand on a painted surface If either should occur rinse the surface off with water To prevent rust have any nicks or other damage on the finish touched up as soon as possible Park your vehicle in a sheltered area whenever possible Care of Chromed Parts and Stainless Steel Clad Parts To prevent rust keep chrome and stainless steel clad parts clean and protected at all times This is especially important during winter driving and in coastal areas where there is exposure to salt air When cleaning chrome or stainless steel clad parts use clean water and a soft cloth or sponge A mild detergent may also be used Sponge gently then rinse If necessary use a nonabra sive chrome cleaner to remove stubborn rust or other material Do not use steel wool Cab Appearance IMPORTANT Use only nonabrasive chrome clean ers on stainless steel clad parts This prevents scratching and marring of the polished surface To help protect the chrome after cleaning apply a coat of polishing wax to the surface Never use wax on parts that are exposed to high heat such as exhaust pipes Dashboard Care Periodically wipe the dashboard with a water dampened cloth A mild detergent can be used but avoid using strong detergents Vinyl Upholstery Cleaning To prevent soiling frequent vacuuming or light b
22. the OFF position The headlights low beam only brake lights fog lights dome lights clearance lights turn sig nals hazard warning lights parking lights and the cigar lighter operate with the ignition switch off regardless of whether the key is inserted In the ACCESSORY position the wipers heated mir rors backup lamps radio ether start system and all electric gauges operate Turn the key fully clockwise to the START position only when starting the engine When the engine starts re 3 1 lease the key When released the key will move to the ON position In the ON position all electrical systems are operable Warning lights and buzzer for low air pressure and low oil pressure operate until the engine is started and mini mum pressures are built up Panel Light Control The panel lights see Fig 3 4 are turned on by the headlight switch The panel light control lever adjusts the brightness of the instrument panel lights Slide the control lever up to brighten the lights and down to dim them Move the control lever all the way down to turn them off Headlight Switch and Daytime Running Lights In the up position all of the lights are off See Fig 3 5 Turning the switch clockwise one position turns on the marker clearance lights taillights parking lights license plate light and panel lights Turning the switch clock wise another position turns on the headlights marker clearance lights taillights pa
23. the vehicle Increase or decrease the pressure on the pedal so that the vehicle comes to a smooth safe stop When the forward speed of the vehicle has decreased almost to the idling speed of the engine push the clutch pedal in and shift the transmission into neutral Apply the spring parking brakes if the vehicle is to be parked The yellow diamond shaped knob Fig 7 1 on the con trol panel actuates the parking brake valve Pulling out the knob applies the spring parking brakes 1421624 Fig 7 1 Parking Brake Valve Knob CAUTION Do not use the spring parking brakes if the service brakes are hot such as after descending a steep grade Also do not use the spring parking brakes during freezing temperatures if the service brakes are wet To do so could damage the brakes if hot or cause them to freeze during cold weather If the brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them Allow hot brakes to cool before using the spring parking brakes Always chock the tires If the brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them Allow hot brakes to cool before using the spring parking brakes Always chock the tires 7 2 Brakes A CAUTION Never apply the service and spring parking brakes simultaneously To do so transmits excessive input force to the brake components which could dam age or cause eventual failure of
24. 80053 1 Date of manufacture by month and year 2 Gross vehicle weight rating developed by taking the sum of all the vehicle s gross axle ratings 3 Gross axle weight ratings developed by considering each component in an axle system including suspension axle wheels and tires The lowest component capacity is the value used for the system Fig 1 2 Certification Label U S Vehicle Identification If purchased for service in the U S trucks built without a cargo body have a certification label Fig 1 3 at tached to the left rear door post In addition after completion of the vehicle a certification label similar to that shown in Fig 1 2 must be attached by the final stage manufacturer This label will be located on the left rear door post and certifies that the vehicle conforms to all applicable FMVSS regulations in effect on the date of completion CHASSIS CAB MFD BY VEHICLE ID NUMBER THIS CHASSIS CAB CONFORMS TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS 101 102108 104106107 11 113 15 120121 126205 206207 208 209 210302 THIS VEHICLE WILL CONFORM TO STANDARD NO IF ITI COMPLETED IN ACCORDANCE WITH THE INSTRUCTIONS CONTAINED IN THE INCOMPLETE VEHICLE DOCUMENT FURNISHED PURSUANT TO 490FR PART S68 CONFORMITY TO THE OTHER SAFETY STANDARDS APPLICABLE TO THIS VEHICLE WHEN COMPLETED IS NOT SUBSTANTIALLY AFFECTED BY THE DESIGN OF THE CHASSIS CAB 09 28 98 f080023 09 30 93 f080024 Fig 1
25. Cab Appearance Paint Shoe Heel Marks Paint should be removed immediately Do not use paint remover or liquid type brush cleaner on vinyl An un printed cloth dampened with naphtha or turpentine may be used Use care to prevent contact with parts of the upholstery that are not vinyl Sulfide Stains Sulfide compounds such as those found in eggs and some canned goods can stain after prolonged contact with vinyl These stains can be removed by placing a clean unprinted piece of cloth over the spotted area and pouring a liberal amount of 6 percent hydrogen per oxide onto the cloth Allow the saturated cloth to remain on the spot for thirty to sixty minutes For stubborn spots allow the hydrogen peroxide saturated cloth to remain on the area overnight Use caution to prevent the solution from seeping into the seams or it will weaken the cotton thread Nail Polish and Nail Polish Remover Prolonged contact with these substances causes per manent damage to vinyl Careful blotting immediately after contact minimizes damage Do not spread the liq uid during removal 8 3 Shoe Polish Most shoe polishes contain dyes which penetrate vinyl and stain it permanently Shoe polish should be wiped off as quickly as possible using naphtha or lighter fluid If staining occurs try the same procedure as that under Sulfide Stains Ball Point Ink Ball point ink can sometimes be removed if rubbed im mediately with a damp cloth
26. Fig 2 7 Passenger s Seat Release Lever typical Seat Belts and Tether Belts General Information Seat belt assemblies are designed to secure persons in the vehicle to help lessen the chance of injury or the N 09 09 97 1910247 2 7 amount of injury resulting from accidents or sudden stops For this reason the manufacturer urges that the driver and all passengers regardless of age or physical condition use seat belts when riding in the vehicle Seat belt assemblies in the vehicle meet Federal Motor Vehicle Safety Standard 209 Type 1 and Type 2 requirements They are recommended for all persons weighing over 50 pounds 23 kg A child restraint system should also be provided for each child weighing 50 pounds 23 kg or less It should meet the requirements of Federal Motor Vehicle Safety Standard 213 Child Restraint Systems When provid ing such a restraint system carefully read and follow all instructions pertaining to installation and usage for the child Make certain the child remains in the restraint system at all times when the vehicle is in motion In addition to seat belt assemblies tether belts are in stalled on suspension type seats Tether belts help se cure the seat to the floor and are intended to restrain the seat and seat belt in case of an accident or sudden stop IMPORTANT Seat belts have a finite life which may be much shorter than the life of the vehicle Regular inspections and replace
27. Foreword Introduction This manual provides information needed to operate and understand the vehicle and its components More detailed information is contained in the Owner s War ranty Information for North America booklet and in the vehicle s workshop and maintenance manuals Custom built Cargo vehicles are equipped with various chassis and cab components Not all of the information contained in this manual applies to every vehicle For details about components in your vehicle refer to the chassis specification pages included in all new vehicles and to the vehicle specification decal located inside the vehicle For your reference keep this manual in the vehicle at all times IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freightliner LLC reserves the right to discontinue models and to change specifications or design at any time without no tice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revi sions and editions without notice Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should first attempt to reclaim and re cycle them To preserve our environment follow appro priate environmental rules and regulations when dispos ing of materials Event Data Recorder This vehicle is equipped with one
28. Gauge Intake Air Restriction Engine Model Service at or Above Cummins 25 inH O Turbocharged engines must be checked at full load and governed engine speed Table 3 3 Intake Air Restriction 3 16 Driver Controls and Instruments Transmission Oil Temperature Gauge With an Allison automatic transmission the transmission oil temperature gauge reading should not exceed 250 F 121 C during normal operation A warning light will activate to alert the driver A CAUTION A sudden increase in oil temperature that is not caused by a load increase may indicate mechanical failure Bring the vehicle to a safe stop and investi gate the cause to prevent further damage Do not operate the engine until the cause has been deter mined and corrected Heater and Ventilation System A dash mounted climate control panel Fig 3 22 allows you to control all of the heating defrosting and ventilat ing functions A temperature control lever is used to select the desired temperature Slide the lever to the left for cool air or to the right for warm air A function control lever controls the direction of warm or cool air 3 17 1 2 3 1830809 Temperature Control Lever Defrost Position Function Control Lever Fig 3 22 Climate Control Panel The Floor Panel position directs air through the windshield floor side panel and center panel unheated vents The Defrost position direct
29. Indicator 3 15 Primary and Secondary Air Pressure Gauges 3 15 Speedometer 3 13 Tachometer 3 12 Transmission Oil Temperature Gauge ek ieee eee 3 17 Voltmeter 3 14 Water Temperature Gauge 3 13 P Pretrip Inspection and Daily Maintenance Procedures 9 3 Pretrip Inspection Checklist 9 1 Subject Page R Rear Axles o o o 6 3 Meritor Drive Axles with Main Differential Lock 6 4 Meritor Main Differential Lock Operation 6 4 Meritor Two Speed Rear Axle 6 3 S Seat Belt Operation 2 8 Lap Belts die sa rar ws 2 9 Three Point Seat Belt with Komfort Latch 2 8 Seat Belts and Tether Belts 2 7 General Information 2 7 Seats voir eee haw es 2 5 National Cush N Aire Il Seat 2 5 Non Suspended Drivers Seat 2 6 Passengers Seat 2 7 Steering System 6 5 General Information 6 5 Power Steering System 6 5 T Tire and Rim Labels 1 3 TOWING c ndida 10 1 Index Subject Page Front Towing Hookup 10 1 Rear Towing Hookup 10 2 V Vehicle Specification Decal 1 1 Vinyl Upholstery Cleaning 8 2 Ball Pointlak lt lt snig aia 8 3 Chewing Gum 8 2 Miscellaneous 8 3 Nail Polish and Nail Polish Remover sarada a a 8 3 Ordinary Ditt 22 opreme sitae 8 2 Paint Shoe Heel Marks 8 3 Sh
30. Vehicle Access and Features 4 09 08 97 1310619 1 First Position 40 Degree Tilt 2 Second Position 50 Degree Tilt Fig 2 16 Cab Tilt Arm 2 Remove the bolt previously placed near the central pin Return the bolt to its original position in the lower opening of the triangular support CAUTION Be sure the shift lever is in neutral and the shift knob will clear the floor opening when the cab is being lowered to avoid damage to the shift lever 2 15 3 Lift the rear part of the cab slightly then pull down ward to lower the cab completely Remove the cab lock handle and secure it in its original position 4 To check for proper locking of the cab turn the igni tion to the ON position An indicator light on the in strument panel will light if the cab is not locked se curely Front Access Panel The parking brake must be fully set before opening the front access panel Failure to do so could result in serious personal injury If your vehicle has an automatic transmission place the gear shift lever in N neutral shut the engine off and set the parking brake If your ve hicle has a manual transmission place the gear shift lever in R reverse shut the engine off and set the parking brake To open the front access panel use a coin to turn the locks located at each end of the outside surface of the panel one quarter turn counterclockwise After tilting the panel open support the panel with
31. ack discs in the stud hole area Use the rec ommended torque values and follow the proper tightening sequence 39 Check components of the air brake system for cor rect operation as follows 9 20 Pretrip Inspection and Daily Maintenance 39 1 Release the parking brakes on the vehicle by pushing in the parking brake control valve knob See Fig 9 7 Check the air governor cut in and cut out pressures Run the engine at fast idle The air governor should cut out the air compressor at approximately 125 psi 862 kPa With the engine idling make a series of foot valve applications The air gov ernor should cut in the air compressor at approximately 95 psi 655 kPa If the air governor does not cut in and out as de scribed above it must be adjusted to these specifications If the air governor cannot be adjusted or repaired replace it before oper ating the vehicle 1421624 9 21 Fig 9 7 Parking Brake Valve Knob 39 2 Check the air pressure buildup time as fol lows 39 3 39 4 Release the parking brakes on the vehicle by pushing in the parking brake control valve knob With the air system fully charged to 125 psi 862 kPa make one full brake ap plication and note the air pressure reading on the gauge Continue to reduce the air pressure by moderate brake applications to a maximum of 90 psi 620 kPa then run the engine at governed rpm If the time re quired to raise the air pressure to 125 psi
32. aise the cab until all loose items inside the cab are removed or fastened down and the doors are closed If the cab is equipped with exterior air lines be sure the air lines will be clear of the body lock 1 Apply the parking brakes and chock the tires 2 The handle for the cab lock control is located on the lower front face of the driver s seat Fig 2 14 Remove the handle from the housing 3 Insert the cab lock handle in the lock control lo cated on the passenger s side of the rear cab panel Fig 2 15 Push the safety hook knob inward then rotate the handle counterclockwise and pull the handle outward The handle will still be engaged Vehicle Access and Features 09 09 97 S 1910245 Fig 2 14 Cab Lock Handle 4 Lift the rear part of the cab and let it tip up to the first position CAUTION To avoid damage to the handle do not put pressure on the lock handle or use the handle to lift the cab 5 To tilt the cab to the second position remove the lower limiting rod triangular support bolt Place the support bolt in the opening in the arm connection 09 08 97 1310618 1 Cab Lock Control 2 Safety Hook Knob Fig 2 15 Back of Cab near the central pin Fig 2 16 The cab can now be pushed forward to the second position To Lower the Cab 1 Make sure the lock indicator is retracted to permit correct cab locking then push the cab back to the first tilting position 2 14
33. ake system air tanks Pretrip Inspection and Daily Maintenance 17 18 19 20 21 22 23 24 25 26 Inspect the fuel tank s and fuel line connections If so equipped be sure the fuel tank shutoff valves are open Check the fuel level in the fuel tank s and be sure the fuel cap vent area is clean If so equipped check the fuel water separator for leaks If needed prime the fuel tank system If so equipped check the transmission oil cooler for debris and for leaks If so equipped inspect the fifth wheel and check it for adequate lubrication If so equipped inspect the 7 way trailer cable re ceptacle s for good connections Inspect the front and rear suspension components including the springs shocks and suspension brackets Clean the headlights rearview mirrors and the out side of the windshield and all window glass Check the condition of the windshield wiper arms and blades Clean the inside of the windshield the gauges on the dash and all window glass Check for excessive play at the steering wheel Adjust the driver s seat then align the rearview mir rors 27 28 29 30 31 32 33 34 35 36 Check the seat belts for secure mounting and for damage Check the cab interior for loose items and secure or remove them Turn on the ignition and start the engine Be sure the air and oil pressure warning systems if equipped are operat
34. and replace any compo nent that is worn cracked or otherwise damaged Do not replace individual leaves of a damaged front or rear suspension leaf spring assembly replace the complete spring assembly Visible damage 9 12 Pretrip Inspection and Daily Maintenance such as cracks or breaks to one leaf causes hidden damage to other leaves Replacement of only the visibly damaged part s is no assurance that the spring is safe If cracks or breaks exist on front spring assemblies in either of the two top leaves a loss of vehicle control could occur Failure to re place a damaged spring assembly could cause an accident resulting in serious personal injury or property damage 23 Clean the headlights rearview mirrors and the out side of the windshield and all window glass Check the condition of the windshield wiper arms and blades Be sure the windshield wiper blades are tensioned against the windshield Inspect the wiper blades for damage and deteriorated rubber Replace the wiper arms if the wiper blades are not tensioned against the windshield Replace damaged or deteriorated wiper blades Replace wiper arms and blades when necessary to maintain good visibility Poor visibility could inter fere with the driver s ability to control the vehicle possibly resulting in serious personal injury or death 9 13 24 Clean the inside of the windshield the gauges on the dash and all window glass 25 Check the steering
35. arance Gabi Washing and Polishing 2c gs gt oie or Oe bad aras dea ra 8 1 Care of Chromed Parts and Stainless Steel Clad Parts 2 0 eee ee ooo 8 1 Dashboard Gare sos aba ea tk a dr de Sod Ge dod Ake Ge as aod dea es Peay Sete we a eRe kA are es 8 2 Vinyl Upholstery Cleah criada eens mares 22 beads nee nak es wae eal dade bata bee gated 8 2 Cloth Upholstery Cleaning Cab Appearance Cab Washing and Polishing To protect the finish of your new vehicle follow these guidelines carefully e During the first 30 days rinse your vehicle fre quently with water If the vehicle is dirty use a mild liquid soap Do not use detergent e During the first 30 days do not use anything abrasive on your vehicle Brushes chemicals and cleaners may scratch the finish e During the first 120 days do not wax your ve hicle To extend the life of your vehicle s finish follow these guidelines Avoid washing your vehicle in the hot sun Always use water After the cab is completely washed dry it with a towel or chamois Do not dust painted surfaces with a dry cloth as this will scratch the paint Do not remove ice or snow from a painted sur face with a scraper of any sort To prevent damage to the finish wax it regularly Before waxing if the finish has become dull re move oxidized paint using a cleaner specifically designed for this purpose Remove all road tar 8 1 and tree sap before waxing Freightliner
36. at the ECU has received input to change operation The MD series transmission system is designed to warn the driver of transmission malfunctions The driver of a vehicle equipped with these transmissions should know the extent of the warning system in order to safely oper ate the vehicle See Chapter 3 for information on the warning system Operation Ah CAUTION The engine should never be operated for more than 30 seconds at full throttle with the transmission in gear and the output stalled Prolonged operation of 52 Transmissions f SELEC MONITOR MODE ON E Noa DF A 10 31 94 1600369a 1 Indicator Panel 2 Mode ID Fig 5 3 Shift Selector this type will overheat the transmission fluid and will result in severe damage to the transmission 1 Start the engine then check the digital display on the push button shift selector Under Select at the top of the unit the display should always show 5 3 the primary shift mode Under Monitor the gear the transmission is in should be displayed WARNING Never shift from neutral N to drive D or reverse R at engine speeds above idle The vehicle will lurch forward or backward which could cause prop erty damage and personal injury 2 Use reverse R to back the vehicle Completely stop the vehicle before shifting from a forward gear to reverse or from reverse to forward There is only one reverse gear 3 Select drive D for all
37. ations shown on the chassis specification sheet A copy of the specification decal is inside the rear cover of the Own er s Warranty Information for North America booklet An illustration of the decal is shown in Fig 1 1 COMPONENT INFORMATION MANUFACTURED BY MODEL VEHICLE ID NO USE VEHICLE ID NO WHEN ORDERING PARTS WHEELBASE DATE OF MFR ENGINE NO ENGINE MODEL TRANS NO TRANS MODEL MAIN FRT AXLE NO FRONT AXLE MODEL REAR AXLE NO REAR AXLE MODEL REAR AXLE NO RATIO PAINT MFR FOR COMPLETE PAINT INFORMATION PAINT NO SEE VEHICLE SPECIFICATION SHEET 02 12 98 f080077 Fig 1 1 Vehicle Specification Decal U S Built Vehicle Shown NOTE Labels shown in this chapter are examples only 1 1 Federal Motor Vehicle Safety Standard FMVSS Labels NOTE Due to the variety of FMVSS certification requirements not all of the labels shown will apply to your vehicle Tractors with or without fifth wheels purchased in the U S are certified by means of a certification label Fig 1 2 and the tire and rim labels These labels are attached to the left rear door post s MFRDBY FRONT AXLE GAWR 3 DE e FIRST INTERMEDIATE AXLE GAWR 3 GWR e SECOND INTERMEDIATE AXLE GAWR 3 VEHICLEIDNO THIRD INTERMEDIATE AXLE GAWR REAR AXLE GAWR THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE VEHICLE TYPE CLASSIFICATION TRUCK TRACTOR 11 21 96 0
38. ay a neds 4 ate tide n ath 4k eae geas a a 6 1 PRC AOS sara aaa acer eh ke gece area acme Gee a Rae 6 3 SlCSHNG SYSTEM son a Ohba oda aah aia le dee Gee deed a w dan aa ed ae E 6 5 Clutches Rear Axles and Steering Clutches General Information The major reason clutches wear out too soon is exces sive heat Clutches are designed to absorb and dissi pate more heat than encountered in typical operation The temperatures developed in typical operation will not break down the clutch friction surfaces However if a clutch is slipped excessively or required to do the job of a fluid coupling high temperatures develop quickly and destroy the clutch Temperatures generated between the flywheel driven discs and pressure plates can be high enough to cause the metal to flow and the friction facing material to char and burn Slipping and excessive heat are practically nonexistent when a clutch is fully engaged But during the moment of engagement when the clutch is picking up the load it generates considerable heat An incorrectly adjusted or slipping clutch will rapidly generate sufficient heat to destroy itself The most important items that a driver should be aware of to ensure long service life of the clutch include start ing in the right gear recognizing clutch malfunctions and knowing when to adjust a clutch 6 1 Clutch Operation Starting the Vehicle in the Correct Gear To drive forward always start in first gear Af
39. brake actuating components Meritor WABCO Antilock Braking System ABS Air Brake Systems The Meritor WABCO Antilock Braking System ABS is an electronic wheel speed monitoring and control sys tem that works with the air brake system ABS passively monitors vehicle wheel speed at all times but controls wheel speed during an emergency or reduced traction stop In normal braking applications the standard air brake system is in effect IMPORTANT For proper ABS system operation do not change tire sizes The sizes of the tires in stalled during production are programmed into the electronic control unit Installing different sized tires could result in a reduced braking force lead ing to longer stopping distances ABS includes signal generating tone wheels and sen sors located in the wheel hubs of each sensed axle The sensors transmit vehicle wheel speed information 7 3 to an electronic control unit located behind the passen ger seat The control unit s main circuit interprets the speed sensor signals and calculates wheel speed wheel retardation and a vehicle reference speed If the calculations indicate wheel lockup the main circuit sig nals the appropriate solenoid control valve to reduce braking pressure During emergency braking the sole noid control valve alternately reduces increases or maintains air pressure supply in the brake chamber to prevent front and rear wheel lockup The electronic control unit
40. c engines may be equipped with a PTO governor The PTO mode is activated by the ON OFF and SET RESUME switches 1 Engage the PTO as follows 1 1 Flip the ON OFF switch to ON 1 2 Hold the throttle pedal down until the ta chometer reaches the desired engine speed 1 3 Momentarily move the SET RESUME switch to SET Engines 2 To disengage the PTO 2 1 Depress the foot brake pedal trailer brake clutch pedal or 2 2 Flip the ON OFF switch to OFF To resume a previously selected engine speed momen tarily move the SET RESUME switch to RESUME Adjust engine speed up or down by holding the SET RESUME switch at SET accelerate or at RESUME decelerate until the desired speed is reached NOTE The resume engine speed memory is not maintained if the cruise control ON OFF switch is turned OFF or if the ignition is shut off Engine Shutdown Cummins Engines 1 With the vehicle stopped apply the parking brakes and place the transmission in neutral 2 It is important to idle an engine 3 to 4 minutes be fore shutting it down This allows the lubricating oil and the water to carry heat away from the combus tion chambers bearings shafts etc This is espe cially important with turbocharged engines Bearings and seals in the turbocharger are sub jected to the high heat of combustion exhaust gases While the engine is running this heat is car ried away by oil circulation but if the engine is stopped suddenl
41. cable to touch the clamps of the other cable Otherwise a spark could occur near a battery possibly resulting in severe personal injury from explosion and acid burns 7 Disconnect the grounded cable from the frame or other nonbattery location Then disconnect the other end of the cable Disconnect the remaining cable from the newly charged battery or jump start post if equipped first Then disconnect the other end Fire in the Cab Urethane foam is flammable Do not allow any flames sparks or other heat sources such as ciga rettes or light bulbs to contact urethane foam Ure thane foam in contact with such heat sources could cause a serious rapid fire which could result in 10 4 In an Emergency death severe burns or gas poisoning as well as damage to the vehicle The incidence of fire in heavy and medium duty trucks is rare according to data from the National Highway Traffic Safety Administration Federal Motor Vehicle Safety Standard 302 limits the flammability of specified materials used inside the cab but despite this most materials will burn The cab of this vehicle contains ure thane foam which is of concern in this respect In Case of a Cab Fire As quickly as possible bring the vehicle to a safe stop apply the parking brake turn off the ignition and get out of the vehicle 10 5 Holland Fifth Wheels Fontaine Fifth Wheels 11 Fifth Wheels Fifth Wheels Holla
42. ces regular main tenance and correct adjustments are factors which will help to stay within the regulations Proper maintenance of the engine which is the respon sibility of the owner operator is essential to keep the emission levels low The driver should be familiar with the vehicle warning system in order to bring the vehicle to a safe stop if the engine malfunctions If the driver doesn t understand how the warning system works an engine shutdown could occur causing a safety hazard See Chapter 3 for information on the control panel for these engines Engines Follow the directions in the Cummins Operation and Maintenance Manual and in this manual for trouble free economical vehicle engine operation 1 Cummins diesel engines produce high horsepower and peak torque characteristics at low rpm Be cause of this it is not necessary to keep the engine wound up to deliver the required horsepower at the wheels These characteristics may also result in less shifting and make shifting at lower rpm to peak torque more practical 2 Depending on the vehicle gearing the posted speed limit can sometimes allow operation in either of the top two gears however for improved operat ing efficiency fuel economy and engine life oper ate in the top gear at reduced rpm rather than in the next lower gear at the maximum rpm 3 Cruise at partial throttle whenever road conditions and speed requirements permit This driving t
43. chains If additional clearance is needed remove the front wheels 7 Connect the clearance lights taillights and signal lights Connect any special towing lights required by local regulations 8 If equipped with air brakes connect the towing ve hicle s air brake system to the vehicle being towed Before releasing the parking brakes make the con nection to the towing vehicle or chock the tires on the disabled vehicle Failure to do so could result in hazardous conditions because the vehicle could suddenly roll and injury could occur 9 Release the parking brakes Rear Towing Hookup Ah CAUTION Using a rear towing hookup on a vehicle equipped with a roof fairing could cause damage to the cab structure IMPORTANT Because of the possibility of exces sive wind force which could cause damage to the cab do not use a rear towing hookup on any ve hicle equipped with a roof fairing 1 Place the front tires straight forward and secure the steering wheel in this position 2 Disconnect the battery ground cable 3 Attach the towing device Due to the many vari ables that exist in towing positioning the lifting and towing device is the sole responsibility of the towing vehicle operator who must be familiar with standard towing industry safety measures 4 Lift the vehicle and secure the safety towing chains If additional clearance is needed remove the bumper extension if equipped 10 2 In an Emergency
44. clutch and transmission to be sure the axle has Clutches Rear Axles and Steering completed the shift into the low range Some ve hicle motion is needed to ensure engagement of the axle Meritor Drive Axles with Main Differential Lock The Meritor main differential lock is a driver controlled traction device operated from the vehicle cab See Fig 6 2 A rocker switch allows the driver to lock or un lock the differential An indicator light in the switch comes on when the differential lock is engaged 10 02 98 1601427a Fig 6 2 Differential Lock Switch The main differential lock provides maximum traction under slippery conditions When the differential lock is engaged the clutch collar completely locks the differen tial case gearing and axle shafts together maximizing traction of both wheels and protecting against spinout Under normal traction conditions do not engage the differential lock Operate the axle with differential action between both wheels Meritor Main Differential Lock Operation To lock the main differential and obtain maximum trac tion under slippery conditions depress the control switch Lock the main differential only when the vehicle is standing still or moving less than 25 mph 40 km h Never lock the main differential when the vehicle is traveling down steep grades or when the wheels are slipping This could damage the differential or lead to loss of vehicle control cau
45. d level Any level within the COLD RUN lower band is satisfactory for oper ating the vehicle If the level is not within the 15 16 17 COLD RUN band add or drain fluid until it reaches the middle of the COLD RUN band e Perform a hot check at the first opportunity after normal operating temperature 160 to 200 F 71 to 93 C is reached Check the fuel water separator if equipped for contaminants With the engine shut down partially open the drain valve under the collection bowl and drain water and contaminants as needed Lower the cab Close the drain valves on the air brake system air tanks Inspect the fuel tank s and fuel line connection If equipped be sure the fuel tank shutoff valves are open Replace leaking fuel tanks Repair or replace any lines or connections that are leaking For proce dures see Group 47of the Cargo Workshop Manual If equipped with fuel tank shutoff valves be sure the valves are fully open Never operate the engine with the fuel tank shutoff valves partly closed This could damage the fuel 9 8 Pretrip Inspection and Daily Maintenance pump causing sudden loss of engine power possi bly resulting in serious personal injury due to re duced vehicle control 18 Check the fuel level in the tank s and be sure the fuel cap vent area is clean Check the fuel water separator if equipped for leaks and if needed prime the fuel tank system A WARNING Never f
46. e Before connecting the fifth wheel to the trailer kingpin always be sure that the fifth wheel plate is completely lubricated with chassis grease 20 5 Clean all foreign material from the fifth wheel top plate Lubricate the top plate surface pickup ramps and mounting bracket pivot pins using a waterproof or multipurpose chassis lubricant Lubricate the jam mecha nism on all units except the Fontaine 5000 series fifth wheel Fontaine recommends that jaws and wedges remain dry to avoid accumulation of abrasive matter 21 22 If so equipped inspect the 7 way trailer cable re ceptacle s for good connections Clean and grease the 7 way socket and plug regu larly especially in regions where magnesium chlo ride or calcium chloride are used as road de icers These chemicals are highly corrosive to brass and copper the base materials for the contact pins used in the 7 way receptacles Clean the socket and plug with a plug brush and apply a moderate amount of dielectric grease to both the socket and plug pins See Group 54 of the Cargo Maintenance Manual for an approved dielectric grease Inspect the front and rear suspension components including the springs shocks and suspension brackets Check for broken spring leaves loose U bolts cracks in the suspension brackets and loose fas teners in the spring hangers and shackles Inspect the shock absorbers for loose fasteners and leaks Tighten all loose fasteners
47. e starter to bump the engine for maintenance proce dures is strictly prohibited Use of these methods to bump the engine over or move the vehicle can cause the pinion to release and re engage which could cause ring gear and starter pinion damage 4 1 IMPORTANT Ring gear and starter pinion damage caused by improper starting procedures is not warrantable 1 Before engine start up perform the engine pretrip inspection and daily maintenance checks in Chap ter 9 of this manual Set the parking brakes Set the throttle to idle Hold the clutch pedal ve hicles with manual transmissions CAUTION Protect the turbocharger during the start up by not opening the throttle or accelerating the engine above 1000 rpm until normal engine idle oil pres sure registers on the gauge 4 For manual transmissions make sure the transmis sion is in neutral For automatic transmissions make sure the transmission shift control is in Neu tral or Park If the outside temperature is 60 F 16 C or higher keep your foot off the throttle pedal during the first five seconds of cranking the engine if the engine does not start in that time apply full throttle while cranking Engines If the outside temperature is below 60 F 16 C fully depress the throttle affer engaging the starter 5 Turn on the ignition switch CAUTION Don t crank the engine for more than 30 seconds at a time during any of the following procedur
48. e in dash indicator Left Side Bank Left Turn Indicator Low Oil Pressure High Coolant Temp Low Coolant Level Wait To Start Exhaust Brake Check A C Do Not Shift or Trans Temp ONDARWN gt gt B 16 Right Side Bank Right Turn Indicator High Beam ABS Brake Parking Brake Differential Lockout Daytime Running Lights Cab Lock Fig 3 2 Warning and Indicator Lights 3 3 4 2 3 09 04 97 1541752 1 Accessory 3 Start 2 On 4 Off Fig 3 3 Ignition Switch comes on The ignition switch must be on for the high beams to operate For vehicles equipped with daytime running lamps DRL switching on the ignition and releasing the park ing brakes automatically activates the headlight low beams at reduced voltage Some vehicles are equipped Driver Controls and Instruments 10 01 98 1601426a Fig 3 4 Panel Light Control Lever with a daytime running lights in dash indicator which will illuminate when the daytime running lights are in operation The daytime running lights will operate until the parking brakes are applied then they will switch off Turning on the regular headlights will override the day time running lights The vehicle cannot be driven unless either the headlights or daytime running lights are activated Dome Light Switch The dome light switch is located on the dome light In addition to the ON and OFF positions a third intermedi
49. e is that bend which the hose will with stand without experiencing damaging stresses or kinking For minimum bend ra dius values see Group 42 of the Cargo Workshop Manual When a rubber hose does not meet mini mum bend radius requirements the outside may appear smooth even if the inner tube is kinked Reroute the hose or replace it with one of adequate length if the bend radius is not within minimum specifications 11 03 94 A 420329a NOTE Center of the hose bend radius should be well away from the fitting A Bend Radius Fig 9 4 Bend Radius Pretrip Inspection and Daily Maintenance 35 10 Check straight hose installations those hoses that do not bend along their routings Pressure changes can cause a hose to lengthen up to two percent or shorten up to four percent A 100 inch 2540 mm length of hose for example can contract to 96 inches 2440 mm If the hose has no slack when it is exhausted of air replace it with one of adequate length to avoid a possible blow off from the fitting during vehicle operation 35 11 Check for kinked or twisted hoses A seven percent twist in the hose can reduce its life by up to 90 percent Also a twisted hose under pressure tends to untwist This could cause it to loosen the fitting Reconnect hoses that are twisted 36 Make sure the brakes are adjusted on all axles Adjust the brakes if necessary See Group 42 of the Cargo Maintenance Manual for checking and
50. e noise control hardware Such vehicles will not have a vehicle noise emis sion control information label For such vehicles it is the final stage manufacturer s responsibility to complete the vehicle in conformity to U S EPA regulations 40 CFR Part 205 and label it for compliance Vehicle Access and Features Cab Door Locks and Handles iaa la a A dd a Ra a ae E NA 2 1 Door WINDOWS Pistia a ad A iz 2 1 Cab Entry and EME ics cen a a a A heen A A A a d A a 2 2 SOSA ari ad doe ah a e ed dde etek dd Ete AA a no daca cee BS 2 5 Seat Belts and Tether Belts ee eee eee eee eens 2 7 Seal Bek Operaio senil ood Beda ane uaa ed ew end A de DA 2 8 Fuse Relay Circuit Breaker Identification 0 cc eee ees 2 11 cl A td db ae pa 2 12 FROME ACCESS PAIN erario win de ch a ah Oe Goce seh ho GA ach hob nos 2 15 Back of Cab Grab Handle Step and Deck Plate 0 0 cc eee eens 2 16 Vehicle Access and Features Cab Door Locks and Handles The same key that operates the ignition switch is used to lock and unlock the cab doors from the outside IMPORTANT Each key is numbered Record the number so that if needed a duplicate key can be made To unlock a door from outside the cab insert the key in the lockset Fig 2 1 and turn the key counterclockwise on the driver s door and clockwise on the passenger s door Pull out on the handle to open the door To lock the door turn the key clockwise on the driv
51. e used on Cummins engines is 30 mph 48 km h A WARNING Do not activate the fifth wheel air slider control valve when the vehicle is in motion Doing so could result in damage to the fifth wheel member kingpin cab or trailer and ultimately to the drivetrain A guard is positioned around the switch to prevent it from being accidentally activated 4h CAUTION Do not attempt to shift gears without using the clutch pedal when the cruise control is engaged Failure to follow this precaution will result in a tem porarily uncontrolled increase in engine speed transmission damage and gear stripping could re sult 1 To cruise at a particular speed 1 1 Flip the ON OFF switch to ON 1 2 Hold the throttle down until the speedometer reaches the desired speed 1 3 Momentarily move the SET RESUME switch to SET 4 7 2 To disengage the cruise control 2 1 Depress the foot brake trailer brake clutch pedal or 2 2 Flip the ON OFF switch to OFF To resume a preselected cruise speed momentarily move the SET RESUME switch to RESUME Cruise will return to the last speed selected Cruise speed can be adjusted up or down by holding the SET RESUME switch at SET accelerate or at RE SUME decelerate until the desired speed is reached NOTE The resume vehicle speed memory is not maintained if the cruise control ON OFF switch is turned OFF or if the ignition is shut off Power Takeoff PTO Governor Cummins electroni
52. eaks or damage Check the intake air restriction indicator to deter mine if the air cleaner filter element needs to be changed Replace the filter element if the yellow signal stays locked at 25 inH 0 for Cummins en gines See Group 09 of the Cargo Workshop Manual for filter element replacement instructions Check the engine air intake piping from the air cleaner to the engine intake Inspect the piping for loose connections cracks torn or collapsed hoses punctures and other damage Tighten loose con nections and replace damaged components Make sure the piping system is airtight so that all of the intake air passes through the air cleaner 9 6 Pretrip Inspection and Daily Maintenance 4h CAUTION Failure to maintain a sealed air intake system could allow the entry of dirt and contaminants into the engine This could adversely affect engine perfor mance and result in engine damage NOTE After replacing the filter element reset the restriction indicator by pressing the reset button 12 Check the fluid level in the clutch fluid reservoir The reservoir is full when the fluid level is up to the MAX mark The fluid level must always be above the MIN mark Use only heavy duty brake fluid DOT 3 in the hydraulic clutch system 13 Check the engine oil level Fig 9 1 The oil level should show between the upper and lower marks on the dipstick Add enough oil to bring the level up to the operating range See the en
53. ech nique permits operating within the most economical power range of the engine 4 When approaching a hill open the throttle smoothly to start the upgrade at full power then shift down as desired to maintain the optimum vehicle speed The high torque of Cummins engines may permit topping some grades without shifting 5 Cummins engines are designed to operate over a wide speed range More frequent shifting than nec essary does not allow proper utilization of this flex ibility The driver who stays in top gear and uses the wider speed range will achieve the best fuel economy 6 The Cummins diesel engine is effective as a brake on downhill grades but care must be used not to overspeed the engine going downhill The governor has no control over engine speed when the engine is being pushed by the loaded vehicle Never turn off the ignition switch while going down hill With the engine still in gear fuel pressure will build up against the shutdown valve and may pre vent it from opening when the ignition key is turned on 4h CAUTION Engine overspeed engine speed exceeds high idle no load rpm can damage the engine 7 Use a combination of brakes and gears to keep the vehicle under control at all times and to keep the engine speed below the rated governed rpm Cruise Control The cruise control is activated by the ON OFF and SET RESUME switches The minimum speed at which cruise 4 6 Engines control can b
54. emp Warning Prove A WARNING out K Not Used Never stand in front of the cab or under the cab L Not Used when the cab is being tilted Doing so could result in serious personal injury Easy access to the engine and transmission is provided by tilting the cab The cab can be tilted 40 degrees for normal repair situations or 50 degrees for removing larger components Torsion bars under the cab make it easy to raise the cab by hand A latching support arm holds the cab in the tilted positions 2 12 Vehicle Access and Features 09 09 97 1541760 1 Signal Flasher located at upper left of fuse panel 2 Warning Chime located at right side of fuse panel 3 Warning Buzzer located at lower left of fuse panel 4 Fuse Relay Circuit Breaker Panel Fig 2 13 Fuse Relay Circuit Breaker Identification To Tilt the Cab Do not release the cab until the transmission has been put into neutral the ignition turned off and the parking brake set Failure to observe these pre cautions could result in serious personal injury 2 13 Do not allow loose clothing to get near moving en gine parts To do so could result in serious per sonal injury CAUTION Ensure the shift lever will clear the floor opening when the cab is tilted to prevent damage to the shift lever Do not r
55. er s door and counterclockwise on the passenger s door The lock cannot be operated when the door is open To lock the door from inside the cab close the door then push the lock button down See Fig 2 1 To open the door from the inside pull the door latch handle toward you This will unlatch the door whether or not it was locked To unlock the door without unlatching it push up on the bottom of the lock button Door Windows To lower the driver s side door window turn its regulator handle clockwise to lower the passenger s side win dow turn its handle counterclockwise See Fig 2 2 2 1 02 11 98 1 Door Latch Handle 2 Lock Button 1601446 3 Exterior Handle 4 Exterior Lock Fig 2 1 Door Handles and Locks Vehicle Access and Features 10 01 98 f601445a Fig 2 2 Window Regulator Handle Cab Entry and Exit Wet or dirty shoe soles greatly increase the chance of slipping or falling If your soles are wet or dirty be especially careful when entering or exiting the vehicle Always maintain three point contact with the cab access system while entering and exiting the cab Three point contact means both feet and one hand or both hands and one foot Driver s Side Entry and Exit When entering or exiting the driver s side of the cab use the grab handles and access steps as follows See Fig 2 3 1 Open the driver s door and place anything that you are carrying
56. es Wait two minutes after each try to allow the starter to cool Failure to do so could cause starter damage Never pour fuel or other flammable liquid into the throttle body air inlet opening in an attempt to start the vehicle This could result in a flash fire causing serious personal injury or property damage 6 When the engine is started it takes a while to get the lubricating oil film reestablished between the shafts and bearings and between the pistons and liners Bring the engine up to operating speed gradually as it warms up and develops stable oil pressure The oil pressure gauge indicates any drop in lubri cating oil pressure or mechanical malfunction in the lubricating oil system The operator should note the loss of oil pressure and shut down the engine be fore damage can occur NOTE Idle diesel engines about three to four min utes at 1000 rpm before operating a loaded ve hicle Starting After Extended Shutdown or Oil Change Do the following steps after an oil change or after the engine has been shut down for more than three days 1 Disconnect the electrical connector from the fuel pump solenoid valve 2 Crank the engine until oil pressure shows on the gauge 3 Connect the electrical connector to the fuel pump solenoid valve 4 Start the engine After one minute shut down the engine and check for leaks 5 Allow five minutes for the oil to settle then check the engine oil level and add oil if
57. etween the kingpin and the fifth wheel jaws by moving the tractor forward and backward against the locked kingpin There should be no slack between the tractor and the trailer If slack is present uncouple the trailer For adjustment instructions refer to the applicable manufacturer s service information Eliminate slack between the trailer and the tractor Incorrect fifth wheel adjustment could cause the trailer to disconnect possibly resulting in serious personal injury or death 11 Retract the trailer landing gear and secure the ratchet handle 12 Remove the chocks from the trailer tires 11 9 13 The load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weigh ing the vehicle on scales designed for this purpose The maximum axle weight ratings are given on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no case should the axle load exceed the maximum axle weight rating given on the FMVSS or CMVSS label Do not overload any tractor axle by improperly loading the trailer This could cause erratic steering and loss of vehicle control possibly resulting in serious personal injury or deat
58. face of the tire a convex shape Fig 9 6 This causes extreme tire wear in the middle part of the tire since this section is primarily in contact with the road Underinflation gives the tread surface a con cave shape Fig 9 6 This causes exces sive tire wear on the outer edges of the tire since they are primarily in contact with the road If a tire has been run flat or underinflated check the wheel for proper lockring and side ring seating and possible wheel rim or tire damage before adding air Moisture inside a tire can result in body ply separation or a sidewall rupture During tire inflation compressed air reservoirs and lines must be kept dry Use well maintained inline moisture traps and service them regularly Inspect the tires for bulges cracks cuts or penetrations A tire pressure check will assist in uncovering hidden damage A weekly 11 03 94 1400061 37 5 Fig 9 5 Check Tire Pressure pressure loss of 4 psi 28 kPa or more in a tire may indicate damage and the tire should be inspected and repaired or replaced Tires should also be inspected for oil con tamination Fuel oil gasoline and other pe troleum derivatives if allowed to contact the tires will soften the rubber and destroy the tire Pretrip Inspection and Daily Maintenance A B C 11 03 94 f400062a A Tire correctly inflated C Tire underinflated B Tire overinflated Fig 9 6 Tire Infla
59. g instructions Parking Brake Control Valve Knob A diamond shaped knob in the control panel operates the parking brake control valve See Fig 3 9 When the knob is out the truck s spring parking brakes are ap plied When the knob is in the parking brakes are re leased Before the parking brakes can be released air pressure in either brake system must be at least 65 psi 447 kPa See Chapter 7 for instructions on the use of the park ing brake valve 3 6 Driver Controls and Instruments 1421624 Fig 3 9 Parking Brake Control Valve Knob Air Suspension Dump Valve Optional The air suspension dump valve allows the air in the ve hicle air suspension to be quickly exhausted lowering the rear of the vehicle This makes it easier to connect to or disconnect from a trailer A control valve toggle switch on the dashboard exhausts and fills the air sus pension To prevent accidental activation a safety re lease button on the switch must be pushed before the switch can toggle A CAUTION Never exhaust air from the suspension while driv ing If the air is exhausted the suspension will not absorb road shocks and could be damaged 3 7 Cigar Lighter Push in the lighter to heat the element See Fig 3 10 The lighter will stay in until the element is hot then it will pop out automatically To open the ashtray pull the ashtray downward To remove the ashtray press down on the tab and pull the tray out
60. g some loss of vehicle control and possibly resulting in serious personal injury 40 Test the service brakes before leaving the lot When starting to move the vehicle and before pick ing up speed test the brakes with the foot valve and parking brake valve to be sure they will bring the vehicle to a safe stop Description Maximum Allowable Service Brakes Air Leakage Air Leakage in psi kPa Per Minute Released Applied Truck or Tractor Only Truck or Tractor w Single Trailer Truck or Tractor w Two Trailers 2 14 3 21 3 21 4 28 5 35 6 42 Table 9 1 Maximum Allowable Service Brakes Air Leakage 41 Test the parking brakes on a 20 percent grade Pull the parking brake control valve knob or apply the hand brake with the vehicle on a 20 percent grade If the parking brakes do not hold the vehicle repair the parking brake system 9 22 In an Emergency Hazard Warning Lights TON eagna e o a dd ed da tia gaa ba ee 10 1 Emergency Starting With Jumper Cables Fire in the Cab In an Emergency Hazard Warning Lights The hazard warning light switch Fig 10 1 is located in the left switch bank on the instrument panel Hazard warning lights are operated by pushing the bottom of the switch When the hazard warning light switch is on all of the turn signal lights and both of the indicator lights on the control panel will flash To cancel the warn ing lights push the top of the
61. gine manufacturer s operation and maintenance manual for recommended lubricants and capacities CAUTION Operating the engine with the oil level below the low mark or above the high mark could result in en gine damage 9 7 f010346 Fig 9 1 Engine Oil Level Checking 14 Check the oil level in the automatic transmission if equipped NOTE The fluid must be warm to ensure an accu rate check The fluid level rises as temperature in creases With the vehicle on a level surface check the oil level in the transmission using one of the following procedures Pretrip Inspection and Daily Maintenance Hot Check e Operate the transmission in a drive range until normal operating temperature 160 to 200 71 to 93 C is reached Park the vehicle Shift to neutral N and ap ply the parking brake Let the engine run at idle Wipe the dipstick clean and check the fluid level A safe operating level is any level within the HOT RUN upper band on the dipstick If the fluid is not within this range add or drain fluid as needed to bring the level to the top of the HOT RUN band See Group 26 of the Cargo Maintenance Manual for fluid types and capacities Cold Check e Acold check may be made when the sump tem perature is 60 to 104 F 15 to 40 C e Run the engine for at least one minute to clear the fluid system of air e With the engine running wipe the dipstick clean and check the flui
62. h Unlocking the Fifth Wheel Lock Mechanism 1 Apply the tractor parking brakes 2 Pull the trailer air supply valve to cut off the air sup ply to the trailer Fifth Wheels 3 Chock the front and rear of the trailer tires to pre vent the trailer from moving WARNING Do not use the trailer service brakes for parking they are not designed for this purpose If air bleeds out of the trailer air tank during parking the vehicle could roll causing serious personal injury or prop erty damage 4 Lower the trailer landing gear until the weight is re moved from the fifth wheel 5 Disconnect the tractor to trailer air system lines and electrical cable Plug the air lines to prevent dirt or foreign material from entering the lines 6 Release the kingpin locking mechanism by lifting the safety latch and pulling the lock control handle to the unlocked position See Fig 11 6 7 Slowly drive the tractor away from the trailer 11 10 Index Subject P Air Brake System Automatic Slack Adjusters General Information Meritor WABCO Antilock Braking System ABS Air Brake Systems Operation Allison Automatic Transmissions General Information Operation Back of Cab Grab Handle Step and Deck Plate Cab Door Locks and Handles Cab Entry and Exit Driver s Side Entry and Exit Passenger s Side Entry and Exit Cab Tilting To Lower the Cab To Tilt the Cab Cab Washing and Polishing Canadian Moto
63. he given gross axle weight rating Tires and rims installed on the vehicle at the time of manufacture may have a higher load capacity than that certified by the tire and rim la bel If the tires and rims currently on the vehicle have a lower load capacity than that shown on the tire and rim label then the tires and rims determine the load limita tions on each of the axles Refer to Fig 1 5 for U S and Canadian tire and rim labels EPA Vehicle Noise Emission Control Label A vehicle noise emission control label Fig 1 6 is at tached to the right rear door post It is the owner s responsibility to maintain the vehicle so that it conforms to EPA regulations 1 3 VEHICLE NOISE EMISSION CONTROL din FREIGHTLINER CORPORATION ATE OF MANUFACTURE 01 86 THIS VEHICLE CONFORMS TO U S EPA REGULATIONS FOR NOISE EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUG THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT WHE REMOVAL OR HENDERING FNOPERATIVE OTHER THAN FOR PURPOSES OF A MAINTENANCE PLACEMENT OF ANY NOISE CONTROL DE ELEMENT OF DESIGN USTED INTHE OWNERS MANUAL INCORPORATED INTO THIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT B THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE Sn 09 28 98 1080078 Fig 1 6 Vehicle Noise Emission Control Label IMPORTANT Certain incomplete vehicles may be produced with incomplet
64. hes and the shift selector Fig 3 13 to automatically control the transmission according to programmed specifications Vehicles with these transmissions have a red do not shift light in the lens and bezel assembly Also there is a service light in the indicator panel on the shift selec tor With the ignition switch on both lights come on for a few seconds then if there is no problem with the 3 8 Driver Controls and Instruments 10 01 98 f601425a Fig 3 12 Hazard Warning Light Switch transmission system the lights will go out Whenever there is a problem with the transmission system the lights will come on and stay on as long as the problem exists If service is displayed in the indicator panel some fea tures may not work but the vehicle can still be driven If the do not shift light comes on while driving accompa nied by eight short beeps from the shift selector oper ating limits will be placed on the transmission such as restricting upshifts and downshifts However the vehicle can still be driven to reach service assistance In either situation have the problem repaired as soon as pos 3 9 SELECT MONITOR SERVICE 1 R MODE 2 N 4 D y 10 28 94 600368a 1 Indicator Panel 2 Mode ID Fig 3 13 Shift Selector sible Refer to the Allison Transmission Service Manual for troubleshooting procedures See Chapter 5 for complete transmission operating instructions Dr
65. horoughly Chewing Gum or Wax Harden the gum or wax with an ice cube wrapped in a plastic bag then scrape off with a dull knife Excess wax can be absorbed by placing a thick white blotter over the wax and heating with a warm not hot iron Remove the remainder by using the same procedure under Grease and Oil Based Stains Mildew Brush the dry fabric with a soft brush Sponge with de tergent and blot If the fabric is colorfast dilute a tea spoon of bleach in one quart one liter of cool water Apply with a swab directly on the mildew stain Dab repeatedly with clear cool water and blot dry 8 4 Pretrip Inspection and Daily Maintenance Prep Inspection Checklists a esc airiai iiaa A Ac A 9 1 Pretrip Inspection and Daily Maintenance Procedures 0 000 cee eee 9 3 Pretrip Inspection and Daily Maintenance Pretrip Inspection Checklist The following pretrip inspection checklist helps ensure that the vehicle components are in good working condi tion before each trip Pretrip inspections cannot be performed in a short pe riod In checklist form the sequence below may seem to be overly time consuming However careful pretrip inspections save time by eliminating stops later to ad just items overlooked or forgotten Each checklist step corresponds with detailed instruc tions found under Pretrip Inspection and Daily Mainte nance Procedures If any system or component does not pass this inspectio
66. ill fuel tanks to more than 95 percent of their liquid capacity This could make them more likely to rupture from impact possibly causing fire and re sulting in serious personal injury or death by burn ing IMPORTANT Use only low sulfur diesel fuels Low sulfur diesel fuels have a maximum 0 05 percent sulfur content compared to a 0 26 to 0 30 percent sulfur content Failure to use low sulfur diesel fuels may void the warranty on emission components 18 1 To keep condensation to a minimum fill the fuel tanks at the end of each day but not to more than 95 percent of liquid capacity Se lect the proper grade of fuel as specified by the engine manufacturer 9 9 Do not mix gasoline or alcohol with diesel fuel This mixture could cause an explosion When filling fuel tanks do not smoke or use an open flame near the fuel tanks Combustion of diesel fuel oil or fuel va pors could result possibly causing personal injury or property damage 18 2 Always strain or filter fuel before filling it into the tanks This will lengthen the life of the engine fuel filter and reduce the chances of dirt entering the engine 18 3 Before installing the fuel cap check the vent line for debris Clean the area around the fuel tank cap with a rag or if necessary clean the cap with solvent CAUTION Don t crank the engine for more than 30 seconds at a time during any of the following procedures Wait two minutes after each try to allow the
67. in the cab 2 Place your left foot on the bottom step Grasp the instrument panel grab handle with your left hand and the steering wheel with your right hand Ref A 3 Place your right foot on the top step Ref B 4 Bring your left foot up to the cab floor Ref C 2 2 Vehicle Access and Features 09 02 97 C D f060165 Fig 2 3 Driver s Side Steps and Grab Handle 5 Place your right foot into the cab and seat yourself Ref D 6 To exit the cab on the drivers side grasp the in strument panel grab handle with your left hand and the steering wheel with your right hand IMPORTANT Do not attempt to exit the cab while carrying any items in your hand 7 Place your right foot on the top step 2 3 8 Bring your left foot to the bottom step 9 Bring your right foot down to the ground then bring your left foot down to the ground Passenger s Side Entry and Exit When entering or exiting the passenger s side of the cab use the grab handles and access steps as follows refer to Fig 2 4 Vehicle Access and Features 09 02 97 Ns NS SOS KN ae 5 S N E Ya S C D 1060166 Fig 2 4 Passenger s Side Steps and Grab Handles Open the passenger s door and place anything that you are carrying in the cab Place your left foot on the bottom step Grasp the instrument panel upper grab handle with your left hand and the lower grab handle with your right hand Ref A
68. ine will have smoky exhaust at high altitudes unless a lower gear is used The engine will not demand full fuel from the fuel system unless the engine is altitude compensated by the use of a turbocharger Shift gears as needed to avoid excessive exhaust smoke Engine Braking System Optional PacBrake Exhaust Brake A PacBrake exhaust brake is available as optional equipment An exhaust brake is an auxiliary braking system that attaches to the engine exhaust system An exhaust brake makes the engine act as a compressor The exhaust brake functions by partially closing off the 4 9 exhaust system from the engine exhaust manifolds cre ating an increase in exhaust back pressure During ve hicle deceleration the engine must turn against the back pressure and this creates a braking effect on the driving wheels WARNING Using the engine brake as a primary braking system when the service brakes are operable is dangerous This can cause long unpredictable stopping dis tances possibly resulting in personal injury or property damage The exhaust brake is not felt as a normal braking force as with the service brakes but is more of a gradual de celerating effect as if the service brakes were lightly applied The exhaust brake is used to aid the engine and the service brakes in slowing the vehicle reducing service brake wear Transmissions Fuller Straight Shit Models mcr a AR Ondine A AAA A ea Se ds 5 1 Allison Automatic Tran
69. ing Leave the engine running Make sure the electric horn and air horn windshield wipers and washer heater and defroster are oper ating properly Check the operation of the backup alarm if so equipped Turn on the lights Check the operation of all gauge lights and interior lights Leave the lights on Make sure all of the lights are working including the brake lights high and low beam headlights turn signals clearance lights and four way flashers Check the condition of the reflectors Turn the lights off Check the outer surfaces of the cab for visible sur face breaks and damage Inspect the air brake components including the brake chamber pushrods air reservoirs and air lines Make sure the brakes are adjusted on all axles 9 2 Pretrip Inspection and Daily Maintenance 37 Check the tire inflation pressures and inspect each tire for bulges cracks cuts and penetrations 38 Check for indications of loose wheel nuts or rim nuts and examine each rim and wheel component 39 Check the air brake system for proper operation 40 Test the service brakes before leaving the lot 41 Test the parking brakes on a 20 percent grade Pretrip Inspection and Daily Maintenance Procedures Whenever equipment requires adjustment replacement repair addition of lubricants or a change of lubricants refer to the Cargo Workshop Manual for repair proce dures and specifications and to the Cargo Maintenance Manua
70. instrument panel With the ignition switch on both lights come on for about two seconds then if there is no problem with the electronic engine system the lights will go out Whenever there is a prob lem within the electronic engine system one of the Driver Controls and Instruments 10 01 98 1601424a Fig 3 8 Interrupt Switch lights will come on and stay on as long as the problem exists If the yellow engine check light comes on while driving some engine features will not work but the vehicle can still be driven If the red engine stop light comes on while driving and if the engine will not accelerate pull off the road and shut down the engine In either situa tion have the problem repaired as soon as possible See Group 54 in the Cargo Workshop Manual for troubleshooting procedures Cruise control and PTO governor are controlled with two switches An ON OFF switch allows the driver to select cruise control or to drive using the foot throttle A spring loaded SET RESUME switch allows the driver to select the cruise speed or to resume the cruise speed after slowing down The power takeoff mode of operation is also controlled with the cruise control switches when the vehicle is sta tionary The engine speed can be set in the 800 to 1600 rem range by placing the ON OFF switch in the ON po sition then pressing the SET RESUME switch when the desired rpm is reached See Chapter 4 for detailed op eratin
71. ion 3 Check the fluid level in the windshield washer res ervoir Add washer fluid as needed Ah WARNING Washer fluids may be flammable and poisonous Do not expose washer fluid to an open flame or any 9 4 Pretrip Inspection and Daily Maintenance burning material such as a cigarette Always com ply with the washer fluid manufacturer s recom mended safety precautions 4 Check the front hub lubricant level if equipped with oil lubricated wheel bearings Observe the level of the wheel bearing lubricant in the hub cap at each end of the front axle and if needed fill the hubs to the level indicated on the hub cap See Group 33 of the Cargo Maintenance Manual for recommended lubricants IMPORTANT Before removing the fill plug always clean the hub cap and plug 5 Tilt the cab Examine the steering gear compo nents Examine the steering gear mounting bolts pitman arm nut and the drag link nuts for tightness Be sure the steering driveline and the U joints are in roadworthy condition without cracks breaks loose ness or other damage Tighten loose nuts and re place damaged parts as needed See Group 46 of the Cargo Workshop Manual for instructions CAUTION Coolant must be filled to the full line of the surge tank Low coolant could result in engine overheat ing which could cause engine damage 9 5 Check the coolant level in the surge tank check the condition of the radiator
72. ir brake systems which use a single set of brake controls Each system has its own reservoir plumbing and brake chambers The primary system operates the service brakes on the rear axle the secondary system operates the service brakes on the front axle Service brake sig nals from both systems are sent to the trailer Do not operate the vehicle with the front brakes backed off or disconnected Backing off or discon necting the front brakes will not improve vehicle handling and may lead to loss of vehicle control resulting in property damage or personal injury Loss of air pressure in the primary system causes the rear service brakes to become inoperative front brakes will continue to be operated by secondary system air pressure In addition trailer brakes will be operated by the secondary system Loss of secondary system air pressure causes the front axle brakes to become inoperative rear service brakes and trailer brakes will be operated by the primary sys tem 7 1 Before driving your vehicle allow time for the air com pressor to build up a minimum of 95 psi 655 kPa pres sure in both the primary and secondary systems Moni tor the air pressure system by observing the dual system air pressure gauge and the low air pressure warning light and buzzer The warning light and buzzer shut off when air pressure in both systems reaches 64 to 76 psi 441 to 524 kPa The warning light and buzzer come on if air pressure drops bel
73. ischarged battery or jump start post if equipped See Fig 10 2 Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable Otherwise a spark could occur near a battery possibly resulting in severe personal injury from explosion and acid burns 3 Connect one end of the second jumper cable to the negative terminal of the booster battery and con nect the other end of the cable to a ground at least 12 inches 300 mm away from the batteries of the In an Emergency C A MED wee B D yay O E E Pza a g ES G NI F x 4 d A 1 2 amp 10 18 94 1540303a A To Ground E To Starter B 3rd F 2nd C To Frame ground G 1st D 4th 1 Booster Battery 2 Discharged Battery Fig 10 2 Jumper Connections vehicle needing the start The vehicle frame is usu ally a good ground Do not connect the cable to or near the discharged batteries Start the engine of the vehicle with the booster bat teries and let the engine run a few minutes to charge the batteries of the other vehicle Attempt to start the engine of the vehicle with the batteries receiving the charge Do not operate the starter longer than 30 seconds and wait at least two minutes between starting attempts to allow the starter to cool 6 When the engine starts let it idle a few minutes Do the next step exactly as instructed and do not allow the clamps of one
74. iver Controls and Instruments Suspension Seat Adjustment Controls All adjustment controls for a suspension seat are lo cated on the seat base Refer to Chapter 2 for com plete instructions Vernier Throttle Control Optional The vernier throttle control can be used to adjust engine speed when the vehicle is parked A quick adjust set ting of engine speed is made by depressing the button on the control knob then pushing in or pulling out the knob Engine speed adjustments can then be made in smaller increments by turning the control knob in either direction Warning and Indicator Lights Warning and indicator light modules located on each side of the speedometer house all of the standard and optional warning and indicator lights Figure 3 14 identi fies the warning and indicator lights All of the standard and optional warning and indicator lights are located in light banks on each side of the speedometer Standard indicator lights include e The green right and left turn signal lights which flash on and off whenever the outside turn signal lights are flashing e The blue high beam indicator light located above the speedometer and tachometer which comes on when the headlights are on high beam e The red parking brake indicator light which comes on whenever the parking brakes are activated and the ignition is on Standard Warning System Standard Warning Lights Standard red warning lights are for alternator n
75. k the buckle and latch for operation and for wear or damage 4 3 N N C 6 5 5 09 30 96 1910173 1 Worn Web 4 Komfort Latch 2 Web 5 Retractor 3 Buckle 6 Tether Belt Fig 9 3 Seat Belt Inspecting typical seat 27 4 Check the Komfort Latch for function and cracks or other damage 9 14 Pretrip Inspection and Daily Maintenance 28 29 27 5 Check the web retractor for function and damage 27 6 Check the mounting bolts for tightness and tighten any that are loose Check the cab interior for loose items and secure or remove them Start the engine and make sure the oil pressure and air pressure warning systems are working When the engine is started oil pressure and air pressure warnings will come on until the oil pres sure rises above a preset minimum and the air pressure in both the primary and secondary air res ervoir systems goes above 64 to 76 psi 441 to 524 kPa If the air pressure in both systems is above 64 to 76 psi 441 to 524 kPa when the engine is started test the low pressure warning system by lowering the pressure to below this range or until the warning system comes on If the warning systems do not come on when the ignition is turned on repair the systems A WARNING Failure to repair the engine shutdown warning sys tem could result in the engine shutting down sud denly without warning during vehicle operation 9 15 This could cause an accident leading t
76. l and dependable warm up of the engine and equipment 2 A unit or installation which is as independent as possible from external influences 3 Modifications which maintain satisfactory operating temperatures with a minimum increase in mainte nance of the equipment and accessories If satisfactory engine temperature is not maintained higher maintenance cost will result due to increased engine wear Special provisions to overcome low temperatures are definitely necessary whereas a change to a warmer climate normally requires only a minimum of revision Most of the accessories should be designed in such a way that they can be disconnected so there is little ef fect on the engine when they are not in use Engines The two most commonly used terms associated with preparation of equipment for low temperature operation are winterization and arctic specifications Winterization of the engine and or components so that starting and operating are possible in the lowest tem perature to be encountered requires e Adequate lubrication with low temperature lubri cating oils Protection from the cold air insulation The metal temperature does not change but the rate of heat dissipation is affected Fuel of the proper grade for the lowest tempera ture Using a block heater to raise the engine block and component temperatures to at least 25 F 32 C for starting in lower temperatures Electrical equipment capab
77. l for lubricant recommendations specifications and maintenance intervals and procedures 1 Drain the air brake system air reservoirs Air reservoirs serve as storage tanks for com pressed air They collect water condensed from the air and small amounts of oil from the air compres sor Water and oil normally enter the reservoir in the form of vapor because of the heat generated during compression 9 3 After the water and oil condense they collect near the tank drain valves Drain the resulting emulsion as follows Failure to drain the air reservoirs as instructed could cause sludge formation in the air brake sys tem Sludge could adversely affect braking causing loss of control which could cause death personal injury or property damage NOTE If the air reservoirs are not equipped with automatic drain valves they must be drained daily If they are equipped with auto matic drain valves they must be drained in this same manner at least once a week 1 1 Open the wet tank valve the drain cock or pull chain drain located on the forward end of the supply air reservoir which is con nected directly to the air compressor Block the valve open When draining the air reservoir do not look into the air jets or direct them toward anyone Dirt or sludge Pretrip Inspection and Daily Maintenance particles may be in the airstream and could cause injury 1 2 Exhaust the remaining air and moisture from the system by
78. le of operating in the lowest expected temperature All switches con nections and batteries in the electrical system should be inspected and kept in good condition to prevent losses through poor contacts Arctic specifications refer to the design of mate rial and specifications of components necessary for satisfactory engine operation in extremely low temperatures to 64 F 53 C Contact the near est Freightliner dealer or Cummins engine dealer to obtain the special items required 4h CAUTION Antileak antifreezes are not recommended for use in Cummins engines Although these antifreezes are chemically compatible with DCA water treatment the antileak agents may clog the coolant filters IMPORTANT Fuel heaters used on vehicles with Cummins engine systems could cause high fuel temperatures that affect engine performance and operation of the electronic engine controls If a fuel heater is used make sure it has thermostatic con trols If the fuel heater has a timer set the timer to activate only for a limited period of time before the engine starts Make sure the fuel heater is used only for starting the engine Engine Break In Cummins Engines Cummins engines are run on a dynamometer before being shipped from the factory In most applications the engine can be put to work immediately but during the initial 100 hours or 3000 miles 4000 km of service the 4 4 Engines operator has an opportunity to establi
79. me Running 8 Do Not Shift or Trans Lights Temp 16 Cab Lock Fig 3 14 Warning and Indicator Lights 3 11 Maximum Water Temperature Maximum Water Engine Model Temperature F C Cummins ISB 210 99 Table 3 1 Maximum Water Temperature Oil Pressure Oil Pressure at Oil Pressure at Engine Model Idle Speed Rated Speed psi kPa psi kPa Cummins ISB 10 69 min 30 207 min Oil pressures are given with the engine at operating temperature With the engine cold oil pressure may be higher Table 3 2 Oil Pressure Other optional warning or indicator lights may include air intake warmer oil level automatic transmission oil temperature low water do not shift air cleaner restric tion check engine engine shutdown When the ignition is turned on oil and brake system warnings as equipped activate until the engine starts and minimum pressures are exceeded If the low oil warning light or brake system warning light remains lit after running the engine for fifteen seconds shut down Driver Controls and Instruments the engine and determine the cause Refer to the ve hicle workshop manual for repair procedures IMPORTANT If the warning system does not acti vate when the ignition is turned on repair the sys tem to provide warning protection for oil pressure coolant temperature and the brake system Meritor WABCO Antilock Braking System ABS Ai
80. ment as needed are the only assurance of adequate seat belt se curity over the life of the vehicle Vehicle Access and Features Seat Belt Operation Three Point Seat Belt with Komfort Latch Wear three point seat belts only as described be low In case of an accident or sudden stop injuries could result from misuse Three point seat belts are designed to be worn by one person at a time 1 Before driving the vehicle slowly pull the link end of the three point seat belt out of the retractor and pull it across your lap from outboard to inboard far enough to engage the buckle If the retractor locks too soon allow the belt to retract slightly then slowly pull it out again 2 Fasten the three point seat belt by pushing the link into the buckle until it latches See Fig 2 8 Give the belt a tug at the buckle If the buckle unlatches repeat this step If the problem continues replace the three point seat belt 3 Position the shoulder strap diagonally across your chest If desired engage the Komfort Latch as fol lows NO 910004a Fig 2 8 Fastening the Three Point Seat Belt typical Pull on the shoulder strap to lessen the pressure of the strap on your shoulder and chest Allow no more than one inch 2 5 cm of slack between your chest and the shoulder harness More slack can significantly reduce the seat belt s effectiveness in an accident or a sudden stop While holding the belt slack pres
81. mproves vehicle control dur ing emergency braking situations the driver still has the responsibility to change driving styles depending on the existing traffic and road conditions For example the ABS system cannot prevent an accident if the driver is speeding or following too closely on slippery road surfaces Automatic Slack Adjusters Automatic slack adjusters are required on all vehicles equipped with air brakes manufactured after October 20 1994 Automatic slack adjusters should never be manually adjusted except during routine maintenance of the foundation brakes e g replacing shoes during slack adjuster installation or in an emergency situation When the brake pushrod stroke exceeds the legal brake adjustment limit on a vehicle there is likely a mechani cal problem with the foundation brake components or the adjuster is improperly installed Visit a repair facility as soon as possible when brakes equipped with automatic slack adjusters are determined to be out of adjustment Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing In fact continual adjustment of automatic slack adjusters may result in premature wear of the adjuster itself Further the improper adjustment of some automatic slack adjusters may cause internal damage to the adjuster thereby preventing it from properly functioning 7 4 Cab Appe
82. n it must be corrected before operating the vehicle Refer to the Cargo Workshop Manual for repair procedures and to the Cargo Mainte nance Manual for lubricant recommendations specifica tions and maintenance intervals and procedures NOTE Apply the parking brakes and chock the tires 1 Drain the air brake system air reservoirs 2 Inspect the batteries and battery cables 3 Check the fluid level in the windshield washer res ervoir 4 Check the front hub lubricant level if equipped with oil lubricated wheel bearings 9 1 5 10 111 12 13 14 15 16 Tilt the cab Examine the steering gear compo nents Check the coolant level in the surge tank sight glass and check the radiator and air to air after cooler cooling fins for clogging or damage Check the radiator for coolant leaks Check the condition of the coolant hoses and heater hoses Check the condition of the drive belts Inspect the engine for fuel oil and coolant leaks Inspect the engine and chassis wiring Inspect the air intake system for leaks or damage Check the intake air restriction indicator if it is mounted on the air intake system Check the fluid level in the hydraulic clutch fluid reservoir if equipped Check the engine oil level Check the oil level in the automatic transmission if equipped Check the fuel water separator if equipped for contaminants Lower the cab Close the drain valves on the air br
83. n into the open lock forces the hinged lock to pivot on a pin and close around the king pin The lock is held in place by a spring loaded plunger The kingpin can be released only by manually operating the release handle The adjustment nut will compensate for wear on the lock or kingpin Fifth Wheel Locking Operation Locking the Fifth Wheel Mechanism 1 Chock the front and rear of the trailer tires to pre vent the trailer from moving Fifth Wheels A 2 B 2 4 1 4 A ES La 3 3 5 07 11 2000 1310841 A Closed Position Locked B Open Position Unlocked 1 Release Handle and Spring 3 Lock Halves 5 Sliding Yoke 2 Adjustment Nut 4 Lock Pivot Fig 11 2 Type B Kingpin Lock Mechanism bottom view 2 The kingpin lock mechanism must be fully open fifth wheel could cause erratic steering and loss of and the fifth wheel plate must be completely lubri vehicle control possibly resulting in serious per cated with chassis grease For lubrication instruc sonal injury or death tions refer to Group 31 of the Cargo Maintenance 3 Position the tractor so that the fifth wheel lock opening is in line both vertically and horizontally with the trailer kingpin To prevent a false lockup A WARNING the kingpin should be in a position to enter the Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding Manual 11 2 Fifth Wheels throat of the locking mechanism
84. nd Fifth Wheels General Information Holland fifth wheels Fig 11 1 are bracket mounted to the tractor frame in a position that best distributes the trailer load over the tractor axles Zo ff a 10 31 94 1310266a 1 Kingpin Lock Release Handle 2 Kingpin Lock Mechanism Fig 11 1 Holland Fifth Wheel The Type B kingpin lock mechanism Fig 11 2 uti lizes two spring loaded lock halves The final forward motion of the kingpin into the open lock halves forces the locks to close in a 360 degree grip around the 11 1 shoulder and neck of the kingpin positioning sliding yokes between the lock halves and tapered rib mem bers of the fifth wheel understructure The kingpin can be released only by manually operating the kingpin lock control handle The adjustment nut will compensate for wear on the lock or kingpin The Holland Lockguard Fig 11 3 is a device that pre vents a false lockup and is used with Type B kingpin lock mechanisms The Lockguard is a spring tensioned smooth surfaced tongue that the kingpin passes over and depresses when entering the lock mechanism The Lockguard will prevent the locks from engaging before the kingpin fully enters the locks If the kingpin enters the fifth wheel incorrectly and does not depress the tongue the locks are unable to close The Type A kingpin lock mechanism Fig 11 4 uti lizes a single hinged lock and cam arm The final for ward motion of the kingpi
85. nding gear and secure the ratchet handle Remove the chocks from the trailer tires The load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weigh ing the vehicle on scales designed for this purpose The maximum axle weight ratings are shown on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no instances should the axle load exceed the maximum axle weight rating given on the FMVSS or CMVSS label Fifth Wheels 3 o 2 3 7 Ko 1 Pa B 1 gt ff fey 4 ad 4 3 11 07 94 D c 1310106a A Locks open B Locks closed C Kingpin correctly entering the lock Note how the depressed tongue allows lock halves to close completely around the neck and shoulder of the kingpin D Kingpin incorrectly entering the lock Note how the steel tongue prevents lock halves from closing preventing false lockup 1 Fifth Wheel Plate 3 Kingpin 2 Trailer 4 Lockguard Fig 11 3 Lockguard Mechanism rear view 11 4 Fifth Wheels Ya A 07 26 96 A Closed Position Locked 1 Release Arm 2 Release Handle XY B 3 4 AA 1 lt 3 4 K ph J A B 1310532 Open Positi
86. nes trailer bod ies kingpins suspensions and axles If the moving parts are catching or pinching the lines correct as needed Check for hose damage caused by abrasion If a hose is abraded replace it Check for the cause of abrasion such as loose or damaged hose clamps Repair or replace the clamps as needed 9 16 Pretrip Inspection and Daily Maintenance 9 17 35 6 35 7 35 8 Observe the hose cover condition especially hoses exposed to water splash and ice If any hose is dried out or ragged the wire or liner is showing through the cover replace the hose Inspect the front air brake lines for leaks at the fitting where they enter the air chamber With an assistant at the front wheels to in spect the brake lines turn the wheels to full lock in one direction and hold the service brake pedal down Inspect the front brake air lines closely near where they enter the air chambers Turn the wheels to full lock in the other di rection hold the service brake pedal down and repeat the inspection If there is a leak the hose should be re placed See Group 42 of the Cargo Work shop Manual for the hose replacement pro cedure Inspect air tubing especially tubing made of nylon In cold weather nylon tubing is sensi tive to damage such as nicks or cuts Re place nicked or cut tubing even if it is not leaking 35 9 Check the bend radii of all hoses See Fig 9 4 The minimum bend radius of a hos
87. normal driving conditions The vehicle will start out in 1st gear and as speed increases the transmission will upshift through each gear automatically As the vehicle slows down the transmission will downshift to the correct gear automatically The pressure of your foot on the accelerator pedal influences the automatic shifting When the pedal is fully depressed the transmission will automatically upshift near the governed speed of the engine A partially depressed position of the pedal will cause the upshifts to occur at a lower engine speed 4 Occasionally the road load or traffic conditions make it desirable to restrict the automatic shifting to Transmissions a lower range The lower the gear range the greater the engine braking power Use the up or down arrow buttons on the shift se lector to reach the desired gear The Select indi cator will display your choice and the Monitor in dicator will show the selected gear once it is reached NOTE In the lower gear ranges the transmission will not upshift above the highest gear selected unless the engine governed speed is exceeded 5 Use neutral N and apply the parking brake when the vehicle is parked with the engine running CAUTION Do not allow the vehicle to coast in neutral This can result in severe transmission damage Also no engine braking is available 5 4 Clutches Rear Axles and Steering AA E E E EEE E Be teas Aso oath deed as a cae
88. ns of cracking weakening or ballooning Re place all hoses including heater hoses at the same time Service type knitted or braided yarn reinforced neoprene hose is acceptable Silicone hoses having an extended service life can be substituted for the reinforced neoprene type See the Service Parts Catalog or contact your dealer Tighten hose clamps as necessary but do not over tighten as hose life can be adversely affected Be sure the hose support brackets are securely fas tened Make sure the hoses are not located near sources of wear abrasion or high heat 8 Check the condition of the drive belts Check the drive belt for signs of glazing wear frayed edges damage breaks or cracks or oil contamination lf a belt is glazed worn damaged or oil soaked replace the belt following the instruc tions in Group 01 of the Cargo Workshop Manual NOTE On Cummins engines a belt tensioner au tomatically adjusts the fan and alternator belt to the correct tension If the belt slips repair or re place the tensioner For instructions see the Cum mins Shop Manual ISB Engines 9 Inspect the engine for fuel oil and coolant leaks Correct any leaks found 10 Inspect the engine and chassis wiring Inspect the engine and chassis for loose wiring chafed insulation and damaged or loose hold down clamps Tighten loose wires or hold down clamps Replace damaged wiring or clamps 11 Check the air intake system for l
89. o charge and the brake system See Fig 3 14 When ever conditions cause the brake system warning light to come on a warning buzzer also alerts the driver The brake system warning light and buzzer activate whenever air pressure in the primary or secondary air reservoir falls below 64 to 76 psi 441 to 524 kPa Optional Warning and Indicator Lights The water temperature warning light and buzzer acti vate whenever the engine coolant temperature exceeds a preset point determined by the engine manufacturer Refer to Table 3 1 for this temperature The oil pressure warning light and buzzer activate whenever the oil pressure falls below the minimum oil pressure recommended by the engine manufacturer Refer to Table 3 2 Driver Controls and Instruments A 4 B 9 2 10 E 3 eh ae 4 12 5 D 13 6 El 14 7 15 OR 8 16 07 15 99 f080071a NOTE Not all vehicles with daytime running lights are equipped with the in dash indicator A Left Side Bank B Right Side Bank 1 Left Turn Indicator 9 Right Turn Indicator 2 Low Oil Pressure 10 High Beam 3 High Coolant Temp 11 ABS 4 Low Coolant Level 12 Brake 5 Wait To Start 13 Parking Brake 6 Exhaust Brake 14 Differential Lockout 7 Check A C 15 Dayti
90. o Maintenance Manual for intervals and procedures CAUTION Failure to lubricate the release bearing as recom mended could result in release bearing damage and damage to the clutch Hydraulic Clutch Fluid Reservoir Checking Make sure that the clutch fluid reservoir is full The res ervoir is full when the fluid level is up to the max mark The fluid level must always be above the min mark Use only heavy duty brake fluid DOT 3 in the hydraulic clutch system Rear Axles Meritor Two Speed Rear Axle The two speed rear axle can be used to operate the vehicle in low range when operating off highway or when starting out with a heavy load on highway See 6 3 Fig 6 1 After the vehicle is moving on the highway the axle can be shifted to high range L j 2 2 hd A a lt Q 10 31 94 DS f600370a A Push down for low speed range B Pull up for high speed range Fig 6 1 Range Selection Lever Operation To shift the axle to the high range keep the throttle pedal down then move the range selection lever to high release the throttle pedal until the axle shifts then accelerate To shift the axle to low range keep the throttle pedal down then move the range selection lever to low re lease and then depress the throttle pedal quickly to in crease engine rpm The axle will shift to low range NOTE When parking the vehicle put the axle in the low range with the engine running Engage the
91. o property damage serious personal injury or death 30 31 32 33 Make sure that both the electric horn and the air horn work Then check the wiper and washer con trol During cold weather check the operation of the heater and defroster controls These devices must be in good working order for safe vehicle operation If they are not working re pair them before trip departure Check the operation of the backup alarm if so equipped Check the operation of all gauge lights and interior lights Turn on the headlights dash lights and four way flashers and leave them on Check the operation of the dome light If any of the gauge bulbs the switch panel label bulb the dome light bulb or the right and left turn indicator bulbs are not working replace them Make sure all of the lights are working Be sure the brake lights taillights side marker lights headlights signal lights and clearance and identification lights are working and are clean Test the high and low beams of the headlights Pretrip Inspection and Daily Maintenance 34 35 Replace light bulbs or sealed beam units that are not working Be sure all reflectors and lenses on the vehicle are in good condition and are clean Replace any bro ken reflectors or lenses Turn the lights off Check the outer surfaces of the cab for visible sur face breaks and damage Inspect the air brake components including the brake chamber pushrod
92. oe Polish 8 3 Sulfide Stains 8 3 Tars Asphalts and Creosote 8 2 WwW Warning and Indicator Lights 3 10 Meritor WABCO Antilock Braking System ABS Air Brake Systems 3 12 Standard Warning System 3 10
93. on Unlocked Lock Pin Hinged Lock Do not overload any tractor axle by improperly loading the trailer This could cause erratic steering 11 5 Fig 11 4 Type A Kingpin Lock Mechanism and loss of vehicle control possibly resulting in serious personal injury or death Unlocking the Fifth Wheel Lock Mechanism 1 Apply the tractor parking brakes Fifth Wheels 2 Pull the trailer air supply valve to cut off the air sup ply to the trailer 3 Chock the front and rear of the trailer tires to pre vent the trailer from moving WARNING Do not use the trailer service brakes for parking they are not designed for this purpose If air bleeds out of the trailer air tank during parking the vehicle could roll causing serious personal injury or prop erty damage 4 Lower the trailer landing gear until the weight is re moved from the fifth wheel 5 Disconnect the tractor to trailer air system lines and electrical cable Plug the air lines to prevent dirt or foreign material from entering the lines 6 Release the kingpin locking mechanism by pulling the kingpin lock control handle Fig 11 1 to the outward position 7 Slowly drive the tractor away from the trailer Fontaine Fifth Wheels General Information On Fontaine fifth wheels kingpin release is accom plished by activating a manual lock control handle lo cated on the left side roadside of the fifth wheel King pin lockup occurs when the kingpin
94. or replace any damaged fifth wheels slides or mountings The use of damaged fifth wheel parts may cause the trailer to detach from the tractor 9 11 possibly resulting in serious personal injury or death NOTE For adjustment and replacement in structions refer to Group 31 of the Cargo Workshop Manual 20 3 With the trailer unhooked from the tractor inspect the fifth wheel daily for the follow ing conditions e Loose nuts or broken bolts on the fifth wheel assembly slide mechanism and mounting brackets Replace bro ken bolts and tighten loose nuts Cracks or wear on the fifth wheel as sembly slide mechanism and mount ing brackets Replace each damaged or worn component Incorrect jaw locking action and cracks or wear on the jaw locking mechanism Replace the mechanism if cracked or worn Repair it if the jaw locking action is incorrect Gouges or wear on the fifth wheel plate Replace the plate if damaged or worn Pretrip Inspection and Daily Maintenance e Fatigue or cracking of welds which must be repaired according to the manufacturer s specifications Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in serious per sonal injury or death 20 4 Lubricate the fifth wheel top plate and other grease points at least once a week and more often in severe servic
95. ormal pressure with the engine running is 95 to 125 psi 655 to 862 kPa in both systems A low air pressure warning light and buzzer connected to both the primary and secondary systems activate when air pressure in either system drops below a minimum pres sure of 62 to 68 psi 427 to 469 kPa When the engine is started the warning light and buzzer remain on until air pressure in both systems exceeds minimum pres sure An air pressure gauge that registers pressure in both the primary and secondary systems may be in stalled on some vehicles Fuel Gauge The fuel gauge see Fig 3 21 indicates the amount of fuel in the fuel tank s Intake Air Restriction Indicator An intake air restriction indicator measures the vacuum on the engine side of the air cleaner at the air cleaner outlet If the yellow signal stays locked at or above the values shown in Table 3 3 after the engine is shut down service the air cleaner then reset the indicator by pressing the reset button Driver Controls and Instruments EES aa ho O12 SL ae Ps 10 01 98 l f601437a Fig 3 20 Air Pressure Gauge NOTE Avoid opening the air cleaner and disturb ing the seals or filter element until the yellow sig nal stays locked at or above the value shown in Table 3 3 When this occurs the air cleaner needs replacing however immediate engine shutdown is not necessary JO y mS Soo No LS 10 01 98 1601438a Fig 3 21 Fuel
96. othly Continue downshifting as conditions require using the same sequence described above IMPORTANT Do not rest your foot on the clutch pedal while driving This causes partial clutch dis engagement which could cause premature clutch wear NOTE With synchronized models disengage the clutch completely when shifting gears Double clutching is unnecessary If the vehicle is moving when shifting depress the clutch pedal just far enough to disengage the clutch Allison Automatic Transmissions General Information MD series MD CR and MD WR automatic transmis sions have six forward speeds and one reverse speed See Fig 5 3 These transmissions have electronic shift controls that can be programmed to allow the use of different numbers of geared speeds For instance the transmission can be programmed to operate as a 4 speed 5 speed or 6 speed unit in the primary shift mode If needed a secondary shift mode can be pro grammed to provide another shift configuration to opti mize vehicle use under different operating conditions To activate a secondary shift mode or other special function programmed into the electronic control unit ECU depress the MODE button Mode On is dis played in the indicator panel just above the push but tons A label just above the MODE button identifies the special function NOTE Each time a push button is depressed on the shift selector a short beep will be heard This indicates th
97. ow 64 to 76 psi 441 to 524 kPa in either sys tem If this happens check the air system pressure gauges to determine which system has low air pres sure Although the vehicle s speed can be reduced us ing the foot brake control pedal either the front or rear service brakes will not be operating causing a longer stopping distance Bring the vehicle to a safe stop and have the air system repaired before continuing Do not drive the vehicle with the parking brakes caged If the vehicle is driven with the parking brakes caged there would be no means of stopping the vehicle if a complete loss of air pressure oc curred This could result in serious personal injury or vehicle damage Before caging the spring park ing brakes make the connection to a towing vehicle or chock the tires Brakes NOTE Before a vehicle with insufficient system air pressure can be moved the spring parking brakes must be released by applying an external air source at the gladhands or by manually caging manually releasing the parking brake springs After correcting the brake system problem uncage the spring parking brakes before resuming normal vehicle Operation Operation Before driving the vehicle secure all loose items in the cab so that they will not fly forward during a full brake application Make sure all occupants are wearing seat belts During normal brake stops depress the foot brake con trol pedal until braking action slows down
98. r Brake Systems The ABS warning light comes on after the engine is started The warning light goes out only if all of the ABS components are working properly IMPORTANT If the ABS warning light does not work as described above or comes on while driv ing repair the ABS system immediately to ensure full antilock braking capability Refer to the vehicle workshop manual for troubleshooting procedures Refer to the brake system operating instructions in Chapter 7 for more instructions Instruments Tachometer A tachometer see Fig 3 15 indicates engine speed in revolutions per minute rpm and serves as a guide for shifting the transmission and keeping the engine in the appropriate rpm range For low idle and rated rpm refer to the engine identification plate 10 01 98 1601443a Fig 3 15 Tachometer The tachometer may include an engine hour meter An engine hour meter records continuous operating hours of the engine In cases where actual mileage does not indicate overall usage maintenance and lubrication in tervals for the engine and engine operated equipment can be determined by operating hours 3 12 Driver Controls and Instruments Speedometer A speedometer see Fig 3 16 registers vehicle speed in both miles per hour mph and kilometers per hour km h Standard speedometer gauges are equipped with an odometer that records total distance traveled in either kilometers or miles The trip odomete
99. r Vehicle Safety Standard CMVSS Labels 1 1 Subject Page Care of Chromed Parts and Stainless Steel Clad Parts 8 1 Cloth Upholstery Cleaning 8 3 Chewing Gum or Wax 8 4 Grease and Oil Based Stains 8 4 Mildew 2 000008 8 4 Sugar and Water Based Stains 8 4 CIUTGNES 6 gcc are ee Hees 6 1 Clutch Adjustments 6 2 Clutch Operation 6 1 General Information 6 1 Hydraulic Clutch Fluid Reservoir CHECKING cai io ee ee a 6 3 Lubrication s 400 26k ee eas 6 3 Cold Start Manifold Heater 4 3 Cold Weather Operation 4 3 Cummins Engines 4 3 COMMONS sarsie Se af de ia el ll be oe 3 1 Air Horn Optional 3 8 Air Suspension Dump Valve Optional cir we a a Of Allison Automatic Transmission GONO Shock ences a hada EE ee aa 3 8 Cigar Lighter 3 7 Cummins Electronic Engine 3 5 Dome Light Switch 3 4 ElectricsHOmn sica amp Sods 3 8 Hazard Warning Light Switch 3 8 Subject Page Headlight Switch and Daytime Running Lights 3 1 Ignition Switch and Key 3 1 Interrupt Switch 3 5 Panel Light Control 3 1 Parking Brake Control Valve KNOD o a we eee eee hae 3 6 Suspension Seat Adjustment Controls 3 10 Turn Signal Switch 3 7 Vernier Throttle Control Optional a 3 10 Windshield Washer 3 5 Windshield Wipers 3 4 D Dashboard Care
100. r registers distance driven and can be reset to zero by depressing the button Water Temperature Gauge During normal engine operation the water temperature gauge see Fig 3 17 should read 175 to 203 F 79 to 95 C If the temperature remains below 160 F 71 C or exceeds the maximum temperature shown in Table 3 1 inspect the cooling system to determine the cause Refer to the vehicle workshop manual for troubleshooting and repair procedures 10 01 98 1601442a 10 01 98 1601436a Fig 3 16 Speedometer 3 13 Fig 3 17 Water Temperature Gauge Driver Controls and Instruments Engine Oil Pressure Gauge The oil pressure gauge see Fig 3 18 should read as shown in Table 3 2 10 01 98 1601440a Fig 3 18 Engine Oil Pressure Gauge Ah CAUTION A sudden decrease or absence of oil pressure may indicate mechanical failure Bring the vehicle to a safe stop and investigate the cause to prevent fur ther damage Do not operate the engine until the cause has been determined and corrected Voltmeter The voltmeter see Fig 3 19 indicates the vehicle charging system voltage when the engine is running and the battery voltage when the engine is stopped By monitoring the voltmeter the driver can be aware of po tential charging system problems and have them fixed before the batteries discharge enough to create starting difficulties 10 01 98 x 1601439a Fig 3 19 Voltme
101. riming 19 If equipped check the transmission oil cooler for pump do the following debris and for leaks Remove the fuel tank cap Remove debris and repair leaks as needed Loosen the fuel supply line at the fuel trans 20 If so equipped inspect the fifth wheel and check it fer pump Partially cover the fuel tank opening with your hand Using an air hose apply no more than 5 psi 35 kPa air pressure to the fuel tank and look for a constant fuel flow at the loosened fuel supply line for adequate lubrication Check to be sure that the trailer is securely con nected to the tractor Failure to achieve complete 9 10 Pretrip Inspection and Daily Maintenance fifth wheel lockup may allow disengagement of the tractor from the trailer possibly resulting in serious personal injury or death 20 1 If the vehicle is a truck trailer combination be sure the trailer hitch is locked and the safety cable or chains are connected Be sure air hoses and the light cable are con nected Check to be sure that the trailer hitch is securely connected to the truck Failure to lock the trailer hitch and to connect safety cables or chains may allow disengagement of the truck from the trailer possibly resulting in serious personal injury or death 20 2 If the vehicle is a tractor trailer combination check that the fifth wheel lock mechanism is locked to the trailer kingpin Refer to Chap ter 11 for instructions Ah WARNING Repair
102. ring the jaw will actuate the jaw and wedge The jaw will move behind the kingpin followed by the wedge The purpose of the wedge is to reinforce the jaw and take up slack around the pin Any wear on the jaw is immediately taken up by the wedge so there is no slack in the connection Fifth Wheel Locking Operation Locking the Fifth Wheel Lock Mechanism 1 Chock the front and rear of the trailer tires to pre vent the trailer from moving 2 The kingpin lock mechanism must be fully open the fifth wheel plate must be completely lubricated with chassis grease For lubrication instructions refer to Group 31 of the Cargo Maintenance Manual 11 7 01 04 95 f310184c NOTE Kingpin correctly entering the lock Note how the steel tongue allows lock halves to close completely around the neck and shoulder of the kingpin A B 1 2 Unlocked Position C Locked Locking Wedge 3 Trailer Kingpin Jaw Fig 11 5 Fontaine Kingpin Lock Mechanism Fifth Wheels Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in serious per sonal injury or death 3 Position the tractor so that the fifth wheel lock opening is in line both vertically and horizontally with the trailer kingpin The kingpin should be in a position to enter the throat of the locking mecha ni
103. rking lights license plate light and panel lights Driver Controls and Instruments 1 2 3 4 5 8 1 9 10 11 1 1 N 12 26 2524 23 20 19 18 171615 14 13 12 12 18 97 1610041 1 Face Level Vent 9 Heater Ventilation Mode Selector 19 Left Switch Bank 2 Tachometer 10 Radio optional 20 Parking Brake Control 3 Warning and Indicator Light 11 Temperature Control 21 Voltmeter Module 12 Interior Grab Handle 22 Fuel Gauge 4 Speedometer 13 Glove Compartment 23 Oil Pressure Gauge 5 Odometer 14 Radio Hot Post optional 24 Headlamp Switch 6 Warning and Indicator Light 15 Not Used 25 Hand Throttle Vernier Type Module 16 Ashtray optional 7 Dual Air Pressure Gauge 17 Cigar Lighter 26 Water Temperature Gauge 8 Not Used 18 Fan Speed Fig 3 1 Instrument and Control Panel Layout typical To change the headlights from low to high beam or instrument panel Fig 3 6 When the headlights are on high to low beam push the control lever away from the high beam an indicator light on the instrument panel 3 2 Driver Controls and Instruments 7 OR 07 15 99 8 B 9 10 11 D 42 13 aa 15 16 f080071a NOTE Not all vehicles with daytime running lights are equipped with th
104. rushing to remove dust and dirt is recommended Harsh clean ing agents can cause permanent damage to vinyl up holstery To preserve the upholstery and prevent dam age carefully review the following sections for recommended cleaning procedures Waxing or refinish ing improves soil resistance and cleanability for all vi nyls Any hard wax such as that used on automobiles may be used Ordinary Dirt Wash the upholstery with warm water and mild soap such as saddle or oil soap Apply soapy water to a large area and allow to soak for a few minutes then rub briskly with a cloth to remove the dirt This can be re peated several times as necessary If dirt is deeply imbedded use a soft bristle brush after applying the soap If dirt is extremely difficult to remove wall washing preparations normally found around the home can be used Powdered cleaners such as those used for sinks and tiles are abrasive and must be used with caution as they can scratch the vinyl or give it a permanent dull appearance Chewing Gum Harden the gum with an ice cube wrapped in a plastic bag then scrape off with a dull knife Any remaining traces of gum can be removed with an all purpose light oil peanut butter will also work and wiped off Tars Asphalts and Creosote Each of these items stains vinyl after prolonged contact They should be wiped off immediately and the area carefully cleaned using a cloth dampened with naph tha 8 2
105. s air reservoirs and air lines Look for worn pins on brake chamber pushrods and missing or damaged cotter pins on the brake cham ber pushrod pins Replace worn pins and install new cotter pins if necessary Check for rusted connections missing snap rings and damaged camshaft grease seals Repair or replace damaged or missing parts Check the air reservoir band fasteners Make sure the outside surfaces of the reservoirs are painted to prevent corrosion damage Inspect the reservoir surfaces for damage such as cracks and dents Replace corroded or damaged reservoirs with new ones Do not repair damaged reservoirs Old or used reser voirs are not acceptable as replacements If a res ervoir requires replacement see Group 42 of the Cargo Workshop Manual for instructions Inspect the air lines as follows 35 1 35 2 35 3 35 4 35 5 Check the clearance between the hoses exhaust manifold and turbocharger or other hot spots Excessive heat will cause the ma terial in the hoses to deteriorate rapidly or become brittle Provide at least six inches 150 mm of clearance More clearance is recommended especially if the hose is lo cated above the heat source Check for kinks dents or swelling of the hoses If a hose is damaged replace it with the same size and type Do not route the hose on top of anything likely to be stepped on or walked on Check for damage to hoses located near moving parts such as driveli
106. s air through the wind shield and side panel vents The center panel vents if left open will provide unheated air Air flow from the side panel vents when directed to ward the door windows will help avoid window fogging The Panel position directs unheated air through the center panel vents only Driver Controls and Instruments A three speed fan switch controls the flow of air to any selected air vents The center air panel vents located on each side of the heater control panel allow unheated forced air to be directed vertically and horizontally and can be opened or closed independently by means of a built in damper See Fig 3 23 The side panel vents allow heated forced air to be di rected vertically and horizontally The roof vent see Fig 3 24 can be adjusted to five different positions but is not removable To adjust hold the lateral bars and incline the ventilator forward back ward or to either side To open completely push the ventilator upward 08 27 97 1601423 1 Center Air Panel Vents 2 Vertical and Volume Airflow Control 3 Horizontal Airflow Control Fig 3 23 Center Air Panel Vents 1601441 1 Roof Vent Adjustment Bars Fig 3 24 Roof Vent The foot level vents located on each side of the front cab wall under the instrument panel are opened or closed by moving the actuator lever on the vent See Fig 3 25 Driver Controls and Instruments 830808
107. s the Komfort Latch lever up clamp ing the belt s webbing See Fig 2 9 and Fig 2 10 2 8 Vehicle Access and Features 01 06 95 ee 1910048a A 1 Inch 2 5 cm Maximum Fig 2 9 Adjusting Shoulder Harness Clearance 4 To unbuckle the three point seat belt push the but ton on the buckle See Fig 2 11 If the Komfort Latch was used release it by giving the shoulder belt a quick tug If you lean forward against the shoulder belt the Komfort Latch will automatically release and will need to be reset NOTE The Komfort Latch does not have to be released in an emergency situation The Komfort Latch will release by itself under rough road or 2 9 2 i x S A N N N 01 06 95 f910006a Fig 2 10 Locking Komfort Latch other abnormal conditions Make sure the three point seat belt is completely retracted when it is not in use Lap Belt 4h WARNING Wear lap belts only as described below In case of an accident or sudden stop injuries could result Vehicle Access and Features gt ee 7 910049a 01 18 95 Fig 2 11 Releasing the Three Point Seat Belt typical from misuse Lap belts are designed to be worn by one person at a time i Slowly pull the link end of the lap belt across your lap See Fig 2 12 If it is necessary to lengthen the belt tip the link end downward and pull the link until it connects with the buckle Fasten the lap belt b
108. sh conditions for the best service life by 1 Operating as much as possible at three quarter load 2 Avoiding operation at engine idle speeds or at maximum horsepower levels longer than five min utes 3 Developing the habit of closely watching the engine instruments during operation Let up on the throttle if the oil temperature reaches 250 F 121 C or if the coolant temperature exceeds 190 F 88 C 4 Checking the oil level frequently during the break in period Engine Operation Operating vehicles with diesel engines in areas where there are concentrated flammable vapors such as die sel gasoline or propane fumes can create a hazard ous situation These vapors can be drawn into the en gine through the air intake and cause engine overspeed Be especially cautious of low lying or closed in areas and always check for signs that flam mable vapors may be present 4 5 Don t operate the engine in an area where flam mable vapors such as gasoline or diesel fumes are present Shut down the engine when in an area where flammable liquids or gases are being handled Failure to observe these precautions could result in serious injury or death Cummins Engines Cummins diesel engines have been built to comply with the requirements of the Federal U S Clean Air Act Once an engine is placed in service the responsibility for meeting both state and local regulations is with the owner operator Good operating practi
109. sing personal injury and property damage If the vehicle is moving maintain a constant vehicle speed while engaging the differential lock Briefly let up 6 4 Clutches Rear Axles and Steering on the accelerator to relieve torque on the gearing al lowing the differential to fully lock The indicator light comes on when the differential is fully locked When the differential is locked the turning radius will increase be cause the vehicle understeers See Fig 6 3 Drive cau tiously and do not exceed 25 mph 40 km h A m Y nah a gl y mt Tt ha 02 09 96 A Turning Radius When Differential is Locked engaged Understeer Condition B Turning Radius When Differential is Unlocked disengaged 1350079a Fig 6 3 Turning Radius To unlock the main differential depress the bottom of the control switch Briefly let up on the accelerator to relieve torque on the gearing allowing the differential to fully unlock 6 5 When the differential lock disengages the indicator light will go off Steering System General Information When there is no load on the vehicle and the front tires are pointed straight ahead the steering wheel spokes should be at the 4 and 8 o clock positions or within 10 degrees of either side See Fig 6 4 See Group 46 of the Cargo Workshop Manual for steering adjustment procedures Power Steering System The power steering system consists of a steering gear which
110. sm as shown in Fig 11 5 Adjust the trailer land ing gear to give enough alignment height for posi tive kingpin lockup 4 With the fifth wheel lock opening aligned with the trailer kingpin back the tractor slowly toward the trailer making sure that the kingpin enters the throat of the locking mechanism Continue the backward motion until positive lockup occurs 5 Apply the tractor parking brakes 6 Make a visual and physical check for positive king pin lockup When lockup has occurred the fifth wheel control handle will have moved to the locked position Make sure that the safety latch is down over the lock control handle See Fig 11 6 This will hold the control handle in the locked position 4 12 05 94 1310265a NOTE Make sure the safety latch is down when the control handle is locked A Unlocked B Locked 1 Lock Control Handle 2 Safety Latch Fig 11 6 Fontaine Fifth Wheel Locking and Unlocking 7 Release the tractor parking brakes Test for kingpin lockup by pulling on the trailer against the chocks 11 8 Fifth Wheels 8 After lockup is completed connect the tractor to trailer air system lines and the electrical cable to the trailer Take care to prevent dirt or foreign mate rial from entering the air system lines 9 Charge the air brake system with air Make sure that the air connections do not leak 10 With the trailer wheels chocked and the brakes set check for clearance b
111. smissions Transmissions Fuller Straight Shift Models General Information Fuller FS 4205A B FS 5205A B and FS 6305A B transmissions have five forward speeds and one re verse speed See Fig 5 1 for the shift pattern R 2 4 e N 41 3 5 03 12 96 260080 Fig 5 1 Shift Pattern FS 4205A B FS 5205A B and FS 6305A B Fuller FS 5306A FS 6306A and FS 8206A transmis sions have six forward speeds and one reverse speed See Fig 5 2 for the shift pattern These transmissions are designed for use with on highway fuel economy engines where a minimum of shifting is desired and less gear reduction is acceptable 5 1 R 1 3 5 N 2 4 6 10 19 2000 260085 Fig 5 2 Shift Pattern FS 5306A FS 6306A and FS 8206A Operation 1 Always use 1st gear when starting to move the ve hicle forward 2 Accelerate to engine governed speed Disengage the clutch and move the shift lever to 2nd gear En gage the clutch and accelerate to engine governed speed 3 Continue upshifting using the same sequence de scribed in step 2 above Follow the pattern on the shift lever 4 When downshifting shift progressively down through each successive lower gear as follows When the engine speed drops to the same rpm to which it fell immediately after upshifting to that Transmissions same gear disengage the clutch and move the shift lever to the next lower gear Engage the clutch smo
112. ssed and the Transmission in Gear Coasting with the clutch released and the transmission in gear can cause high driven disc rpm through multipli cation of ratios from the final drive and transmission Do not coast with the clutch released pedal de pressed and the transmission in gear High driven disc rpm could cause the clutch facing to be thrown off the disc Flying debris could cause injury to per sons in the cab Engaging the Clutch While Coasting Engaging the clutch while coasting can result in tremen dous shock loads and possible damage to the clutch as well as to the entire drivetrain Reporting Erratic Clutch Operation Promptly Reporting erratic clutch operation as soon as possible will give maintenance personnel a chance to inspect the clutch components CAUTION Operating the vehicle with incorrect clutch pedal free travel could result in clutch damage See Group 25 of the Cargo Workshop Manual for free pedal ad justment procedures and specifications Clutch Adjustments Some clutches have an internal adjustment See the applicable section in Group 25 of the Cargo Workshop Manual for clutch adjustment procedures and specifica tions CAUTION Operating the vehicle with the clutch incorrectly ad justed could result in clutch or clutch brake failure 6 2 Clutches Rear Axles and Steering Lubrication The release bearing should be lubricated at frequent intervals See Group 25 of the Carg
113. starter to cool Failure to do so could cause starter damage IMPORTANT Before doing any of the following procedures make sure there is an adequate amount of fuel in the tank s Do not fill the Pretrip Inspection and Daily Maintenance Remove the air hose and tighten the fuel supply line tank s to more than 95 percent of liquid ca pacity 18 4 On vehicles equipped with a single tank Start the engine Once the engine has prime the fuel system if needed On ve hicles with dual tanks go to the next sub step If the engine is equipped with a priming pump do the following Unlock and operate the engine priming pump plunger until resistance is felt Push the plunger in and tighten it by hand Start the engine If it does not start more priming is needed Once the engine has started it may run rough If this occurs run the engine at low idle until it runs smoothly started it may run rough If this occurs run the engine at low idle until it runs smoothly IMPORTANT To prevent fuel loss or entry of air into a fuel line make sure that all fuel line connections are tight 18 5 On vehicles equipped with dual tanks and single suction and return lines with cross over line prime the fuel system if needed Use the same procedure provided in the previous substep for vehicles equipped with a single tank Do the procedure on the tank equipped with the supply line If the engine is not equipped with a p
114. switch 10 01 98 1601425a Fig 10 1 Hazard Warning Light Switch 10 1 Towing Do not tow an unbraked vehicle if the combined weight of both vehicles is more than the sum of the gross axle weight ratings GAWR of the towing ve hicle Otherwise brake capacity will be inadequate which could result in personal injury or death IMPORTANT When it is necessary to tow the ve hicle make sure the instructions below are closely followed to prevent damage to the vehicle Front Towing Hookup 1 Disconnect the battery ground cable 2 If the vehicle is to be lifted and towed remove the drive axle shafts CAUTION Failure to remove the axle shafts when towing the vehicle with the rear wheels on the ground could result in damage to the transmission and other parts 3 Cover the ends of the hubs with metal plates or plywood cut to fit the axle opening and drilled to fit In an Emergency the axle shaft studs This prevents lubricant from leaking out and will keep contaminants from getting into the axle lubricant and damaging the wheel bearings 4 Remove the bumper extension and chrome bumper if installed 5 Attach the towing device Due to the many vari ables that exist in towing positioning the lifting and towing device is the sole responsibility of the towing vehicle operator who must be familiar with standard towing industry safety measures 6 Lift the vehicle and secure the safety towing
115. ter 3 14 Driver Controls and Instruments The voltmeter will normally show approximately 13 7 to 14 1 volts when the engine is running The voltage of a fully charged battery is 12 7 to 12 8 volts when the en gine is stopped A completely discharged battery will produce only about 12 0 volts The voltmeter will indi cate lower voltage as the vehicle is being started or when electrical devices in the vehicle are being used If the voltmeter shows an undercharged or overcharged condition for an extended period have the charging system and batteries checked at a repair facility On a vehicle equipped with a battery isolator system the voltmeter measures the average voltage of all the batteries when the engine is running When the engine is stopped the voltmeter shows only the gel cell battery voltage and does not indicate the voltage of the engine starting batteries CAUTION Gel cell batteries can be damaged if the battery voltage is allowed to drop below 12 0 volts or if the charging voltage is more than 14 1 volts Start the engine to recharge the gel cell before the battery becomes fully discharged If an external charger is needed disconnect the gel cell battery and use only an external battery charger that has been approved for gel cell batteries 3 15 Primary and Secondary Air Pressure Gauges These air pressure gauges see Fig 3 20 register the constant pressure in the primary and secondary air sys tems N
116. ter the clutch is fully engaged the engine should be acceler ated to the correct rom for the upshift into the next higher gear Gear Shifting Techniques Many drivers upshift into the next gear or even skip shift into a higher gear before the vehicle has reached the correct speed This type of shifting is almost as bad as starting off in a gear that is too high since the en gine rpm and vehicle speeds are too far apart requiring the clutch to absorb the speed difference by generating heat For transmission operating instructions see Chapter 5 Vehicle Overload or Overloading the Clutch Clutches are designed for specific vehicle applications and loads These limitations should not be exceeded Ah CAUTION Overloading will not only result in damage to the clutch but also to the entire powertrain Clutches Rear Axles and Steering Riding the Clutch Pedal Riding the clutch pedal is destructive to the clutch since partial clutch engagement permits slippage gen erating excessive heat Riding the clutch pedal will also put a constant thrust load on the release bearing which can thin out the lubricant Release bearing failures can be attributed to this type of misuse Holding the Vehicle on an Incline With a Slipping Clutch A slipping clutch accumulates heat faster than it can be dissipated resulting in early clutch failures Never use the clutch as a hill holder Coasting With the Clutch Released Pedal Depre
117. the rod Vehicle Access and Features To close the front access panel lift the panel slightly to release the support rod Secure the support rod and press the panel down until it locks Back of Cab Grab Handle Step and Deck Plate When climbing onto the frame rails or deck plate use the grab handle and step Always maintain three point contact with the back of cab access system A grab handle is mounted on the cab When an optional deck plate is included it is mounted across the top of the frame rails 2 16 Driver Controls and Instruments Instrument and Control Panel A a RES DATES 3 1 COMMONS vaa da al a as Dad olas Alok Whe Oi a ta ti 3 1 Warming and Indicator Lights goess ers perayaan k AE boa be e y 3 10 Hes UUM NU Ss aia a da a aaa ett 3 12 Heater and Ventilation System Driver Controls and Instruments Instrument and Control Panel Figure 3 1 represents a typical dash equipped with all of the standard and many of the optional instruments and controls Warning and indicator light modules located on each side of the speedometer house all of the standard and optional warning and indicator lights Figure 3 2 identi fies the warning and indicator lights Controls Ignition Switch and Key The ignition switch can be turned to four positions OFF ACCESSORY ON and START See Fig 3 3 The igni tion switch key also locks and unlocks the cab doors The key can be inserted and removed only from
118. the handle and pull forward or push back to the de sired setting Lumbar Support Push the rocker switch on the side of the seat up to inflate lumbar support Push the rocker switch down to deflate lumbar support Back of Cushion Height To adjust the height at the back of the cushion rotate the lever to the desired setting Isolator Optional Also called a Chugger Snubber the isolator is locked out by moving the handle down Vehicle Access and Features Non Suspended Driver s Seat Fore Aft Seat Adjustment Move the control lever at the front of the seat to release the locking mechanism then exert slight body pressure to move the seat forward or rearward as desired See Fig 2 6 e 1 5 a 4 A 11 02 95 a 1910128 1 Back Cushion Tilt Knob 2 Lumbar Support Switch 09 09 97 910246 3 Height Adjustment Switch 4 Fore Aft Seat Adjustment Lever Fig 2 6 Non Suspended Driver s Seat Control Lever 5 Bottom Cushion Front Height Handle 6 Isolator Handle Release the lever to lock the seat in place Push the 7 Back of Cushion Height Adjustment Handle seat back and forth to ensure that it is locked in place Fig 2 5 National Cush N Aire II Seat 2 6 Vehicle Access and Features Passenger s Seat The passenger s seat is not adjustable See Fig 2 7 Access to the storage compartment under the seat is obtained by moving the release lever and tilting the seatback forward
119. tion 38 Check for indications of loose wheel nuts or rim nuts and examine each wheel component Check the wheel nuts or rim nuts for indications of looseness Remove all dirt and foreign material from the assembly Dirt or rust streaks from the stud holes metal buildup around stud holes or out of round or worn stud holes may be caused by loose wheel nuts See Group 40 of the Cargo Maintenance Manual for torque specifications and the correct tightening sequence Examine the wheel assembly components includ ing rims rings flanges studs and nuts for cracks or other damage See Group 33 and Group 35 of the Cargo Work shop Manual for service procedures on the studs and hubs and see Group 40 of the same manual for wheel and tire servicing Replace broken cracked badly worn bent rusty or sprung rings and rims Be sure that the rim base lockring and side ring are matched according to size and type Ah WARNING Have any worn or damaged wheel components re placed by a qualified person using the wheel manu facturer s instructions and the wheel industry s standard safety precautions and equipment Other wise a vehicle or workshop accident could occur possibly resulting in serious personal injury or death Ah CAUTION Insufficient wheel nut rim nut torque can cause wheel shimmy resulting in wheel damage stud breakage and extreme tire tread wear Excessive wheel nut torque can break studs damage threads and cr
120. using water or rubbing al cohol If this does not work try the procedure used un der Sulfide Stains Miscellaneous If stains do not respond to any of the treatments de scribed above it is sometimes helpful to expose the vinyl to direct sunlight for up to 30 hours Mustard ball point ink certain shoe polishes and dyes often bleach out in direct sunlight leaving the vinyl undamaged Cloth Upholstery Cleaning To prevent soiling frequent vacuuming or light brushing to remove dust and dirt is recommended Spot clean with a mild solvent or upholstery shampoo or the foam from a mild detergent When using a solvent or a dry cleaning product follow instructions carefully and clean Cab Appearance only in a well ventilated area Avoid any product that contains carbon tetrachloride or other toxic materials With either method pretest a small area before pro ceeding Use a professional upholstery cleaning service when extensive cleaning is needed Grease and Oil Based Stains Dampen a small absorbent cloth with dry cleaning sol vent or spot remover Apply carefully to the spot from the outer edge to the center Pat and blot with a clean dry cloth Repeat several times as necessary turning cloths so that the stain does not redeposit on the fabric Sugar and Water Based Stains Apply water based detergent or cleaner working in cir cular motions Pat and blot as dry as possible Repeat if necessary before drying t
121. wheel for excessive play With the front tires straight ahead turn the steering wheel until motion is observed at the front wheels Align a reference mark on a ruler then slowly turn the steering wheel in the opposite direction until motion is again detected at the wheels Measure the lash free play at the rim of the steering wheel See Fig 9 2 Excessive lash exists if steering wheel movement exceeds 4 3 4 inches 121 mm with a 20 inch 470 mm steering wheel If there is excessive lash check the steering system for wear or incorrect ad justment of the linkage and steering gear before operating the vehicle 26 Adjust the driver s seat then align the rearview mir rors 27 Inspect the seat belts and tether belts if so equipped See Fig 9 3 WARNING Inspect and maintain seat belts as instructed below Worn or damaged seat belts could fail during a sud den stop or crash possibly resulting in serious in jury or death Pretrip Inspection and Daily Maintenance 10 02 95 f460158b A Lash Area Fig 9 2 Measuring Lash at the Steering Wheel NOTE When any part of a seat belt system needs replacement the entire seat belt must be replaced both retractor and buckle side 27 1 Check the web for fraying cuts or extreme wear especially near the buckle latch plate and the D loop guide area 27 2 Check the web for extreme dirt or dust and for severe fading from exposure to sunlight 27 3 Chec
122. y the turbocharger temperature may rise as much as 115 F 46 C The extreme heat may cause bearings to seize or oil seals to leak 3 Do not idle the engine for excessively long periods Long periods of idling are not good for an engine because the combustion chamber temperatures drop so low the fuel may not burn completely This will cause carbon to clog the injector spray holes and piston rings and may result in stuck valves If the engine coolant temperature becomes too low raw fuel will wash the lubricating oil off the cylinder walls and dilute the crankcase oil causing all mov ing parts of the engine to suffer from poor lubrica tion Ah CAUTION Stop the engine at the first sign of malfunction Al most all malfunctions give some warning to the op erator before significant damage occurs Many en gines are saved because alert operators heed the warning signs sudden drop in oil pressure un usual noises etc and immediately shut down the engine 4 8 Engines 4 lf the engine is not being used shut it down by turning the ignition key off High Altitude Operation Cummins Engines lose horsepower when operated at high alti tude because the air is too thin to burn as much fuel as at sea level This loss is about 3 percent for each 1000 feet 300 m altitude above sea level for a naturally as pirated engine Most turbocharged engines are rated for higher altitudes than naturally aspirated engines An eng
123. y pushing the link into the buckle until they latch Make sure the belt is not 01 06 95 f910068a A Pull on loose end to shorten belt 1 Buckle 3 Link 2 Belt Release Button Fig 2 12 Lap Belt Adjustment twisted Check the engagement by trying to pull the link out of the buckle If they come apart repeat this step If the problem continues replace the belt NOTE The belt can be shortened after it is con nected by pulling on the loose end until the belt is snug but comfortable 3 To release the belt push the release button on the buckle and pull the link from the buckle 2 10 Vehicle Access and Features Fuse Relay Circuit Breaker Identification NOTE The fuse relay circuit breaker panel Fig 2 13 is located under the glove box De pending on vehicle options fuse relay circuit breaker locations may vary from those shown Re fer to Fig 2 13 or Table 2 1 for the Fuse Relay Circuit Breaker Identification information Fuse Relay Circuit Breaker Identification fra Description baie Rating 1 Daytime Running Lights 10A 2 Interior Lamps 10A 3 Turn Signal 25A 4 Customer Use Battery 5 Cigar Lighter 10A 6 Horn 10A 7 Trailer Clearance Marker 20A Lamps 8 Not Used 15A 9 Headlamps CB 10 Not Used 11 Warning Lamps 10A 2 11 Fuse Relay Circuit Breaker Identification

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